PREPARATION METHOD FOR COMPOSITE MATERIAL

Abstract

The present application provides a method for preparing a composite material. The present application provides a method for preparing a composite material comprising a metal foam and a polymer component, wherein the polymer component is formed in an asymmetrical structure on both sides of the metal foam, and a composite material prepared in such a manner.

Claims

1. A method for preparing a composite material, that comprises a metal foam and a polymer component, the method comprising: irradiating with light only a first surface of the metal foam on which a photo-curable composition is present, thereby forming the polymer component on the first surface, wherein the metal foam is in a film shape and further comprises a second surface opposite the first surface, wherein the polymer component has an area ratio (A) on the first surface and the polymer component has an area ratio (B) on the second surface and a ratio (B/A) is in a range of 0 to 0.99.

2. The method according to claim 1, wherein the metal foam has a skeleton comprising one or more metals or metal alloys selected from the group consisting of iron, cobalt, nickel, copper, phosphorus, molybdenum, zinc, manganese, chromium, indium, tin, silver, platinum, gold, aluminum, stainless steel and magnesium.

3. The method according to claim 1, wherein the metal foam has a thickness in a range of 5 m to 5 cm.

4. The method according to claim 1, wherein the metal foam has porosity in a range of 40% to 99%.

5. The method according to claim 1, wherein the photo-curable composition is an acrylic photo-curable composition, an epoxy photo-curable composition, an isocyanate photo-curable composition, a urethane photo-curable composition or a silicone photo-curable composition.

6. The method according to claim 1, wherein the polymer component on the first surface has a thickness in a range of 1 nm to 1 cm.

7. The method according to claim 1, wherein the area ratio (A) of the polymer component present on the first surface is 90% or more.

8. The method according to claim 1, wherein the ratio (B/A) is greater than 0, and the polymer component is in a pillar form on the second surface.

9. The method according to claim 1, wherein a length (P) extends, in a direction to the second surface, from the first surface to a point where the polymer component is present in the interior of the metal foam, and a length (T) extends from the first surface to the second surface, and wherein a ratio (P/T) is in a range of 0 to 1.

10. The method according to claim 9, wherein the ratio (P/T) is greater than 0 and is less than 0.95.

11. The method according to claim 1, wherein the photo-curable composition is formed on the first surface of the metal foam to a thickness of 1 nm to 2 cm.

12. The method according to claim 1, further comprising removing uncured photo-curable composition after the irradiating step.

13. A composite material comprising: a metal foam in a film shape having opposing first and second surfaces and a polymer component present on the first surface, wherein the polymer component has an area ratio (A) on the first surface and the polymer component has an area ratio (B) on the second surface, and wherein a ratio (B/A) is in a range of 0 to 0.99.

14. The method according to claim 1, wherein the photo-curable composition is present on the second surface.

15. The method according to claim 14, wherein the irradiating step further comprises irradiating with light the second surface, thereby forming the polymer component on the second surface.

16. The composite material according to claim 13, wherein the polymer component is present on the second surface.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0049] FIG. 1 is a schematic side view of a composite material of the present application.

[0050] FIG. 2 is a top view of the composite material formed in Example 1.

[0051] FIG. 3 is a bottom view of the composite material formed in Example 1.

[0052] FIG. 4 is a cross section view of the composite material formed in Example 1.

MODE FOR INVENTION

[0053] Hereinafter, the present application will be described in detail by way of examples and comparative examples, but the scope of the present application is not limited to the following examples.

EXAMPLE 1

[0054] A metal foam was a copper metal foam, where the copper metal foam being in the form of a film having a thickness of about 40 m or so and having porosity of approximately 75% or so was used. As a photo-curable composition, a material obtained by mixing DPHA (dipentaerythritol hexxaacrylate) as an ultraviolet curing monomer and TPO (Darocure) as a radical initiator was used. The photo-curable composition was coated on the surfaces of the copper metal foam to a thickness of about 70 m or so. Subsequently, ultraviolet rays (wavelength: 320 nm) were irradiated only on the upper surface of the metal foam at a light quantity of about 3 J/cm.sup.2 or so. After the ultraviolet irradiation, the uncured composition was removed by a developing process using a developer (ethanol) to prepare a composite material.

[0055] FIG. 2 was the surface irradiated with ultraviolet rays as a top view of the composite material formed by the above process, where almost the entire area of the metal foam surface was covered with the polymer component as in the drawing. At this time, the thickness of the polymer component layer was about 50 to 60 m or so.

[0056] FIG. 3 is a bottom view of the composite material formed by the above process, which is a view of the surface opposite to the surface irradiated with ultraviolet rays. As in the drawing, the polymer component (pillar) covered only a part of the surface of the metal foam, and the metal foam was exposed on the surface. At this time, the thickness of the polymer component (pillar) was about 10 m or so, and the polymer component (pillar) covered an area of about 36% in the metal foam surface. FIG. 4 is a cross section view of the composite material formed by the above process.

EXAMPLE 2

[0057] A composite material was prepared in the same manner as in Example 1, except that the light quantity was changed to about 100 mJ/cm.sup.2 upon ultraviolet irradiation. In this case, due to the lowered light quantity of the ultraviolet irradiation, the composite material was formed, in which the pillar of the polymer component was not formed on the surface opposite to the surface irradiated with ultraviolet rays, and inside the metal foam, the polymer also existed to a depth of about 20 m from the side irradiated with ultraviolet rays in the thickness direction. In this case, the thickness of the polymer component on the surface irradiated with ultraviolet rays was about 50 m or so, and in the case of the opposite side, the area ratio was 0%.