A metal-foam structure is used to shield or reduce harmful electromagnetic waves that are generated by electronic devices. A metal-foam material has regulated pores and is incorporated in an electronic device. The metal foam structure shields, prevents, or reduces harmful electromagnetic waves generated by the electronic device from reaching the human body or interfering with a sensitive electronic component. This metal foam is a relatively lightweight material having regulated microscale pore structure. The pores in the metal foam can also form directionality relative to the direction of incoming electromagnetic waves for more effective reflection or absorption of electromagnetic waves. The metal foam can also be used as both an electromagnetic-shielding and a heat-dissipating component for electronics including popular consumer electronics such as mobile phones, notebooks, and high-power desktop computers.
The successful fabrication of alloy foam (or porous alloy) is very rare, despite their potentially better properties and wider applicability than pure metallic foams. The processing of three-dimensional copper-nickel alloy foams is achieved through a strategic solid-solution alloying method based on oxide powder reduction or sintering processes, or both. Solid-solution alloy foams with five different compositions are successfully created, resulting in open-pore structures with varied porosity. The corrosion resistance of the synthesized copper-nickel alloy foams is superior to those of the pure copper and nickel foams.
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sinteringApparatus specially adapted therefor
Morphology, microstructure, compressive behavior, and biocorrosive properties of magnesium or magnesium alloy foams allow for their use in biodegradable biomedical, metal-air battery electrode, hydrogen storage, and lightweight transportation applications. Magnesium or Mg alloy foams are usually very difficult to manufacture due to the strong oxidation layer around the metallic particles; however, in this invention, they can be synthesized via a camphene-based freeze-casting process with the addition of graphite powder using precisely controlled heat-treatment parameters. The average porosity ranges from 45 to 85 percent and the median pore diameter is about a few tens to hundreds of microns, which are suitable for bio and energy applications utilizing their enhanced surface area. This invention based on powder-slurry freeze-casting method using camphene as a volatile solvent is also applicable for other metal foams such as iron, copper, or others to produce three-dimensional metal foams with high strut connectivity.
B22F 3/22 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sinteringApparatus specially adapted therefor for producing castings from a slip
A metal-foam mesh structure is used for various applications where flexible mesh structures are utilized, such as vapor chamber wicks and various diaphragms and energy electrodes. A new metal-foam-mesh hybrid material possesses three dimensionally connected fine pore structure with improved mechanical properties including good strength, ductility, flexibility, and other properties.
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 15/01 - Layered products essentially comprising metal all layers being exclusively metallic
B32B 15/02 - Layered products essentially comprising metal in a form other than a sheet, e.g. wire, particles
B32B 15/20 - Layered products essentially comprising metal comprising aluminium or copper
B22F 7/00 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting
B22F 7/04 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite layers with one or more layers not made from powder, e.g. made from solid metal
06 - Common metals and ores; objects made of metal
Goods & Services
manufacturing materials and components, namely, metal foams for use as a structural and electrochemical components of battery and electrolyzer electrodes
A metal foam vape structure is used for fluid filtration or purification, such as vapor or gas filtration. It is also used for inhaling and exhaling vapor containing nicotine and flavoring produced by a device. This metal foam structure can thus be used in electronic cigarettes or ecigarettes and related devices.
A24F 47/00 - Smokers’ requisites not otherwise provided for
H05K 3/40 - Forming printed elements for providing electric connections to or between printed circuits
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sinteringApparatus specially adapted therefor
7.
Metallic Foam Anode Coated with an Active Oxide Material
A three-dimensional metallic foam is fabricated with an active oxide material for use as an anode for lithium batteries. The porous metal foam, which can be fabricated by a freeze-casting process, is used as the anode current collector of the lithium battery. The porous metal foam can be heat-treated to form an active oxide material to form on the surface of the metal foam. The oxide material acts as the three-dimensional active material that reacts with lithium ions during charging and discharging.
B22D 15/00 - Casting using a mould or core of which a part significant to the process of high thermal conductivity, e.g. chill castingMoulds or accessories specially adapted therefor
B22D 21/00 - Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedureSelection of compositions therefor
B22D 25/00 - Special casting characterised by the nature of the product
B22F 3/24 - After-treatment of workpieces or articles
B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
A sodium-chloride-space-holder process with two-step heat treatment is used to create an open-porous metal foam (e.g., titanium foam) with a high porosity of about 70 to 90 percent for use in load-bearing applications. A mechanically reliable titanium foam is manufactured using a space-holder method containing two-step heat treatment where a sodium chloride powder is first sieved for desired pore size range, mixed with titanium powder, and compacted under pressure at high temperature. An additional heat treatment is applied to further strengthen the chemical bonding between the titanium particles after the removal of sodium chloride in water to create pores. This process uses a pneumatic pressing machine in combination with a furnace under an argon gas to simultaneously apply both the pressure and temperature. The resulting titanium foam is chemically well bonded and has enhanced durability for proper used in structural applications.
