CN107497303B - Method for manufacturing filter material - Google Patents

Method for manufacturing filter material Download PDF

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Publication number
CN107497303B
CN107497303B CN201710795433.4A CN201710795433A CN107497303B CN 107497303 B CN107497303 B CN 107497303B CN 201710795433 A CN201710795433 A CN 201710795433A CN 107497303 B CN107497303 B CN 107497303B
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pores
filler
coating
filter material
support body
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CN107497303A (en
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高麟
汪涛
王韬
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Intermet Technology Chengdu Co Ltd
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Intermet Technology Chengdu Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D69/00Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/10Supported membranes; Membrane supports
    • B01D69/105Support pretreatment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D46/00Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/54Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms
    • B01D46/543Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms using membranes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D67/00Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus

Abstract

The invention discloses a manufacturing method of a filter material, which effectively solves the problem that in the prior art, the performance of the filter material is influenced because a constituent of a filter membrane precursor coating enters pores of a porous support body. The method comprises the following operations: disposing a solid filler in pores of a porous support; arranging a filter membrane precursor coating on the surface of the support, and blocking the components of the coating from entering the area provided with the filler in the pores through the filler; and (3) converting a filter material precursor formed after the coating is arranged on the surface of the support body into a filter material target product through heating treatment, wherein in the process, the filler is heated and volatilizes through the pores. The solid filler is arranged in the pores of the porous support, so that the components of the filter membrane precursor coating are blocked by the filler from entering the areas of the pores in which the filler is arranged.

