Hierarchical porous material

Abstract

A hierarchical porous material consists of multistage porous materials, comprising a material body, the body is formed bar a pore cavity graded according to the pore size of the material and a cavity wall surrounding to form the pore cavity. The pore cavities are uniformly distributed. The characteristics are as follows. A lower-level pore cavities are disposed on the cavity wall of an upper-level pore cavity formed by surrounding a three-dimensional space. Each level of pore cavities are mutually connected and the pore cavities within same level are also connected with each other. The uniform distribution of the pore cavities means that similar amount of pore cavities are distributed under any unit volume of the hierarchical porous material. The hierarchical structure of the cavity of the material enables it to meet a wide range of functional requirements.

Claims

1. A hierarchical porous material consists of a multilevel porous material, comprising: a material body, the material body is formed by a plurality of pore cavities classified according to a pore size of the multilevel porous material; and a plurality of cavity walls surrounding to form the plurality of pore cavities: wherein the plurality of pore cavities are uniformly distributed such that a similar amount of pore cavities are distributed over any unit-level volume of the hierarchical porous materials, and a lower-level of pore cavities are disposed on a cavity wall of an upper-level pore cavity, wherein the upper-level pore cavity is formed by the cavity wall surrounding a three-dimensional space; the pore cavities of a same level are mutually connected, the pore cavities of different levels are mutually connected.

2. The hierarchical porous material of claim 1, wherein each level of a plurality of the multilevel porous materials in the material both is a continuous structure.

3. The hierarchical porous material of claim 2, wherein a maximum outer boundary of each level of the plurality of multilevel porous materials is equivalent to a space boundary of the entire material body.

4. The hierarchical porous material of claim 1, wherein each level of the multilevel porous material in the material body has its own physicochemical properties.

5. The hierarchical porous material of claim 1, wherein a lower-level porous material forms the cavity will of the upper-level pore cavity.

6. The hierarchical porous material of claim 1, wherein, the cavity all of the upper-level pore is formed by a plurality of lower-level multilevel porous materials.

7. The hierarchical porous material of claim 1, wherein the cavity wall of the upper-level pore is formed by a composite of all levels of the lower-level porous material.

8. The hierarchical porous material of claim 1, wherein a unit-level volume refers to a cubic centimeter level or cubic millimeter level or a less unit-level volume.

9. The hierarchical porous material of claim 8, wherein masses of a plurality of three-dimensional blocks with volumes less than or equal to one cubic centimeter and the same sizes randomly selected from the hierarchical porous material are substantially the same.

10. The hierarchical porous material of claim 9, wherein the masses are substantially the same means, the plurality of three-dimensional blocks with volumes less than or equal to one cubic centimeter and having the same size are randomly selected from the hierarchical porous material, each of the plurality of three-dimensional block is measured to obtain an average value of the mass, and an absolute value of a deviation of the mass of any of the plurality of three-dimensional blocks from the mass average value is less than or equal to 4% of the mass average value of the plurality of three-dimensional blocks.

11. The hierarchical porous material of claim 8, wherein the masses of a plurality of three-dimensional blocks with volumes less than or equal to one cubic millimeter, having the same size and randomly selected from the hierarchical porous material, are substantially the

12. The hierarchical porous material of claim 11, wherein the masses are substantially the same means, the plurality of three-dimensional blocks with volumes less than or equal to one cubic millimeter and having the same size, are randomly selected from the hierarchical porous material, each of the plurality of three-dimensional block is measured to obtain an average value of the mass, and an absolute value of a deviation of the mass of any three-dimensional block from the mass average value is less than or equal to 4% of the mass average value of the plurality of three-dimensional blocks.

13. The hierarchical porous material of claim 2, wherein each level of the multilevel porous material in the material body has its own physicochemical properties.

14. The hierarchical porous material of claim 3, wherein each level of the multilevel porous material in the material body has its own physicochemical properties.

15. The hierarchical porous material of claim 2, wherein a lower-level porous material forms the cavity wall of the upper-level pore cavity.

16. The hierarchical porous material of claim 3, wherein a lower-level porous, material forms the cavity wall of the upper-level pore cavity.

17. The hierarchical porous material of claim 4, wherein a lower-level porous material firms the cavity wall of the upper-level pore cavity.

18. The hierarchical porous material of claim 13, wherein a lower-level porous material forms the cavity wall of the upper-level pore cavity.