A metal-foam structure is used to shield or reduce harmful electromagnetic waves that are generated by electronic devices. A metal-foam material has regulated pores and is incorporated in an electronic device. The metal foam structure shields, prevents, or reduces harmful electromagnetic waves generated by the electronic device from reaching the human body or interfering with a sensitive electronic component. This metal foam is a relatively lightweight material having regulated microscale pore structure. The pores in the metal foam can also form directionality relative to the direction of incoming electromagnetic waves for more effective reflection or absorption of electromagnetic waves. The metal foam can also be used as both an electromagnetic-shielding and a heat-dissipating component for electronics including popular consumer electronics such as mobile phones, notebooks, and high-power desktop computers.
A metal foam ball, several millimeters in diameter, is manufactured to have an open-pore structure to absorb fluid (e.g., gas and liquid) such as water or lubricant. As an example, a copper foam ball is manufactured via a freeze casting method using prepared oxide powder slurry where a spherical silica gel mold is used to freeze the slurry, which is subsequently dried at low temperature in vacuum and then sintered at high temperature. For improved oxidation, copper alloy foam ball or copper foam ball coated with tin can also be manufactured through the same method. For improved strength, steel, copper-nickel alloy, or titanium foam ball can also be manufactured through the same method.
C22C 9/06 - Alloys based on copper with nickel or cobalt as the next major constituent
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sinteringApparatus specially adapted therefor
B22F 3/22 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sinteringApparatus specially adapted therefor for producing castings from a slip
F16C 33/66 - Special parts or details in view of lubrication
C23C 18/16 - Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coatingContact plating by reduction or substitution, i.e. electroless plating
A capacitor and supercapacitor design are based on metal-foam electrodes. An electrolytic capacitor has a metal foam dielectric (e.g., aluminum oxide, titanium oxide, iron oxide, or others). An electric double-layer supercapacitor has an electrode with metal foam (e.g., copper, nickel, titanium, iron, steel alloy, or aluminum) filled with activated carbon, or graphene, or metal foam with activated carbon foam, or any combination of these to enhance the electrical conductivity and thus the power and capacity of the cell. A pseudocapacitor device has an electrode with metal foam (e.g., iron, cobalt, nickel, copper, titanium, aluminum, magnesium, tin, manganese, and stainless steel, and their alloy foams) coated with an oxide- or hydroxide-based material containing highly active zones. The pseudocapacitor metal-foam electrode can also be filled with activated carbon in the form of a slurry to further enhance its capacity.
H01G 11/24 - Electrodes characterised by structural features of the materials making up or comprised in the electrodes, e.g. form, surface area or porosityElectrodes characterised by the structural features of powders or particles used therefor
A gas sensing device is manufactured with three dimensionally connected metal oxide foam structure of large surface area and elongated channel pores within the three-dimensional porous structure for gas sensing applications, thereby increasing the surface area of the sensing layer and expediting sensitivity and sensor response. A gas sensor device includes the fabricated metal-oxide-foam sensing material attached via silver paste to platinum electrodes and ruthenium heater that are printed on low temperature co-fired ceramic substrate. This device will provide improved gas sensing performance with improved sensitivity and response time. Gas sensors including the metal oxide foam sensing material exhibit higher sensitivity to toxic gases such as ethanol and carbon monoxide due to the large surface area achieved from the porous three-dimensional structure providing increased chemical reaction sites and the larger porous channels allowing gases to easily pass, shortening the gas diffusion reaction path.
G01N 27/12 - Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating resistance of a solid body in dependence upon absorption of a fluidInvestigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating resistance of a solid body in dependence upon reaction with a fluid
A facile method is based on a pack-cementation process using large-area copper foil instead of copper powder. By controlling a pack-cementation time and an amount of alloying element (e.g., aluminum), a hierarchical microporous or nanoporous copper can be created. When coated with tin active material, the hierarchical microporous or nanoporous copper can be used as an advanced lithium-ion battery anode. A coin-cell test exhibited a four-fold higher areal capacity (e.g., 7.4 milliamp-hours per square centimeter without any performance degradation up to 20 cycles) as compared to a traditional graphite anode.
