Cellular material and method for its production

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This invention describes a novel cellular material that consists of a highly porous structure in which a secondary material is dispersed within the pores via an infiltration process. The cellular structure can be made from ceramics, glass, or a combination, and the dispersed phase may include metals, alloys, other ceramics, or polymers. The method allows precise control over the functional and mechanical properties of the final composite material—such as electrical conductivity, thermal conductivity, and mechanical strength—by carefully selecting and infiltrating the dispersed material into specific pore structures.

Use CasesContent extracted from patent full text and abstract with AI.

• Lightweight structural components in transportation (automotive, aerospace) due to high strength-to-weight ratio
• Highly efficient catalytic substrates or catalyst carriers for chemical processes
• Thermal management materials in electronics and batteries (e.g., heat sinks, heat exchangers)
• Electrically conductive foams for sensors, electromagnetic shielding or heating elements
• Porous filters for liquids and gases, including catalytic filtration
• Energy storage and conversion systems such as thermal or sorption-based heat storage
• Structural components in composite sandwich panels and lightweight construction
• Tailored scaffolds for biomedical applications (e.g., bone implants with specified strength and porosity)

BenefitsContent extracted from patent full text and abstract with AI.

• Significant improvement in mechanical strength and/or thermal and electrical properties without sacrificing the key benefits of cellular (porous) materials
• Tunable and customizable material properties by adjusting the type and amount of infiltrated phase
• Retention of high porosity (thus low weight and high permeability), even after infiltration
• Wide material compatibility—applicable to ceramics, glasses, metals, alloys, and polymers
• Process enables functionalization of otherwise inert or brittle cellular materials (e.g., imparting conductivity or catalytic activity)
• Scalable and flexible manufacturing method (can use multiple infiltration cycles, operate at relatively low temperatures, and avoid high-pressure processes)
• Materials retain permeability for fluids or gases, critical for applications in catalysis, filtration, or sensors
• Enhanced durability and toughness possible by combining properties of different phases (e.g., ceramic strength with polymer toughness or metal conductivity)

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to a cellular material (1), comprising a porous cellular material (2) in which a material (3) is dispersed, and to a method for producing same.