19. The hierarchical porous material of claim 14, wherein a lower-level porous material forms the cavity wall of the upper-level pore cavity.

20. The hierarchical porous material of claim 2, wherein, the cavity wall of the upper-level pore is formed by a lower-level multilevel porous material.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0024] The specific embodiments are given on the premise of the technical solutions of the present invention, but the protection scope of the present invention is not limited to the following embodiments. It will be apparent to those skilled in the art that various changes and modifications may be made without departing from or changing the above technical conception of the present invention, and should be construed as being included in the scope of the present invention.

[0025] The embodiments of the present invention are given below in detail.

Embodiment 1

[0026] The hierarchical porous material of the present embodiment is porous alumina with a secondary pore structure. Wherein a uniformly distributed and interconnected second pore cavity is disposed on the cavity wall of a uniformly distributed and interconnected first pore cavity. The first pore and the second pore are also interconnected, which is a three-dimensional interconnection. Each level porous material of the hierarchical porous material is a continuous structure, the maximum outer boundary of each level porous material is equivalent to the space boundary of the entire material body, each level porous material has its own physicochemical properties. The total effective porosity is 60%, the average pore size of the large pores is 10 m and penetrating; small pores with an average pore size of 750 nm are on the cavity wall of the large pores.

[0027] Nine of three-dimensional blocks having the same size of 10 mm10 mm10 mm are randomly selected from the hierarchical porous material by a machining method the masses of which are measured respectively at a room temperature of 20 C. using a METTLER-TOLEDO XP26 Microbalance. Measuring steps are as follows:

[0028] 1) preheating: turn on the power, preheating the microbalance to a specified time;

[0029] 2) selecting the basic mode of balance: tap the ON button, turn on the display, and choose the normal mode:

[0030] 3) calibration: using Target (TAR) key to clear, and using Calibration (CAL) minus and calibration weight to calibrate;

[0031] 4) weighing: pressing the TAR key to display zero, putting the three-dimensional blocks successively on the scale pan, reading the mass value of the three-dimensional block until the figure is stable, i.e. the 0 at the lower left corner of the display disappears.

[0032] The measurement results are shown in Table 1. wherein the absolute value of the deviation from the average value is expressed as a percentage, and the value thereof is the absolute value of the deviation from the average value divided by the mass average value. As shown in Table 1, the mass deviation is less than or equal to 4%.

TABLE-US-00001 TABLE 1 Absolute value of the deviation No Mass (mg) from the average value (%) 1 1560.624 1.6% 2 1568.554 1.1% 3 1538.420 .sup.3% 4 1552.694 2.1% 5 1559.038 1.7% 6 1649.440 .sup.4% 7 1628.822 2.7% 8 1606.618 1.3% 9 1609.790 1.5% Mass average value 1586

[0033] The preparation method of this material is as follows:

[0034] (1) Material Preparation

[0035] The alumina powder with a particle size of 3 m and urea with a particle size of 86030 nm are used as pore-forming agent for the smallest pore cavity of the hierarchical porous material. The pore-forming agent is mixed uniformly and the starch with a particle size of 86030 nm is used as binder. A slurry is prepared by the alumina powder, urea, starch and distilled water with the volume ratio of 3:1.5:1:12.

[0036] The slurry is uniformly tilled into a polyester foam with a strut diameter of 15 m by a foam impregnation method to form a green body and dry the green body, and then crush to obtain mixed grains with a grain size of 15 m containing a raw material, a pore-forming agent and a polyester foam.

[0037] (2) The mixed grains and methyl cellulose with a particle size of 15 m are uniformly mixed into a closed mould by volume ratio of 3:1 to be pressed into a compact green body,

[0038] (3) The compact green both is Vacuum sintered. After the sintering, the green body is subjected to conventional follow-up treatment according to the alumina process to obtain porous alumina with secondary pores.

[0039] The material can be used for solid-liquid separation, achieving accurate grading filtration. Pores of two levels respectively filter particles with different sizes, avoiding the accumulation of particles and achieving the efficient separation.

Embodiment 2

[0040] The hierarchical porous material of the present embodiment is porous nickel with a secondary pore structure. The hierarchical porous material is classified into different levels according to the pore size of the material. Wherein all levels of pores are three-dimensionally interconnected. Each level porous material of the hierarchical porous material is a continuous structure, the maximum outer boundary of each level porous material is equivalent to the space boundary of the entire material body, each level porous material has its own physicochemical properties. The total effective porosity is 70%, the average pore size of the large pores is 30 m, and a penetrating small pore with an average pore size of 600 nm is on the cavity wall of the large pores.

