PREPARATION METHOD FOR METAL FOAM

Abstract

The present application relates to a method for preparing a metal foam. The present application can provide a method capable of preparing a metal foam which is thin and has suitable porosity and pore sizes by a simple and efficient process.

Claims

1. A method for preparing a metal foam, the method comprising steps of: forming a metal foam precursor with a slurry that comprises comprising a metal component, a dispersant, a binder and an antisolvent; and sintering the metal foam precursor.

2. The method for preparing the metal foam according to claim 1, wherein the ratio of the metal component in the slurry comprises 45 wt % or more of the metal component.

3. The method for preparing the metal foam according to claim 1, wherein the binder is alkyl cellulose, polyalkylene carbonate, polyvinyl alcohol or polyvinyl acetate.

4. The method for preparing the metal foam according to claim 2, wherein the slurry comprises the binder in a range of 1 to 500 parts by weight relative to 100 parts by weight of the metal component.

5. The method for preparing the metal foam according to claim 1, wherein the dispersant is an alcohol.

6. The method for preparing the metal foam according to claim 2, wherein the slurry comprises the dispersant in a range of 30 to 2,000 parts by weight relative to 100 parts by weight of the binder.

7. The method for preparing the metal foam according to claim 1, wherein the antisolvent comprises one or more selected from the group consisting of a monohydric alcohol, a polyhydric alcohol, an alkanolamine, an alkyl ether, an aryl ether, an ester, a ketone, an alkylbenzene, an arylbenzene and a halobenzene.

8. The method for preparing the metal foam according to claim 2, wherein the slurry comprises the antisolvent in a range of 0.5 to 2,000 parts by weight relative to 100 parts by weight of the binder.

9. The method for preparing the metal foam according to claim 2, wherein the total weight of the dispersant and the antisolvent are present in the slurry in a total weight in a range of 10 to 1,000 parts by weight relative to 100 parts by weight of the metal component.

10. The method for preparing the metal foam according to claim 2, wherein the weight ratio (dispersant/antisolvent) of the dispersant and the antisolvent are present in the slurry in a weight ratio (dispersant/antisolvent) in a range of 0.5 to 20.

11. The method for preparing the metal foam according to claim 1, wherein the metal foam comprises one or more pores, and wherein the pore the one or more pores have a size of the prepared metal foam is in a range of 0.1 m to 200 m.

12. The method for preparing the metal foam according to claim 1, wherein a porosity of the prepared metal foam is in a range of 30% to 90%.

13. The method for preparing the metal foam according to claim 1, wherein the metal foam is in the form of a film or sheet.

14. The method for preparing the metal foam according to claim 13, wherein the film or sheet has a thickness of 500 m or less.

15. The method for preparing the metal foam according to claim 1, wherein forming the metal foam precursor further comprises drying the slurry before sintering the metal foam precursor.

16. The method for preparing the metal foam according to claim 15, wherein drying the slurry is performed at a temperature in a range of 20 C. to 250 C.

17. The method for preparing the metal foam according to claim 1, wherein sintering is performed in an atmosphere including hydrogen and argon.

18. The method for preparing the metal foam according to claim 1, wherein the metal component comprises metal powder.

19. The method for preparing the metal foam according to claim 1, wherein the metal component comprises copper powder.

20. The method for preparing the metal foam according to claim 1, wherein sintering is performed by induction heating.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0052] FIG. 1 is a scanning electron micrograph of the metal foam prepared in Example 1.

[0053] FIG. 2 is a scanning electron micrograph of the metal foam prepared in Comparative Example 1.

[0054] FIG. 3 is a view showing pore size distributions of the metal foams prepared in Examples and Comparative Example.

MODE FOR INVENTION

[0055] Hereinafter, the present application will be described by way of Examples and Comparative Examples, but the scope of the present application is not limited to the following Examples.

EXAMPLE 1

[0056] Copper powder having an average particle diameter (D50) in a range of about 10 to 20 m, a binder (polyvinyl acetate), a dispersant (alpha-terpineol) and an antisolvent (isopropanol) were combined in a weight ratio of about 5:0.5:4.05:0.45 (copper powder: binder: dispersant: antisolvent) to prepare a slurry. The slurry was coated in a film form and dried at about 100 C. for about 2 hours to form a metal foam precursor. At this time, the thickness of the coated metal foam precursor was about 200 m or so. An external heat source was applied in an electric furnace so that the precursor was maintained at a temperature of about 900 C. for 2 hours in a hydrogen/argon gas atmosphere, and sintering was performed to prepare a copper foam. The porosity of the prepared copper foam in the form of a sheet was a level of about 76% or so. FIG. 1 is a photograph of the metal foam formed in Example 1.

EXAMPLE 2

[0057] Copper powder having an average particle diameter (D50) in a range of about 10 to 20 m, a binder (polyvinyl acetate), a dispersant (alpha-terpineol) and an antisolvent (isopropanol) were combined in a weight ratio of about 5:0.5:3.15:1.35 (copper powder: binder: dispersant: antisolvent) to prepare a slurry. The slurry was coated in a film form and dried at about 100 C. for about 2 hours to form a metal foam precursor. At this time, the thickness of the coated metal foam precursor was about 200 m or so. An external heat source was applied in an electric furnace so that the precursor was maintained at a temperature of about 900 C. for 2 hours in a hydrogen/argon gas atmosphere, and sintering was performed to prepare a copper foam. The porosity of the prepared copper foam in the form of a sheet was a level of about 78% or so.

Comparative Example 1

[0058] Copper powder having an average particle diameter (D50) in a range of about 10 to 20 m, a binder (polyvinyl acetate) and a dispersant (alpha-terpineol) were combined in a weight ratio of about 5:0.5:4.5 (copper powder: binder: dispersant) to prepare a slurry. The slurry was coated in a film form and dried at about 100 C. for about 2 hours to form a metal foam precursor. At this time, the thickness of the coated metal foam precursor was about 200 m or so. An external heat source was applied in an electric furnace so that the precursor was maintained at a temperature of about 900 C. for 2 hours in a hydrogen/argon gas atmosphere, and sintering was performed to prepare a copper foam. The porosity of the prepared copper foam in the form of a sheet was a level of about 74% or so. FIG. 2 is a photograph of the prepared metal foam.

[0059] From the comparison of FIGS. 1 and 2, it can be confirmed that the pore size of the metal foam has been increased even under similar levels of porosity through the application of the antisolvent. FIG. 3 is pore size distributions of the metal foams of Examples 1 and 2 and Comparative Example 1, where it can be confirmed that the pore size of the metal foam can be controlled even under similar levels of porosity by using the antisolvent and also adjusting the amount thereof.