Multi-channel structures and processes for making such structure

Details Multi-channel structures and processes for making such structure Multi-channel structures and processes for making such structure

1996-11-06

1998-06-30

Jordan, Charles T.

Powder metallurgy processes

Powder metallurgy processes with heating or sintering

Making porous product

419 3, 419 4, 419 37, 419 41, 419 45, 419 54, 419 55, 264 56, 264 59, 264 63, 501 81, 501 95, 501 99, 425550, B22F 312, C04B 3804, C04B 3806

Patent

active

057747792

ABSTRACT:
A method for making multi-channel structures suitable for use as filters, catalyst carriers or the like.
A composite rod comprising an outer shell and an inner core is formed of respective mixtures of powders. The mixture for the outer shell comprises a sinterable powdered structural material such as ceramics, metals, intermetallics, and a powdered binder such as paraffin, wax or polymer. The inner core comprises a powdered channel-forming filler material such as melamine or polymers, or soluble inorganic compounds or a metal that can differentially be removed from the structural material of the shell.
The composite rod may be deformed, as by extrusion, to reduce its diameter. In any event, a bundle of composite rods is assembled and deformed, as by extrusion, to reduce the diameter of the bundle and of its component composite rods. Further bundles of the reduced diameter bundles of composite rods may be likewise deformed by extrusion to reduce further the diameter of the component composite rods of the successive bundles, thereby also increasing the number of such rods per given cross section area of the bundle. The final assembly of bundles is consolidated and the binder is removed, as by heating, followed by removal of the inner cores of the composite rods of the assembly of bundles and sintering of the remaining structure of ceramic or metal, as the case may be. In certain embodiments, the material of the inner core may be removed by heating it in the course of heating the structure to perform the sintering step. In other embodiments, the binder and/or filler material may be removed by means of a suitable solvent.

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