Method for forming porous sintered bodies with controlled pore s

Details Method for forming porous sintered bodies with controlled pore s Method for forming porous sintered bodies with controlled pore s

1996-12-17

2000-07-11

Thibodeau, Paul

Stock material or miscellaneous articles

All metal or with adjacent metals

Porous

264 42, 264 44, 501 81, 501 88, B32B 518, C04B 3806, C04B 3552, B29C 6500

Patent

active

060870249

ABSTRACT:
The present invention is based, in part, on a method for combining a mixture of hydroxide and hydride functional siloxanes to form a polysiloxane polymer foam, that leaves no residue (zero char yield) upon thermal decomposition, with ceramic and/or metal powders and appropriate catalysts to produce porous foam structures having compositions, densities, porosities and structures not previously attainable. The siloxanes are mixed with the ceramic and/or metal powder, wherein the powder has a particle size of about 400 .mu.m or less, a catalyst is added causing the siloxanes to foam and crosslink, thereby forming a polysiloxane polymer foam having the metal or ceramic powder dispersed therein. The polymer foam is heated to thermally decompose the polymer foam and sinter the powder particles together. Because the system is completely nonaqueous, this method further provides for incorporating reactive metals such as magnesium and aluminum, which can be further processed, into the foam structure.

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