Graded Composite Material via Pore-Controlled Infiltration
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Solution Overview
Problem
Existing methods for producing composite materials with a matrix of a first material infiltrated by a second material, such as powder sintering, fail to achieve homogeneous or graded composite materials with controlled physical properties, often requiring additional debinding or surface treatment steps.
Innovation Solution
A method involving a matrix of interconnected pores with controlled pore sizes, allowing for the infiltration of a second material to create homogeneous or graded composite materials with targeted volume and surface properties, using techniques like selective laser printing or sintering, and controlling the spatial distribution of the second material within the porous lattice of the first material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If powder sintering methods are used to produce composite materials, then the manufacturing process is simple, but the resulting materials are not homogeneous or graded in terms of physical properties
Solution Approach 1:
The porous lattice structure is pre-formed with controlled pore size distribution before infiltration. The pore architecture is designed in advance to ensure homogeneous or graded physical properties, eliminating the need for post-sintering adjustments or additional processing steps to achieve homogeneity.
Solution Approach 2:
The invention controls the pore size parameter (70-700 μm) and pore size distribution (uniform or graded) to achieve desired physical properties. By adjusting these geometric parameters of the porous lattice, the composite material achieves homogeneous or graded characteristics without complex manufacturing processes.
2Ease of manufacture
If powder sintering methods are used, then composite materials can be produced, but additional debinding or surface treatment steps are required
Solution Approach 1:
The invention extracts and eliminates the need for debinding and surface treatment steps by using a pre-formed porous lattice structure that directly accepts the second material through infiltration. The porous structure serves both as the scaffold and as the infiltration channel, removing unnecessary intermediate processing steps.
Solution Approach 2:
The porous lattice formation and material infiltration are merged into a single integrated process. The pre-formed porous structure is directly infiltrated with the second material without requiring separate debinding or surface treatment operations, simplifying the overall manufacturing process.
3Manufacturing precision
If the pore size is controlled within 70-700 μm with uniform distribution, then homogeneous composite materials are achieved, but the manufacturing precision requirements increase
Solution Approach 1:
The invention applies local quality control by designing the porous lattice with specific pore size characteristics (70-700 μm) in different regions or uniformly throughout the structure, depending on the application requirements. This localized or global pore size control achieves homogeneous or graded physical properties without requiring overly complex manufacturing processes.
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
Enables the easy and controlled production of composite materials with uniform or graded physical properties, allowing for versatile coupling of various first and second materials, enhancing their structural and functional performance.
Implementation Method 1
have a size t of around 70 to around 700 μm, the size of at least 95% of said pores of the assembly (P) being equal to t±10%, or forming a gradient between a size (ta)±10% and a size (tb)±10%
Data Source
AI summary
The present invention relates to a composite material with a graded or homogeneous matrix, the production method thereof, and the uses of same.