Description

Method for manufacturing filter material
Technical Field
The invention relates to the technical field of filtration, in particular to a manufacturing method of a filter material, a filter material precursor used for the method and the filter material prepared by the filter material precursor.
Background
The filtration precision and the filtration flux are the most key technical indexes for measuring the filtration performance of the filter material. In a gas-solid separation system or a liquid-solid separation system, the filtration precision refers to the capability of a filter material for intercepting solid impurities, and theoretically, the higher the filtration precision is, the higher the filtration efficiency is, and the more thorough the separation between a gas-solid phase and a liquid-solid phase is; the filtration flux refers to the volume of gas or liquid filtered per unit filtration area (i.e. the contact area of the filter material with the object to be filtered) per unit time, and the larger the filtration flux is, the higher the permeability of the filter material is, and the smaller the filtration pressure difference required for maintaining the filtration is. The filtering performance of the filtering material is improved, and the filtering precision and the filtering flux of the filtering material are mainly improved.
The filtering precision of a certain filtering material is improved, and basically, the measures which can be taken are not both the reduction of the pore size of the filtering material and the increase of the thickness of the filtering material. Both measures, however, certainly reduce the filtration flux. In order to solve the above contradiction, the conventional filter material generally adopts a structure composed of a porous support body and a filter membrane arranged on the surface of the porous support body, wherein the filter membrane has smaller pores and as thin as possible, and the support body has larger pores and high enough strength, so that the filter precision of the filter material can be ensured, the filter flux of the filter material can be ensured, and in addition, the strength and the service life of the filter material can be ensured.
In general, a filtration membrane itself is difficult to be produced separately and then attached to a support surface, and therefore, a filtration membrane precursor coating is usually provided on the support surface, and then a filtration material precursor formed by providing the filtration membrane precursor coating on the support surface is subjected to a heating treatment to convert the filtration material precursor into a filtration material target product (i.e., a filtration material to be obtained), and at this time, the filtration membrane is formed on the support of the filtration material. Wherein, the coating used by the coating can select suspension, liquid sol with solid dispersoid or filtering membrane precursor powder; the arrangement mode of the coating mainly adopts spray coating, dip coating and coating. And the heat treatment process can be set correspondingly according to the properties of the coating and the target product of the filter material.
However, there is a problem in the coating layer setting process that: because the pores of the support body are large, when the coating is arranged on the surface of the support body, the components of the coating easily permeate into the pores of the support body, so that plugs are formed in the pores of the support body, and the filtration flux of the filter material is further reduced. For example, when the coating material used for the coating layer is a suspension (the suspension is generally formed by mixing a filtration membrane precursor powder, a dispersant and a binder) or a filtration membrane precursor powder, in order to prevent the powder from excessively penetrating into the pores, it is generally required that the ratio of the average particle diameter of the powder to the average pore diameter of the pores of the support is not less than 0.5, which makes it difficult to achieve the desired pore size of the filtration membrane, and in this case, the thickness of the filtration membrane must be increased to ensure the filtration accuracy of the filtration material.
Disclosure of Invention
The invention aims to provide a manufacturing method of a filter material, a filter material precursor used for the method and the filter material prepared by the filter material precursor, which effectively solve the problem that in the prior art, the performance of the filter material is influenced because a constituent of a filter membrane precursor coating enters pores of a porous support body.
In order to achieve the above object, according to one aspect of the present invention, there is provided a method of manufacturing a filter material, the method including the operations of: disposing a solid filler in pores of a porous support; arranging a filter membrane precursor coating on the surface of the support, and blocking the components of the coating from entering the area provided with the filler in the pores through the filler; and (3) converting a filter material precursor formed after the coating is arranged on the surface of the support body into a filter material target product through heating treatment, wherein in the process, the filler is heated and volatilizes through the pores.
Further, the support body is any one of a metal wire mesh, a metal fiber felt, a foam metal and a sintered metal powder porous material.
Further, the coating is mainly composed of a filter membrane precursor powder; the powder is converted into a filtration membrane of a filter material by a sintering process as the heating process.
Further, the average pore diameter of the pores of the support is 5 to 20 times the average particle diameter of the powder.
Further, the coating is mainly composed of a filter membrane precursor sol; the filtration membrane precursor sol is converted into a filtration membrane of a filtration material by a calcination treatment as the heating treatment.
Further, the filler adopts sodium carboxymethyl cellulose, paraffin, stearic acid or polyvinyl butyral.
Further, a filler precursor slurry is first prepared, then the slurry is infiltrated into the pores, and finally the slurry is solidified to complete the operation of disposing the filler in the pores.
Further, infiltrating said slurry into said pores comprises I contacting said support body with said slurry; and II, carrying out blade coating on the surface of the support body by using a scraper so as to extrude the slurry on the surface of the support body into the pores through the scraper.
Further, the gap between the blade and the surface of the support body at the time of blade coating is set to 0.1 to 0.15 mm.
Further, the scraper is heated so as to form a heated volatilization area of the slurry on the surface of the support body between the scraper and the support body during scraping.
In order to achieve the above object, according to another aspect of the present invention, there is provided a filter material precursor including a porous support and a filter membrane precursor coating layer on a surface of the support, wherein a solid filler capable of being volatilized by heat during a heat treatment for converting the filter material precursor into a target filter material product is further provided in pores of the support, and the solid filler is used for blocking a constituent of the coating layer from entering a region in the pores where the filler is provided.