The successful fabrication of alloy foam (or porous alloy) is very rare, despite their potentially better properties and wider applicability than pure metallic foams. The processing of three-dimensional copper-nickel alloy foams is achieved through a strategic solid-solution alloying method based on oxide powder reduction or sintering processes, or both. Solid-solution alloy foams with five different compositions are successfully created, resulting in open-pore structures with varied porosity. The corrosion resistance of the synthesized copper-nickel alloy foams is superior to those of the pure copper and nickel foams.
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sinteringApparatus specially adapted therefor
An innovative fuel cell system with membrane electrode assemblies (MEAs) includes a polymer electrolyte membrane, a gas diffusion layer (GDL) made of porous metal foam, and a catalyst layer. A fuel cell has a metal foam layer that improves efficiency and lifetime of the conventional gas diffusion layer, which consists of both gas diffusion barrier (GDB) and microporous layer (MPL). This metal foam GDL enables consistent maintenance of the suitable structure and even distribution of pores during the operation. Due to the combination of mechanical and physical properties of metallic foam, the fuel cell is not deformed by external physical strain. Among many other processing methods of open-cell metal foams, ice-templating provides a cheap, easy processing route suitable for mass production. Furthermore, it provides well-aligned and long channel pores, which improve gas and water flow during the operation of the fuel cell.
Anode and cathode electrodes of a rechargeable lithium-ion battery are manufactured using metal foam. This lithium-ion battery with the metal-foam electrodes can have pores coated or filled, or both, with high-capacity active materials for greater energy density, better safety, improved power, and longer cycle life. Aluminum (or nickel) and copper metal-foam electrodes are manufactured using space-holder and freeze-casting methods. An anode can be filled with a graphite or silicon slurry, or a combination. A cathode can be filled with a lithium cobalt oxide (or other higher-capacity active materials) slurry. The relatively thick metal-foam electrodes are attached to the cell, separated by a separator, and wetted by an electrolyte, forming a high-capacity secondary battery. The battery will have higher density, improved power, and good cycle life.
H01M 4/505 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of manganese of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy
H01M 4/525 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
H01M 4/1395 - Processes of manufacture of electrodes based on metals, Si or alloys
Morphology, microstructure, compressive behavior, and biocorrosive properties of magnesium or magnesium alloy foams allow for their use in biodegradable biomedical, metal-air battery electrode, hydrogen storage, and lightweight transportation applications. Magnesium or Mg alloy foams are usually very difficult to manufacture due to the strong oxidation layer around the metallic particles; however, in this invention, they can be synthesized via a camphene-based freeze-casting process with the addition of graphite powder using precisely controlled heat-treatment parameters. The average porosity ranges from 45 to 85 percent and the median pore diameter is about a few tens to hundreds of microns, which are suitable for bio and energy applications utilizing their enhanced surface area. This invention based on powder-slurry freeze-casting method using camphene as a volatile solvent is also applicable for other metal foams such as iron, copper, or others to produce three-dimensional metal foams with high strut connectivity.
B22F 3/22 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sinteringApparatus specially adapted therefor for producing castings from a slip
B22F 1/06 - Metallic powder characterised by the shape of the particles
B22F 1/10 - Metallic powder containing lubricating or binding agentsMetallic powder containing organic material
An electrode for the use of an advanced lithium battery is fabricated using three-dimensionally structured metal foam coated with an active material. The metal foam is porous metal foam that can be used as an anode current collector of a lithium-ion battery and is coated with an anode active material, such as tin, through a sonication-assisted electroless plating method. Additionally, the coated metal foam is heat-treated at an appropriate temperature in order to improve the integrity of the coating layer and hence, the cyclic performance of the lithium-ion battery.
B22D 15/00 - Casting using a mould or core of which a part significant to the process of high thermal conductivity, e.g. chill castingMoulds or accessories specially adapted therefor
B22D 21/00 - Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedureSelection of compositions therefor
B22D 25/00 - Special casting characterised by the nature of the product
B22F 3/22 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sinteringApparatus specially adapted therefor for producing castings from a slip
B22F 3/24 - After-treatment of workpieces or articles
B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
A metal foam, such as copper metal foam, is used for water filtration and purification. A method is used to manufacture a new water purification device with the capability of killing bacteria and viruses using three dimensionally connected copper foam filter consisting of random or elongated channel pores and large surface area, thereby increasing the copper surface area in contact with contaminated water drops and purifying them. The copper foam water filter has pores on the order of several to tens of micrometers and porosity ranging from 50 percent to 75 percent to properly control the water filtration time and the contact time between the copper foam pore surface and water drops during filtration.
