Composite Body Manufacturing via Sintered Salt Powder and Binder
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Solution Overview
Problem
Current methods for producing composite bodies are complex and cost-intensive, requiring multiple processing steps and post-processing to achieve the desired fluid permeability and impermeability, which increases production costs and time.
Innovation Solution
A method involving a permanently connected rigid, fluid-impermeable support body and a porous shaped body created by mixing salt or metal powder with a binder, where the support body forms the molded part and is sintered together with the powder mixture, eliminating the need for separate molding and post-processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional molding methods with separate carrier bodies and stamps are used, then composite bodies can be produced with fluid-impermeable and fluid-permeable layers, but the manufacturing process becomes complex and cost-intensive
Solution Approach 1:
The patent combines the carrier body and closure means into a single integrated component. The support body serves dual functions as both the carrier during molding and the final fluid-impermeable closure, eliminating the need for separate closure means and reducing manufacturing steps.
Solution Approach 2:
The support body performs multiple functions: it acts as the carrier body during the molding process, serves as the mold cavity form, and becomes the final fluid-impermeable closure means. This multi-functionality simplifies the overall manufacturing process and reduces the number of components required.
2Manufacturing precision
If mechanical compression with stamps is used to compact powder mixtures in molded parts, then layered composite bodies can be formed, but post-processing becomes time-consuming and cost-intensive
Solution Approach 1:
The support body is pre-formed with the exact geometry and cavity structure needed for the final product. The powder mixture is compacted directly within this pre-formed support body, eliminating the need for subsequent removal and post-processing steps. The preliminary preparation of the support body ensures that no additional processing is required after molding.
3Reliability
If salt or metal powder mixtures are used to create porous shaped bodies, then fluid permeability can be achieved, but the binder must be carefully controlled to maintain pore structure
Solution Approach 1:
The patent specifies precise parameter ranges for the binder content (5-20% by weight) and the heating temperature (above binder melting point but below salt/metal melting points). By carefully controlling these parameters, the binder softens to form bridges that hold the porous structure together without filling the pores, maintaining fluid permeability while ensuring structural stability.
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 method simplifies the production process, reduces post-processing requirements, and results in a composite body with excellent machinability, retention of pore structure, and suitable properties for applications like air plain bearings, bulk material conveyance, and gassing devices, while being cost-effective and environmentally friendly.
Implementation Method 1
tempering the carrier body loaded with uncompressed powder mixture in an oven to a temperature at which the binder particles soften but do not flow away and binder bridges are formed, which connect adjacent salt and/or metal particles with one another and then the binder hardens
Data Source
Figure 1~3
AI summary
The method involves preparing a salt powder or metallic powder, binder powder and a rigid, fluid-impermeable carrier body (12) and mixing the salt powder or metallic powder and the binder powder to a powder mixture. The carrier body is loaded with the powder mixture. The carrier body is sintered or tempered in a furnace. The pump mixture hardens a molded body (17) provided with multiple channels for transmission of fluid. A composite body (11) is formed by carrier body and the molded body, where a mixture of polyester resin powder and epoxy resin powder is utilized. An independent claim is also included for a composite body, which has a molded body provided with a micro porous structure skeleton of salt or metal particle.