# US 12,109,617 B2 · Method for manufacturing composite material for thermal shields, and composite material for thermal shields manufactured thereby

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- Number: US 12,109,617 B2
- Document ID: US12109617B2
- Status: Granted
- Kind: B2
- Application number: 17/815,104
- Filed: 2022-07-26
- Published: 2022-11-17
- Granted: 2024-10-08
- Earliest claimed: 2020-01-31
- Assignees: Pukyong National University Industry-University Cooperation Foundation
- Applicants: Pukyong National University Industry-University Cooperation Foundation
- Inventors: Hansang Kwon
- Web page: https://patentgrep.com/patent/US12109617B2

## CPC

- C22C 1/05: Mixtures of metal powder with non-metallic powder (C22C1/08 takes precedence)
- B22F 3/10: Sintering only
- B22F 3/105: by using electric current {other than for infrared radiant energy}, laser radiation or plasma (B22F3/11 takes precedence){; by ultrasonic bonding (B22F3/115 takes precedence)}
- B22F 7/02: of composite layers {(B22F7/002 takes precedence)}
- B22F 1/14: Treatment of metallic powder (mixing with lubricating or binding agents or with organic material B22F1/10)
- B22F 2003/1051: {by electric discharge}
- B22F 2202/13: Use of plasma
- B22F 2301/052: Aluminium
- B22F 2302/253: Aluminum oxide (Al2O3)
- B22F 2302/256: Silicium oxide (SiO2)
- B22F 2302/45: Others, including non-metals
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER

## Abstract

A method of manufacturing a composite material for thermal shields, and a composite material manufactured by the method are proposed. The method may include preparing a mixed powder including (i) a metal powder including a powder of aluminum or aluminum alloy and (ii) a polymer or ceramic powder. The method may also include sintering the mixed powder through pressureless sintering or spark plasma sintering to produce a composite material. According to the present disclosure, a powder of polymer, ceramic, and/or metal which have a relatively low level of thermal conductivity can be compounded with a metal material including aluminum through a sintering process of powder metallurgy, such as pressureless sintering or spark plasma sintering. Thus, a heterogeneous composite material with a low-level thermal conductivity (10 W/mk or less) can be obtained, and the composite material can be used as a material for various thermal shields.

## Claims

### Claim 1

A method of manufacturing a composite material for thermal shields, the method comprising:
preparing a mixed powder comprising (i) 30% to 85% by volume of a metal powder containing 50% by volume of aluminum and 50% by volume of magnesium and (ii) 15% to 70% by volume of a polyarylate (PAR) powder; and
sintering the mixed powder through spark plasma sintering performed at a temperature in a range of 200° C. to 400° C. at a pressure in a range of 5 MPa to 100 MPa for a duration of 1 minute to 10 minutes to produce a composite material.

### Claim 2 (depends on 1)

A composite material for thermal shields, manufactured by the method of claim 1.

### Claim 3 (depends on 2)

The composite material of claim 2, wherein the composite material is a functionally graded material having a sheet shape and structured such that a volume fraction of the polyarylate (PAR) powder continuously changes from a first side to a second side of the sheet.