Porous aluminum nitride (AlN) provides a greater surface area and higher permeability, which is especially desirable for advanced functional application. Porous or bulk aluminum nitride is very difficult to manufacture due mainly to its high melting point (e.g., 2200 degrees Celsius). A new processing method synthesizes porous aluminum nitride through a complete transformation from porous aluminum using a remarkably low nitriding or sintering temperature. The manufactured porous aluminum nitride foam can be used for such applications as filters, separators, heat sinks, ballistic armor, electronic packaging, light- and field-emission devices, and highly wear-resistant composites when infiltrated with metal such as aluminum, titanium, or copper.
C01B 21/072 - Binary compounds of nitrogen with metals, with silicon, or with boron with aluminium
C04B 35/581 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on aluminium nitride
C04B 38/00 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof
24.
Metallic foam anode coated with active oxide material
A three-dimensional metallic foam is fabricated with an active oxide material for use as an anode for lithium batteries. The porous metal foam, which can be fabricated by a freeze-casting process, is used as the anode current collector of the lithium battery. The porous metal foam can be heat-treated to form an active oxide material to form on the surface of the metal foam. The oxide material acts as the three-dimensional active material that reacts with lithium ions during charging and discharging.
B22D 15/00 - Casting using a mould or core of which a part significant to the process of high thermal conductivity, e.g. chill castingMoulds or accessories specially adapted therefor
B22D 21/00 - Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedureSelection of compositions therefor
B22D 25/00 - Special casting characterised by the nature of the product
B22F 3/24 - After-treatment of workpieces or articles
B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
H01M 4/13 - Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulatorsProcesses of manufacture thereof
A receiver may receive a signal and process each of a plurality of sub-bands of the received signal via a respective one of a plurality of first-type receive chains. The receiver may utilize a signal output by a first one of the plurality of the first-type receive chains to remove undesired signals from a signal output by a second one of the plurality of the first-type receive chains. The undesired signals may comprise aliases and/or harmonics of one or more signals that fall within a sub-band of the first one of the plurality of the first-type receive chains. The receiver may downconvert, filter, and digitize each of the plurality of sub-bands via a corresponding one of the plurality of the first type receive chains. The received signal may encompass the cable television band, and each of the plurality of sub-bands may comprise a plurality of cable television channels.
H04B 1/10 - Means associated with receiver for limiting or suppressing noise or interference
H04B 15/04 - Reducing interference from electric apparatus by means located at or near the interfering apparatus the interference being caused by substantially sinusoidal oscillations, e.g. in a receiver or in a tape-recorder
26.
Fabrication of three-dimensional porous anode electrode
An electrode for the use of an advanced lithium battery is fabricated using three-dimensionally structured metal foam coated with an active material. The metal foam is porous metal foam that can be used as an anode current collector of a lithium-ion battery and is coated with an anode active material, such as tin, through a sonication-assisted electroless plating method. Additionally, the coated metal foam is heat-treated at an appropriate temperature in order to improve the integrity of the coating layer and hence, the cyclic performance of the lithium-ion battery.
B22D 15/00 - Casting using a mould or core of which a part significant to the process of high thermal conductivity, e.g. chill castingMoulds or accessories specially adapted therefor
B22D 21/00 - Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedureSelection of compositions therefor
B22D 25/00 - Special casting characterised by the nature of the product
B22F 3/24 - After-treatment of workpieces or articles
B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
A three-dimensional metallic foam is fabricated with an active oxide material for use as an anode for lithium batteries. The porous metal foam, which can be fabricated by a freeze-casting process, is used as the anode current collector of the lithium battery. The porous metal foam can be heat-treated to form an active oxide material to form on the surface of the metal foam. The oxide material acts as the three-dimensional active material that reacts with lithium ions during charging and discharging.
B22D 15/00 - Casting using a mould or core of which a part significant to the process of high thermal conductivity, e.g. chill castingMoulds or accessories specially adapted therefor
B22D 21/00 - Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedureSelection of compositions therefor
B22D 25/00 - Special casting characterised by the nature of the product
B22F 3/24 - After-treatment of workpieces or articles
B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
H01M 4/52 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron
An innovative fuel cell system with MEAs includes a polymer electrolyte membrane, a gas diffusion layer (GDL) made of porous metal foam, and a catalyst layer. A fuel cell has a metal foam layer that improves efficiency and lifetime of the conventional gas diffusion layer, which consists of both gas diffusion barrier (GDB) and microporous layer (MPL). This metal foam GDL enables consistent maintenance of the suitable structure and even distribution of pores during the operation. Due to the combination of mechanical and physical properties of metallic foam, the fuel cell is not deformed by external physical strain. Among many other processing methods of open-cell metal foams, ice-templating provides a cheap, easy processing route suitable for mass production. Furthermore, it provides well-aligned and long channel pores, which improve gas and water flow during the operation of the fuel cell.
