Elastic Composite Manufacturing via Preform Sintering
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Solution Overview
Problem
Conventional metals lack ductility and elasticity, while elastomers lose flexibility under high pressure and high temperature conditions, limiting their application as seal materials, and there is a need for improved elastic materials and manufacturing methods.
Innovation Solution
A method of manufacturing elastic composites by forming a preform from a filler-filled one-dimensional elastic structure with a matrix material pattern, and processing it through sintering, compression molding, or hot isostatic pressing, involving alternating layers of matrix and filler materials, and combining these with various forming techniques like bending, folding, and rolling to achieve the desired properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional metals are used, then high temperature tolerance and corrosion resistance are achieved, but ductility and elasticity are insufficient
Solution Approach 1:
The patent creates a composite material consisting of metal particles embedded in an elastomer matrix. This composite structure combines the high temperature tolerance and corrosion resistance of metals with the ductility and elasticity of elastomers, resolving the contradiction between thermal stability and mechanical flexibility.
2Strength
If elastomers are used, then flexibility and elasticity are achieved, but high pressure and high temperature resistance is insufficient
Solution Approach 1:
The elastomer matrix provides the desired flexibility and elasticity, while the dispersed metal particles contribute high temperature and pressure resistance. This composite approach allows the material to maintain elastomeric properties while gaining thermal and pressure stability.
3Temperature
If filler is added to elastic structures, then high temperature resistance is improved, but uniform distribution and material properties are difficult to achieve
Solution Approach 1:
The patent extracts the filler material from bulk form and processes it into fine particles. This particle form facilitates uniform distribution throughout the elastomer matrix during mixing and molding, resolving the distribution uniformity problem while maintaining high temperature resistance.
Solution Approach 2:
The patent changes the physical state and size parameters of the filler material by converting it to particles with specific size distributions. This parameter modification enables better dispersion and uniformity in the composite while preserving the thermal resistance properties of the original filler material.
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
The method produces elastic composites with enhanced elasticity, high temperature resistance, and corrosion resistance, suitable for a wide range of applications by ensuring uniform filler distribution and optimal material properties.
Implementation Method 1
sintering the molded product at a sintering temperature of greater than about 150° C. and less than the melting points of both the filler material and the matrix material to provide the elastic composite
Implementation Method 2
molding the preform at a pressure of about 500 psi to about 50,000 psi and a molding temperature of about 20° C. to about 30° C. to form a molded product
Implementation Method 3
forming the elastic composite from the preform via one or more of the following: sintering; compression molding; or hot isostatic pressing
Data Source
AI summary
A method of manufacturing an elastic composite includes forming a preform from a filler filled one-dimensional elastic structure that contains a filler and a matrix material forming a pattern that provides elasticity to the one-dimensional elastic structure; and forming the elastic composite from the preform via one or more of the following: sintering; compression molding; or hot isostatic pressing.