[0041] Nine of three-dimensional blocks having the same size of 1 mm1 mm1 mm are randomly selected from the hierarchical porous material by a machining method, the masses of which are measured respectively using a METTLER-TOLEDO XP26 Microbalance. Measuring temperature and steps are the same as that in embodiment I. The results are shown in Table 2, wherein the absolute value of the deviation from the average value is expressed as a percentage, and the value thereof is the absolute value of the deviation from the average value divided by the mass average value. As shown in Table 2, the mass deviation is less than or equal to 4%.

TABLE-US-00002 TABLE 2 Absolute value of the deviation No Mass (mg) from the average value (%) 1 2.635 1.3% 2 2.638 1.2% 3 2.587 3.1% 4 2.606 2.4% 5 2.622 1.8% 6 2.774 3.9% 7 2.742 2.7% 8 2.707 1.4% 9 2.723 .sup.2% Mass average value 2.670

[0042] The preparation method of the porous nickel is as follows:

[0043] (1) Material Preparation

[0044] Nickel powder with a particle size of 3 m and ammonium chloride with a particle size of 700 nm are used as pore-forming agents for the smallest pore. The pore-forming agents are mixed uniformly and the starch with a particle size of 700 nm is used as binder. A slurry is prepared by the nickel powder, ammonium chloride, starch and distilled water with the volume ratio of 2:1.5:1:10.

[0045] The slurry is uniformly filled into a polyester foam with a strut diameter of 40 m by a foam impregnation method to form a green body and dry the green body, and then crush to obtain a mixed grains with a grain size of 40 m containing a nickel powder, a pore-forming agent and a polyester foam.

[0046] (2) The mixed grains and ethyl cellulose with a particle size of 40 m are uniformly mixed into a closed mould by volume ratio of 3:1 to be pressed into a compact green body.

[0047] (3) The compact green body is vacuum sintered. After the sintering, the embryoid body is subjected to conventional follow-up treatment according to the alumina process to obtain porous nickel with secondary pores.

[0048] This kind of material is used to make electrodes, which has the advantages of low energy consumption and high efficiency compared with the traditional single-cavity porous materials.

Embodiment 3

[0049] The hierarchical porous material of the present embodiment is porous tantalum with a tertiary pore structure. Wherein a uniformly distributed and interconnected secondary pore cavities are disposed on the cavity wall of a uniformly distributed and interconnected first pore cavity, a uniformly distributed and interconnected tertiary pore cavities are disposed on the cavity wall of the uniformly distributed and interconnected secondary pore cavity. The first, secondary and tertiary pore cavities are also interconnected, which is a three-dimensional interconnection. Each level porous material is a continuous structure, the maximum outer boundary of each level porous material is equivalent to the space boundary of the entire material body, each level porous material of the hierarchical porous material has its own physicochemical properties. The total effective porosity is 80%, the average pore size of the first pores is 510 m, the penetrating second pores with an average pore size of 25 m are disposed on the cavity wall of the first pore, and the penetrating third pores with an average pore size of 780 nm are disposed on the cavity wall of the secondary pore.

[0050] Nine of three-dimensional blocks having the same size of 10 mm10 mm10 mm are randomly selected from the hierarchical porous material by a machining method, the masses of which are measured respectively using a METTLER-TOLEDO XP26 Microbalance. Measuring temperature and steps are the same as that in embodiment 1. The results are shown in Table 3, wherein the absolute value of the deviation from the average value is expressed as a percentage, and the value thereof is the absolute value of the deviation from the average value divided by the mass average value. As shown in Table 3, the mass deviation is less than or equal to 4%.

TABLE-US-00003 TABLE 3 Absolute value of the deviation No Mass (mg) from the average value (%) 1 3282.624 1.6% 2 3292.63 1.3% 3 3242.592 2.8% 4 3265.944 2.1% 5 3285.960 1.5% 6 3469.440 .sup.4% 7 3409.392 2.2% 8 3396.048 1.8% 9 3379.368 1.3% Mass average value 3336

[0051] The preparation method of this material is as follows:

[0052] (1) Material Preparation

[0053] Polystyrene beads with a particle size of 90030 nm is selected to assemble to form a three-dimensional ordered colloid template. Tantalum nanocrystal solution is prepared, introducing the tantalum nanocrystal solution into the three-dimensional colloid template made of polystyrene beads, drying the mixture of the three-dimensional colloid template/tantalum nanocrystal solution and then breaking it into grains with a gain size of 5 m.

