Cold Gas Sprayed Porous Component for Leak Testing
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Solution Overview
Problem
Current methods for producing porous components for separation processes and leak testing face challenges such as inconsistent porosity, long-term gas permeability fluctuations, and the risk of blockages, particularly with nano-/microporous membranes and crushed metal capillaries.
Innovation Solution
The method involves cold gas spraying to create a partially porous component with adjustable and consistent porosity, using parameters like particle size and process gas temperature to achieve a defined gas permeability, suitable for both test leaks and separation processes, and allowing for the application of porous material layers on any surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If nano-/microporous membranes are used for separation processes and leak testing, then defined porosity is achieved, but gas permeability fluctuates over time and blockages occur
Solution Approach 1:
The patent applies parameter changes by systematically varying cold gas spraying parameters (particle size, process gas temperature, spraying distance, spraying speed) to precisely control and adjust the porosity of the produced component. This enables definition of specific pore structures with consistent porosity values while maintaining long-term stability, resolving the contradiction between manufacturing precision and reliability.
2Ease of manufacture
If crushed metal capillaries are used as test leaks, then ease of production is improved, but gas permeability is not constant and blockage risk increases
Solution Approach 1:
The patent replaces the mechanical crushing process with cold gas spraying technology. Instead of mechanically crushing capillaries to create pores, the cold gas spraying process deposits material with controlled porosity through kinetic energy of particles. This substitution maintains ease of production while achieving consistent gas permeability and eliminating blockage risks associated with crushed structures.
3Manufacturing precision
If cold gas spraying is used to produce porous components, then porosity consistency and gas permeability control are improved, but process complexity increases
Solution Approach 1:
The patent manages process complexity through systematic parameter optimization in cold gas spraying. By establishing defined relationships between parameters (particle size, temperature, distance, speed) and porosity outcomes, the complex process becomes controllable and reproducible. This enables precise porosity definition while maintaining manageable process complexity through parameter standardization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a component with stable porosity over time, enabling precise control of gas permeability and leakage rates, suitable for calibration of leak detectors and separation processes with minimal technical effort, while preventing blockages and maintaining heat-sensitive material integrity.
Implementation Method 1
At least a porous first region of a component is produced by cold gas spraying
Implementation Method 2
During cold gas spraying, the particles of a powdery base material are accelerated to such a level that they form a dense and firmly adhering layer upon impact with the substrate without any prior melting or melting
Implementation Method 3
In particular, what is meant is an open-pore porosity, i.e. a porosity in which only the open pores are taken into account. These allow gases, liquids and/or solid particles to pass through
Data Source
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AI summary
The invention relates to a method for producing a component that is at least partially porous, a component itself, and a use of such a component. In the method for producing a component (10) that is at least partially porous, at least one porous first region (11) of a component (10) is produced by cold gas spraying. This allows a defined porosity to be achieved with particularly low technical effort.