Metal Foam Polymer Composite With Porous Oxide Interface for Heat Control
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Solution Overview
Problem
Conventional heat-dissipating composite materials with high thermal conductivity suffer from poor processability and impact resistance due to the need for large amounts of filler components, which can make them hard and brittle.
Innovation Solution
A composite material comprising a metal foam with a high metal content and a polymer component, where the metal foam has a porous structure with a metal oxide protrusion on its surface, allowing for excellent thermal conductivity while maintaining processability and impact resistance, achieved by introducing a polymer component into the metal foam and controlling the thickness ratio and porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a large amount of filler components is used to achieve high thermal conductivity, then thermal conductivity is improved, but impact resistance deteriorates and the material becomes hard and brittle
Solution Approach 1:
The patent employs a porous metal foam structure as the base material instead of using filler components in a polymer matrix. The metal foam inherently provides high thermal conductivity through its metallic structure while the porous architecture maintains flexibility and impact resistance, eliminating the need for large amounts of filler that would otherwise cause brittleness
Solution Approach 2:
The patent creates a composite structure by combining metal foam with polymer components. The metal foam provides the thermal conductivity function while the polymer component can be introduced to modify properties and improve impact resistance, achieving a balance between thermal performance and mechanical properties without relying on excessive filler content
2Temperature
If a large amount of filler components is used to achieve high thermal conductivity, then thermal conductivity is improved, but processability deteriorates
Solution Approach 1:
The porous metal foam structure provides inherent thermal conductivity without requiring additional filler components. This eliminates the processing difficulties associated with handling and distributing large amounts of filler in a matrix, as the metal foam itself is a processable material that can be formed into various shapes and integrated with other components
3Ease of manufacture
If the metal foam content is reduced to improve processability and impact resistance, then processability and impact resistance are improved, but thermal conductivity may be compromised
Solution Approach 1:
The metal foam structure achieves high thermal conductivity with low material content due to its porous architecture. The metallic framework provides efficient heat conduction pathways while the pores reduce material density, allowing high thermal performance with minimal metal content that maintains processability and impact resistance
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 composite material achieves high thermal conductivity while ensuring stable processability and impact resistance, even with a small amount of metal foam, making it suitable for heat control applications.
Implementation Method 1
contacting the porous metal sintered body with oxygen by electrochemical oxidation
Implementation Method 2
ceramic materials having good thermal conductivity... composite material produced by blending the ceramic filler or the like exhibiting high thermal conductivity in a polymer matrix
Implementation Method 3
a composite material comprising a metal foam and a polymer component... has high thermal conductivity... can be used as a material for controlling heat
Data Source
Figure 1
AI summary
The present application provides a composite material and a method for producing the same. The present application can provide a composite material which comprises a metal foam and a polymer component, and has other excellent physical properties such as impact resistance, processability and insulation properties while having excellent thermal conductivity.