Further, the support body is any one of a metal wire mesh, a metal fiber felt, a foam metal and a sintered metal powder porous material.
Further, the coating layer is mainly composed of a filter membrane precursor powder.
Further, the average pore diameter of the pores of the support is 5 to 20 times the average particle diameter of the powder.
Further, the coating layer is mainly composed of a filter membrane precursor sol.
Further, the filler adopts sodium carboxymethyl cellulose, paraffin, stearic acid or polyvinyl butyral.
Further, the coating is in contact with a surface of the support; the coating and the filler have a coating penetration layer formed in the pores therebetween.
In order to achieve the above object, according to still another aspect of the present invention, there is also provided a filter material prepared from the above filter material precursor, and including a porous support and a filter membrane on a surface of the support, most of pores in the support forming voids not occupied by the filter membrane.
Further, the filtration membrane is composed of a nanoparticle thin film formed on the surface of the support body by a sol-gel method.
Further, the support body is composed of a sintered metal powder porous material.
The solid filler is arranged in the pores of the porous support body, and the filler blocks the components of the coating of the precursor of the filter membrane from entering the area, in which the filler is arranged, of the pores, so that the problem that the components of the coating enter the pores to influence the performance of the filter material in the prior art is effectively solved. In the heating treatment process of converting the precursor of the filter material into the target product of the filter material, the filler is heated and volatilized, so that most of pores in the support body form gaps which are not occupied by the filter membrane, and the permeability of the filter material is ensured.
The invention is further described with reference to the following figures and detailed description. Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, are included to assist in understanding the invention, and are included to explain the invention and their equivalents and not limit it unduly. In the drawings:
fig. 1 is a schematic view of a method for manufacturing a filter material according to an embodiment of the present invention.
Labeled as: support 110, pores 111, coating 120a, filter membrane 120, filler 130.
Detailed Description
The present invention will now be described more fully hereinafter. Those skilled in the art will be able to implement the invention based on these teachings. It is to be noted in particular that:
the technical solutions and features provided in the present invention in the respective sections including the following description may be combined with each other without conflict.
Moreover, the embodiments of the present invention described in the following description are generally only examples of a part of the present invention, and not all examples. Therefore, all other embodiments obtained by a person of ordinary skill in the art based on the embodiments of the present invention without any creative effort shall fall within the protection scope of the present invention.
With respect to terms and units in the present invention. The terms "including" and "consisting essentially of … …" in the description and claims and related parts of this specification are intended to cover non-exclusive inclusions. The term "metal" includes metals and metal-based alloys.
As shown in fig. 1, a method for manufacturing a filter material according to an embodiment of the present invention includes the steps of:
first, the solid filler 130 is disposed in the pores 111 of the porous support 110;
secondly, a filter membrane precursor coating 120a is provided on the surface of the support 110, and the filler 130 blocks the components of the coating 120a from entering the region of the pores 111 where the filler 130 is provided;
again, the filter material precursor formed after the coating layer 120a is disposed on the support surface is converted into a filter material target product by a heating process, in which the filler 130 is heated and volatilized through the pores 111.
Obviously, the implementation of the above method can obtain a filter material precursor and a filter material prepared from the filter material precursor.
Specifically, as shown in a product corresponding to the left side of reference numeral "S3" (the meaning of the reference numeral will be described later) in fig. 1, the filter material precursor includes a porous support 110 and a filter membrane precursor coating 120a on the surface of the support 110, a solid filler 130 capable of being volatilized by heat during a heating process for converting the filter material precursor into a target filter material product is disposed in the pores 111 of the support 110, and the filler 130 is used for blocking a constituent of the coating 120a from entering a region in the pores 111 where the filler 130 is disposed.
The filter material prepared from the filter material precursor includes a porous support 110 and a filter membrane 120 located on the surface of the support 110, as shown in a product corresponding to the left side of reference numeral "S4" (the meaning of the reference numeral will be described later) in fig. 1, and most of the pores in the support form voids not occupied by the filter membrane 120. Obviously, the filter membrane 120 is transformed by a coating 120a on the filter material precursor.
The support 110 may be made of a material having the same or similar properties as those of the porous support in the filter material of the prior art, which is composed of the porous support and the filter membrane disposed on the surface of the porous support. The embodiment of the present invention preferably uses any one of a wire mesh, a metal fiber mat, a metal foam, and a sintered metal powder porous material as the support body 110.
Among these supports 110, the applicant has proposed, among other things, the use of wire mesh and sintered metal powder porous materials. The wire mesh is readily available and inexpensive, and in addition, has the desired strength and rigidity at the appropriate thickness, and the mesh structure of the wire mesh is also suitable for the present invention.
The sintered metal powder porous material refers to a metal porous material formed by sintering a raw material powder. Sintered metal powder porous materials can be classified into rigid sintered metal powder porous materials and flexible sintered metal powder porous materials. Among them, rigid sintered metal powder porous materials are known as support materials for existing "asymmetric membranes".
And the flexible sintered metal powder porous material is mainly a "flexible porous metal foil" provided in patent documents with publication numbers CN104588651A, CN 104759629A. The flexible sintered metal powder porous material is generally lower in cost and can be bent compared to the rigid sintered metal powder porous material, so that the filter element using the flexible sintered metal powder porous material has a larger filtering area and high cost performance.
The coating material used for the coating layer 120a may be selected from a suspension, a sol in which a dispersoid is solid, or a filter membrane precursor powder. When the coating material is selected as a suspension, the suspension is generally formed by mixing a filtration membrane precursor powder, a dispersant and a binder. When the coating is selected to be the hydrosol with the dispersoid being solid, the hydrosol is the precursor sol of the filter membrane.