[0054] (2) Starch with a particle size of 90030 nm is selected to mix with distilled water by a weight ratio of 1:40 to prepare starch solution. A slurry is prepared by the above particles, ethyl cellulose with a particle size of 35 m and the starch solution by the weight ratio of 12:1:8, which is uniformly impregnated into a polyester foam with a pore size of 60020 m.

[0055] (3) The impregnated polyester foam is sintered in a vacuum or a protective atmosphere and then subjected to conventional follow-up treatment according to the tantalum process to obtain porous tantalum with tertiary pores.

[0056] The porous tantalum can be used as a bone regeneration material. The size of the first pore is particularly suitable for the growth of living tissues such as blood vessels. The secondary pore is particularly suitable for the residence of various kinds of cells. The tertiary pore is particularly favorable for satisfying the needs of cell adhesion and differentiation due to the large number of nanopores. It also has a high specific surface area and can load a large amount of growth factors. Moreover, the connectivity of the pores is good with the pores at all levels interconnected and the pores within each level connected with each other, which can fully meet the infiltration and transmission of blood and tissue fluid, achieving the excretion of the products of protein degradation and metabolites. Therefore, it is a real bone regeneration material.

Embodiment 4

[0057] The hierarchical porous material of the present embodiment is porous titanium with a tertiary pore structure. Wherein a uniformly distributed and interconnected secondary pore cavity is disposed on the cavity wall of a uniformly distributed and interconnected first pore cavity, a uniformly distributed and interconnected tertiary pore cavity is disposed on the cavity wall of the uniformly distributed and interconnected secondary pore cavity. The first, secondary and tertiary pore cavities are also interconnected, which is a three-dimensional interconnection. Each level porous material is a continuous structure, the maximum outer boundary of each level of porous material is equivalent to the space boundary of the entire material body, each level porous material has its own physicochemical properties. The total effective porosity is 74%, the average pore size of the first pores is 450 m, the penetrating second pores with an average pore size of 30 m are disposed on the cavity wall of the first pore, and the penetrating third pores with an average pore size of 670 nm are disposed on the cavity wall of the second pore.

[0058] Nine of the three-dimensional blocks having the same size of 10 mm10 mm10 mm are randomly selected from the hierarchical porous material by a machining method, the masses of which are measured respectively using a METTLER-TOLEDO XP26 Microbalance. Measuring temperature and steps are the same as that in embodiment 1. The results are shown in Table 4, wherein the absolute value of the deviation from the average value is expressed as a percentage, and the value thereof is the absolute value of the deviation from the average value divided by the mass average value. As shown in Table 4, the mass deviation is less than or equal to 4%.

TABLE-US-00004 TABLE 4 Absolute value of the deviation No Mass (mg) from the average value (%) 1 1156.184 1.4% 2 1135.077 3.2% 3 1151.493 1.8% 4 1157.356 1.3% 5 1145.630 2.3% 6 1217.159 3.8% 7 1197.225 2.1% 8 1191.362 1.6% 9 1201.915 2.5% Mass average value 1172.600

[0059] The preparation method of the porous titanium is as follows:

[0060] (1) Material Preparation

[0061] The titanium powder with a particle size of 2 m is used as a raw material, starch with a particle size of 770 nm is used as pore-forming agent for the smallest pore cavity, and stearic acid with a particle size of 770 nm is used as binder. A slurry is prepared by the titanium powder, starch, stearic acid and distilled water with the volume ratio of 3:1:1:11.

[0062] The slurry is uniformly filled into a polyester foam with a strut diameter of 30 m by a foam impregnation method to form a green body and dry the green body, and then crush to obtain a mixed grains with a grain size of 30 m containing a raw material, a pore-forming agent and a polyester foam.

[0063] (2) The mixed grains and methyl cellulose with a particle size of 30 m are uniformly mixed in a volume ratio of 3:1 to pour into a three-dimensionally interconnected polyester foam with a strut diameter of 56020 m and a pore size of 400+15 m, then putting the polyester foam to a closed mould to press into a compact green body.

[0064] (3) The compact green body is vacuum sintered. After the sintering, the green body is subjected to conventional follow-up treatment according to the titanium process to obtain porous titanium with tertiary pores.

Similar to embodiment 3, this material is particularly suitable for using as bone regeneration material.