Fluid-permeable article producing method

• US 4,909,300 A
• Filed: 01/27/1989
• Issued: 03/20/1990
• Est. Priority Date: 10/16/1986
• Status: Expired due to Fees

• Current Assignee: Nabeya Iron & Tool Works Limited
• Original Assignee: Nabeya Iron & Tool Works Limited
• Inventors: Horie, Takao
• Primary Examiner(s): Seidel, Richard K.
• Application Number:
  US07/302,257
• Time in Patent Office: 417 Days
• Field of Search: 164/91, 164/97, 164/98, 164/100, 164/101, 164/102, 164/103, 164/104, 164/105, 164/106, 164/112, 164/69.1, 29/423, 29/424
• US Class Current: 164/69.1
• CPC Class Codes: B01D 39/2093 Ceramic foam
• CPC Class Codes: B22D 19/00 Casting in, on, or around objects which form part of the product B22D23/04 takes precedence; alumino-thermic welding B23K23/00; coating by casting molten material on the substrate C23C6/00
• CPC Class Codes: B28B 1/50 specially adapted for producing articles of expanded material, e.g. cellular concrete chemical aspects or making expanded aggregate C04B
• CPC Class Codes: C04B 2111/00284 Materials permeable to liquids
• CPC Class Codes: C04B 35/00 Shaped ceramic products characterised by their composition porous ceramic products C04B38/00; ceramic articles characterised by particular shape, see the relevant classes, e.g. linings for casting ladles, tundishes, cups or the like B22D41/02; ceramic substrates for microelectronic semi-conductors H01L23/15; Ceramics compositions containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides other than as macroscopic reinforcing agents C22C; shaping of ceramics B28B; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products chemical preparation of powders of inorganic compounds C01; infiltration of sintered ceramic preforms with molten metal C04B41/51
• CPC Class Codes: C04B 38/0615 the burned-out substance being a monolitic element having approximately the same dimensions as the final article, e.g. a porous polyurethane sheet or a prepreg obtained by bonding together resin particles C04B38/0022 takes precedence
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4505 characterised by the method of application
• CPC Class Codes: C04B 41/51 Metallising , e.g. infiltration of sintered ceramic preforms with molten metal covering materials with metals in general C23C; ceramic compositions containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides, other than as macroscopic reinforcing agents C22C; infiltration of preforms containing free metal, e.g. cermets C22C
• CPC Class Codes: C04B 41/88 Metals
• CPC Class Codes: F16C 29/025 Hydrostatic or aerostatic this type of bearing for rotary parts F16C32/06
• CPC Class Codes: F16C 32/0618 via porous material
• CPC Class Codes: F16C 33/103 retained in or near the bearing
• CPC Class Codes: Y10T 428/249974 Metal- or silicon-containing element
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 428/2975 Tubular or cellular

Abstract

A fluid-permeable article which permits fluid to pass therethrough includes a porous ceramic structure having a multiplicity of hollow members made of ceramic material which are concatenated with each other to form a framework having a continuous capillary passageway system. A continuous space is formed outside of the framework and is defined by the outer surfaces of the hollow members. A continuous matrix material fills the continuous space outside of the framework and cooperates with the porous ceramic structure to provide an integral composite structure consisting of the ceramic material and the matrix material. The continuous passageway system is open in at least a portion of the exposed surfaces of the article and permits fluids to pass therethrough.

Claims

1. A method of producing a fluid-permeable article which permits a fluid to pass therethrough, comprising the steps of:

preparing a casting mold having a cavity;

preparing a porous ceramic structure consisting of a multiplicity of hollow members which are made of a ceramic material and which are concatenated with each other so as to form a framework having therein a continuous capillary passageway system, said porous ceramic structure having a continuous space which is formed outside said framework and which is defined by outer surfaces of said hollow members;

placing said porous ceramic structure in position within said cavity of said casting mold;

pouring a molten metal into said cavity so as to fill said continuous space formed outside framework of said porous ceramic structure, and allowing solidification of a mass of the poured molten metal within said continuous space, together with a mass of the molten metal surrounding said porous ceramic structure within said cavity, to thereby form a cast product as said fluid-permeable article wherein said porous ceramic structure is integrally embedded within the mass of the solidified cast metal, with said continuous capillary passageway system left within said framework of said porous ceramic structure; and

forming an inlet and an outlet for said continuous capillary passageway system in exposed surface portions of said cast product to permit fluid to pass therethrough.

2. A method according to claim 1, wherein said framework of said hollow members consists of a three-dimensional network of said ceramic material.

3. a method according to claim 2, wherein said step of preparing a porous ceramic structure comprises the steps of:

preparing a foamed body of a synthetic resin having a three-dimensional porous network structure;

applying an unfired ceramic material to said foamed body, so as to surround said three-dimensional porous network structure; and

firing said unfired ceramic material while burning out said porous network structure of said synthetic resin, so that said three-dimensional network of said framework of said porous ceramic structure is formed by the fired ceramic material, such that said continuous capillary passageway system corresponds to the burned-out porous network structure of the synthetic resin.

4. A method according to claim 1, wherein the step of forming the inlet and outlet for said continuous capillary passageway system comprises cutting said cast product.