Whether the coating material is selected from a suspension (containing the filtration membrane precursor powder) or the filtration membrane precursor powder itself, the conversion of the powder into the filtration membrane 120 is generally achieved by a sintering process. The principle and method of transforming the powder into the filter membrane 120 by sintering treatment is known, for example, from the previously described sintered metal powder porous material.
It is to be noted that during the conversion of the powders into the filter membrane 120, chemical reactions may occur between the powders and/or between the powders and the support body 110, so that the filter membrane 120 formed is constituted by the products of such reactions. In the patent document with publication number CN104874798A, an example of chemical reaction between powders or between powders and a support to form a filter membrane is provided.
If the coating material is selected from the group consisting of the above-mentioned sols, the sols are generally converted into the filtration membrane 120 by a calcination treatment. The principle of the process of converting the sol into the filtering membrane 120 is to use a sol-gel method to prepare a nanoparticle thin film, so that the formed filtering membrane 120 is formed by the nanoparticle thin film formed on the surface of the supporting body 110 by the sol-gel method, and the filtering membrane 120 achieves high filtering precision.
The filler 130 is preferably made of sodium carboxymethylcellulose, paraffin, stearic acid or polyvinyl butyral, which can be made into a solution, is convenient for curing, and has better heating volatility. In this way, the filler 130 can be easily disposed in the pores 111, and the filler 130 can be heated and volatilized through the pores 111 during the heating process.
The filler 130 may be disposed in the following manner: a filler precursor slurry is first prepared, then the slurry is infiltrated into the pores 111, and finally the slurry is cured to dispose the filler 130 in the pores 111.
Wherein the process of infiltrating the slurry into the pores 111 may include:
contacting said support body 110 with said slurry;
and II, coating the surface of the support body 110 by using a scraper so as to extrude the slurry on the surface of the support body 110 into the pores 111 by using the scraper.
To facilitate the implementation of the above processes i and ii, the slurry may be infiltrated into the pores 111 using the filter material manufacturing equipment provided in chinese patent application nos. 2016108768704 and 2016108766709 by the applicant of the present invention.
In order to better perform the above process ii, the gap between the doctor blade and the surface of the support 110 is preferably set to 0.1 to 0.15 mm during the doctor coating. In the case where the gap is set to 0.1 to 0.15 mm, the slurry on the surface of the support body 110 can be sufficiently removed to avoid affecting the subsequent arrangement of the coating layer 120a as much as possible, and the gap can be kept between the doctor blade and the support body 110 to avoid contact friction resistance.
In addition, when the above process ii is performed, the doctor blade may be further heated to form a heated volatilization region of the slurry on the surface of the support body between the doctor blade and the support body 110, so that even if the slurry remaining on the surface of the support body 110 is quickly volatilized, the slurry in the pores 111 is accelerated to be solidified, and the waiting time or the heating baking time for solidifying the slurry is reduced or even eliminated.
The heating means for heating the doctor blade is many, and for example, the doctor blade head may be formed of a resistive material, and the doctor blade head may be energized to generate heat, and the heat generation temperature may be set by the magnitude of the current.
As can be seen from the above, since the filler 130 is provided in the pores 111 of the support 110, the filler 130 can block the components of the coating layer 120a from entering the regions of the pores 111 where the filler 130 is provided; in the heating process of converting the precursor of the filter material into the target product of the filter material, the filler 130 is heated and volatilized, so that most of the pores 111 in the support body 110 form gaps which are not occupied by the filter membrane 120, and the permeability of the filter material is ensured.
Since the constituents of the coating layer 120a can be effectively prevented from entering the pores 111, when the coating layer 120a is mainly composed of a filter membrane precursor powder, the particle diameter of the powder can be set smaller with the pores 111 sized. Generally, the ratio of the average pore diameter of the pores 111 of the support 110 to the average particle diameter of the powder may be 5 to 20 times, which can greatly improve the filtering accuracy of the filtering membrane 120.
An embodiment of the present invention is further described below with reference to fig. 1.
As shown in fig. 1, the method for manufacturing the filter material of this embodiment includes the steps of:
s1 (step one), obtaining the support body 110. The support 110 uses a 304 stainless steel mesh with a thickness of 0.08 mm and a mesh size of 270 mesh.
S2 (step two), the solid filler 130 is disposed in the pores 111 of the support 110. The filler 130 is made of CMC (sodium carboxymethylcellulose), and the specific setting mode is as follows:
adding CMC into deionized water and stirring to prepare filler precursor slurry;
immersing a support body 110 in the slurry, taking out the support body 110, and blade-coating the surface of the support body 110 with a blade, the gap between the blade and the surface of the support body 110 being set to 0.1 mm;
the support 110 after the doctor-blading is then dried at a temperature of 120 ℃ for 30 minutes, so as to complete the filling of the solid CMC in the pores 111 of said support 110.
S3 (step three), a filter membrane precursor coating 120a is provided on the surface of the support 110. Wherein the coating of the coating layer 120a is prepared by the following method:
preparing Ni powder and Cu powder with the particle size of 3-5 mu m into mixed powder according to the weight percentage of 30% of Cu, and then preparing the paint by adding 3 g of PVB and 70 g of the mixed powder into each 100 ml of ethanol by using ethanol as a dispersing agent and PVB as a bonding agent;
and spraying the coating on the surface of the support body 110, and drying for 4 hours at 60 ℃ to form the coating 120a, thereby obtaining the precursor of the filter material.
S4 (step four), the filter material precursor is sintered in a segmented manner, so that the coating 120a is transformed into a sintered nickel-copper alloy porous filter membrane, and the filler 130 is completely volatilized after sintering, and the pores 111 filled with the original filler 130 in the support 110 are left.
And (4) obtaining a target product of the filter material after the steps. When the filter material is used for gas filtration, higher filtration precision and larger filtration flux are achieved at the same time.
The contents of the present invention have been explained above. Those skilled in the art will be able to implement the invention based on these teachings. All other embodiments, which can be derived by a person skilled in the art from the above description without inventive step, shall fall within the scope of protection of the present invention.

