Nanoporous Copper Production via Folding and Corrosion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for producing nanoporous copper, such as dealloying using strip casting, are costly and complex, limiting the widespread adoption of this high-performance material for applications in energy, photoelectric conversion, and catalysis due to high preparation costs and operational intricacies.
Innovation Solution
A method involving the formation of a copper alloy layer with active metal layers, repeated folding and pressing to create a precursor, followed by corrosion to produce nanoporous copper, which reduces crystal size, introduces defects, and simplifies the production process, potentially using reinforcements like carbon nanotubes to enhance mechanical strength without increasing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If strip casting is used to form copper alloy precursor, then fine grain size and high defect density are achieved, but preparation cost increases and operation becomes complicated
Solution Approach 1:
The patent changes the processing parameters by replacing strip casting with rolling and folding operations. Specifically, it uses repeated folding (2-10 times) and rolling (0.5-5 passes per fold) to achieve fine grain size and high defect density without the complexity of strip casting equipment and processes
Solution Approach 2:
The patent segments the copper alloy sheet into multiple folded layers, creating a multi-layered precursor structure. This segmentation through folding allows the material to be processed in simple steps while achieving the fine microstructure needed for uniform pore formation during dealloying
2Reliability
If conventional dealloying method is used, then nanoporous copper is obtained, but preparation cost is high and operation is complicated
Solution Approach 1:
The patent performs preliminary actions by pre-forming the copper alloy precursor with specific microstructure (fine grain, high defect density) through folding and rolling before dealloying. This preliminary structuring ensures uniform pore formation during the subsequent simple dealloying process, improving reliability while simplifying overall manufacturing
Solution Approach 2:
The patent uses a disposable precursor structure created through simple folding and rolling that is optimized for single-use dealloying. The precursor is designed to be consumed in the dealloying process, eliminating the need for complex equipment while ensuring high-quality nanoporous copper production
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 significantly reduces production costs, simplifies operations, and maintains the structural integrity of reinforcements, enabling the production of nanoporous copper with controlled pore size and high performance at a lower cost compared to conventional methods.
Implementation Method 1
The dealloying method utilizes a principle of chemical or electrochemical corrosion to make the electrochemically active elements in an alloy dissolve into electrolyte
Implementation Method 2
The dealloying method utilizes a principle of chemical or electrochemical corrosion to make the electrochemically active elements in an alloy dissolve into electrolyte
Implementation Method 3
repeated folding and pressing to create a precursor, followed by corrosion to produce nanoporous copper, which reduces crystal size, introduces defects
Data Source
AI summary
A method of making a nanoporous copper is provided. A copper alloy layer and at least one active metal layer are provided. The copper alloy layer comprises a first surface and a second surface. The at least one active metal layer is located on the first surface and the second surface to form a structure. The structure is processed to form a composite structure. A process of folding and pressing the composite structure is repeated to form a precursor. The precursor is corroded to form the nanoporous copper.