Porous Structure Cavity via Partial Coating and Particle Removal

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Solution Overview

Problem

The manufacturing of porous ceramics or metals involves complex and costly processes, requiring high temperatures and multiple steps to create cavities with porous structures, which is time-consuming and resource-intensive.

Innovation Solution

A method involving a substrate with a recess where loose particles are introduced and partially coated to form a solidified porous structure, allowing for selective removal of uncoated particles to create a cavity, with the porous structure acting as a lid or membrane, enabling fluid diffusion and reducing material usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional methods are used to manufacture porous ceramics or metals, then porous structures can be produced, but the process requires high temperatures, multiple steps, and is time-consuming and resource-intensive

Engineering Contradiction:

Improveporous structure qualityVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The invention changes the temperature parameter from high temperatures (traditional sintering/pyrolysis) to low temperatures (coating process at or near room temperature). The coating process forms a solidified shell around loose particles without requiring thermal treatment, fundamentally altering the manufacturing parameters to achieve porous structures efficiently

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention extracts and removes the solidified shell material after it has served its purpose as a mold or support structure. This extraction creates the final porous structure by leaving behind the loose particles in the desired configuration, eliminating the need for complex sintering processes

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If traditional methods are used to manufacture porous structures, then porous materials can be produced, but multiple processing steps are required to create blanks and integrate them into cavities

Engineering Contradiction:

Improveporous structure integrityVSAvoidnumber of processing steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention merges multiple traditional processing steps into a single integrated process. The coating process simultaneously forms the solidified shell, defines the cavity shape, and supports the loose particles, eliminating the need for separate steps to create blanks and integrate them into final structures

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention performs preliminary action by first forming the solidified shell around the loose particles before removing the shell material. This preliminary shell formation provides structural support and defines the final cavity geometry, making the subsequent removal process straightforward and eliminating the need for complex integration steps

Inventive Principle:

Principle #10Preliminary action

3Strength

If the coating process penetrates deeply into the recess, then more particles are connected to form the porous structure, but fewer particles remain to form the cavity

Engineering Contradiction:

Improveporous structure stabilityVSAvoidcavity volume

Core Design Contradiction:

StrengthVSVolume of stationary object

Solution Approach 1:

The invention applies partial action by controlling the coating process to penetrate only to a specific depth within the recess, not completely filling it. This partial penetration allows the coating to connect enough particles to form a stable porous structure while leaving sufficient uncoated particles to maintain the desired cavity volume after shell removal

Inventive Principle:

Principle #16Partial or excessive action

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 of cavities with porous structures by reducing material volume and processing steps, allowing for efficient fluid communication and integration with the substrate, while maintaining the porous structure and enabling the use of different materials for the particles and the structure.

Implementation Method 1

introducing a coating material that solidifies to form a solidified shell around the loose particles

Methodology Applied

Scientific EffectCoating/Deposition: Deposition (physical)

Implementation Method 2

maintaining the porous structure and enabling the use of different materials for the particles and the structure

Methodology Applied

Scientific EffectDiffusion: Diffusion

Data Source

PatentUS11268122B2Method of producing a cavity having a porous structure

Publication Date: 2022.03.08 FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV

AI summary

A method of producing a device includes providing a substrate which has a recess. A multitude of loose particles is introduced into the recess. A first portion of the particles is coated by using a coating process having a depth of penetration which extends from an opening of the recess, along a direction of depth, and into the recess, so that the first portion is connected to form a solidified porous structure. The depth of penetration of the coating process which extends into the recess is set such that a second portion of the particles is not connected by means of the coating, and such that the solidified first portion of the particles is arranged between the second portion of the particles and surroundings of the recess. According to the invention, the second portion of the particles is at least partly removed from the recess.