Claims (7)

1. A method for manufacturing a filter material, characterized in that it comprises the following operations: disposing a solid filler in pores of a porous support; arranging a filter membrane precursor coating on the surface of the support, and blocking the components of the coating from entering the area provided with the filler in the pores through the filler; converting a filter material precursor formed after the coating is arranged on the surface of the support body into a filter material target product through heating treatment, wherein in the process, the filler is heated and volatilizes through the pores; the process of arranging the solid filler in the pores of the porous support comprises the steps of firstly preparing filler precursor slurry, then infiltrating the slurry into the pores, and finally solidifying the slurry so as to finish the arrangement of the filler in the pores; the process of penetrating the slurry into the pores comprises I, making the support body fully contact with the slurry; scraping the surface of the support body by using a scraper so as to extrude the slurry on the surface of the support body into the pores by using the scraper; and heating the scraper to form a heated volatilization area of the slurry on the surface of the support body between the scraper and the support body during the scraping.
2. The method of claim 1, wherein: the support body is any one of a metal wire mesh, a metal fiber felt, foam metal and a sintered metal powder porous material.
3. The method of claim 1, wherein: the coating is mainly composed of filter membrane precursor powder; the powder is converted into a filtration membrane of a filter material by a sintering process as the heating process.
4. The method of claim 3, wherein: the average pore diameter of pores of the support is 5-20 times of the average particle diameter of the powder.
5. The method of claim 1, wherein: the coating is mainly composed of a filtering membrane precursor sol; the sol is converted into a filtration membrane of a filter material by a firing treatment as the heating treatment.
6. The method of claim 1, wherein: the filler is sodium carboxymethyl cellulose, paraffin, stearic acid or polyvinyl butyral.
7. The method of claim 1, wherein: the clearance between the scraper and the surface of the support body is set to be 0.1-0.15 mm during scraping.
CN201710795433.4A 2017-09-06 2017-09-06 Method for manufacturing filter material Active CN107497303B (en)

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CN108159781A (en) * 2017-12-26 2018-06-15 东华大学 A kind of three-dimensional structure filtration fabrics and preparation method thereof
CN108249947A (en) * 2018-03-12 2018-07-06 成都易态科技有限公司 The preparation method of porous membrane green body and preparation method thereof and porous membrane
CN111318188B (en) * 2020-03-19 2022-03-08 辽宁科京新材料有限公司 Preparation method of porous composite membrane with high permeability and high stability

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