Sintered porous frame and its producing method

Abstract

A structure and construction method of sintered porous frame. The structure of present invention can be applied as a soot filter and catalyst converter to treat exhaust gas from internal combustion engines by coating a layer of catalyst material such as platinum. The inventor use the combustible material foam as a porous substrate to coat a metallic layer. Further the procedure is to apply a sintering process to form a sintered porous frame. Thus the user can use the sintered porous frame to proceed catalyst coating or photo-catalyst coating.

1 . A sintered porous frame, which comprising: 
 a porous structure with metallic-bond or covalent bond inside the structure to connect the whole-body, and the material of the porous structure have the bearing ability for a sintering process with certain temperature range;    wherein the material of porous structure is at least 90 percent to whole body formed by metallic material.    
   
   
       2 . The sintered porous frame as claimed in  claim 1 , wherein the porous structure has little holes inside and the wall of little hole have the residual carbon compound generated by the heating process of sintering.  
   
   
       3 . The sintered porous frame as claimed in  claim 1 , wherein the porous structure is bended allowable to form a special shape to fit the predetermined space in the flowing-fluid device.  
   
   
       4 . The sintered porous frame as claimed in  claim 1 , wherein the certain temperature range is from 150-900 Centigrade.  
   
   
       5 . The sintered porous frame as claimed in  claim 1 , wherein the porous structure is coated with a catalyst material or anti-microbe material.  
   
   
       6 . The sintered porous frame as claimed in  claim 1 , wherein the metallic material comprises copper, aluminum or their alloy.  
   
   
       7 . The sintered porous frame as claimed in  claim 1 , wherein the metallic material comprises nickel or chromium to have the ability to heat the porous structure with electrical power for industrial application.  
   
   
       8 . A method to produce the sintered porous frame comprising the following steps: 
 providing a porous substrate by a kind of combustible material;    proceeding a coating process by a metallic material being able to bearing the combustion temperature of the combustible material; and    putting a coated porous substrate into sintering process to remove the combustible substrate and to generate the porous structure by metallic material through metallic-bond or covalent bond inside the structure to connect the whole-body to produce the sintered porous frame.    
   
   
       9 . The method to produce the sintered porous frame as claimed in  claim 8 , wherein the coating process contains two sub-processes, the pre-coating process and the enhanced-coating process, the pre-coating process for binding a layer of metal-plating-allowable material on the porous substrate, the enhanced-coating process for plating a thick layer of metallic material to construct the main porous structure of the sintered porous frame.  
   
   
       10 . The method to produce the sintered porous frame as claimed in  claim 9 , wherein the pre-coating process is to sputter metal or metal-plating-allowable material on the porous substrate.  
   
   
       11 . The method to produce the sintered porous frame as claimed in  claim 9 , wherein the pre-coating process is to spread the conductive glue on the porous substrate.  
   
   
       12 . The method to produce the sintered porous frame as claimed in  claim 11 , wherein the spreading method for conductive glue is by spraying.  
   
   
       13 . The method to produce the sintered porous frame as claimed in  claim 9 , wherein the pre-coating process is to put the porous substrate into the specified chemical solution, the specified chemical solution being contained the metal-plating-allowable material.  
   
   
       14 . The method to produce the sintered porous frame as claimed in  claim 8 , wherein the metallic material comprise nickel or chromium to have the ability to heat the porous structure with electrical power for industrial application.  
   
   
       15 . The method to produce the sintered porous frame as claimed in  claim 8 , wherein the metallic material comprises copper, aluminum or their alloy.  
   
   
       16 . The method to produce the sintered porous frame as claimed in  claim 8 , wherein the sintering process contains the process to generate the metal deoxidation in the gas contained ammonia.