Porous Metal-Ceramic Component with Integral Low-Porosity Joint
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Solution Overview
Problem
Existing porous components with open-pored structures face challenges in maintaining stability and creating secure connections for media or energy supply due to mechanical stress and weak joints at joining points, particularly in applications like electrical heating elements and heat exchangers.
Innovation Solution
A method involving a semi-finished product with a polymeric open-pored foam body coated with metallic or ceramic particles, followed by a suspension containing metallic or ceramic particles and gas bubbles, which forms distinct volume regions with varying porosities through sintering, creating integral and form-locked connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an open-pored foam body is used to maintain filtering or heat exchange functionality, then the component can perform its intended function, but strength and stability are reduced
Solution Approach 1:
The patent applies composite materials by combining an open-pored foam body with a supporting frame structure. The frame provides mechanical strength and stability while the foam body maintains filtering or heat exchange functionality. This composite structure resolves the contradiction by integrating two materials with complementary properties.
Solution Approach 2:
The patent segments the component into distinct functional regions: an open-pored foam body for filtering/heat exchange and a separate frame structure for mechanical support. This segmentation allows each part to optimize its specific function without compromising the other.
2Strength
If a frame structure is added to increase strength, then strength and stability are improved, but connection options to supply or remove media or energy become problematic
Solution Approach 1:
The patent applies local quality by creating a localized connection region with different properties from the main foam body. This connection region provides structural support for connections while maintaining the open-pored structure's functionality, allowing media or energy to be supplied or removed without compromising overall strength.
3Ease of manufacture
If a form-locked connection is used to connect the foam body to a frame, then structural connection is achieved, but struts in the connecting region may break due to mechanical stresses
Solution Approach 1:
The patent introduces a connection element as an intermediary between the foam body and frame structure. This intermediary distributes mechanical stresses and prevents direct load transfer to vulnerable struts, maintaining both structural connection and strut integrity.
4Strength
If welding or bonding is used to create an integral joint, then connection strength is improved, but weak spots or interfaces that may result in breakage occur at the joining points
Solution Approach 1:
The patent extracts the connection function from the main structural elements and implements it through a separate connection element. This removes the weak interface problem from critical load-bearing paths, as the connection element is specifically designed for joining without creating stress concentration points in the main structure.
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
Enhances the stability of open-pored components by integrating secure and permanent connections for media or energy supply, reducing the risk of joint failure under mechanical stress.
Implementation Method 1
a portion of this suspension penetrates into open pores of the foam body
Implementation Method 2
a drying process using a thermal treatment is carried out, during which first liquid contained in the suspension is expelled
Implementation Method 3
polymeric components, in particular polymeric components of the binder and the polymeric material of the foam body, are removed
Implementation Method 4
a sintering process is carried out. During sintering, a first volume region is formed with the metal or the ceramic material originating from the suspension
Implementation Method 5
This can be achieved, for example, by way of a CVD or PVD method, which is known per se
Implementation Method 6
galvanically or according to the so-called Schwartzwalder process, in which the struts have been provided with a coating containing metallic or ceramic particles
Data Source
AI summary
An open-pored polymeric foam body is provided with a metallic coating or a coating at the surfaces of struts of the foam body. At the semi-finished product, a suspension that is formed with metallic or ceramic particles, in which additionally gas bubbles are present, is brought in contact with the surface of the foam body in surface regions and is brought into a predefined shape. A portion of this suspension penetrates into open pores of the foam body. Thereafter, a thermal treatment is carried out, during which liquid is expelled, polymeric components are removed, and subsequently a sintering process is carried out. A first volume region is formed with the metal or the ceramic originating from the suspension, which has a smaller porosity. Adjoining this first volume region, a second volume region is created, which is likewise porous.