# US 12,214,425 B2 · Method for manufacturing composite material, and composite material

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- Number: US 12,214,425 B2
- Document ID: US12214425B2
- Status: Granted
- Kind: B2
- Application number: 17/617,328
- Filed: 2020-06-17
- Published: 2022-07-14
- Granted: 2025-02-04
- Earliest claimed: 2019-06-17
- Assignees: LG Chem, Ltd.
- Applicants: LG Chem, Ltd.
- Inventors: Yeon Soo Lee; Dong Woo Yoo; Jin Kyu Lee
- Web page: https://patentgrep.com/patent/US12214425B2

## CPC

- B22F 3/1121: {by using decomposable, meltable or sublimatable fillers}
- B22F 3/26: Impregnating {(making ferrous alloys by impregnation C22C33/0242)}
- B22F 3/1103: {with particular physical characteristics}
- B22F 3/1146: {After-treatment maintaining the porosity (B22F3/114 takes precedence)}
- B22F 3/24: After-treatment of workpieces or articles {(B22F3/1146 takes precedence)}
- B22F 7/06: of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)}
- B22F 2007/066: {using impregnation}
- B22F 2998/10: Processes characterised by the sequence of their steps
- 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

Methods for manufacturing a composite material and composite materials are provided. The method may include preparing a metal foam, preparing a mixture including the metal foam and a curable polymer, curing the curable polymer of the mixture to obtain a composite material, and performing a planarization treatment. The planarization treatment may be performed on the metal foam before preparing the mixture, on the mixture before curing the curable polymer, and/or on the composite material. The composite materials may include a metal foam and a polymer that is on a surface and/or in pores of the metal foam. The composite material may have a surface roughness of 2 μm or less and/or may have a thermal resistance of 0.5 Kin2/W or less at 20 psi.

## Claims

### Claim 1

A method for manufacturing a composite material, the method comprising steps of:
(a) providing a metal foam;
(b) preparing a mixture comprising the metal foam and a curable polymer;
(c) curing the curable polymer of the mixture to obtain the composite material; and
(d) performing a planarization treatment on at least one of the metal foam before preparing the mixture, the mixture before curing the curable polymer, or the composite material,
wherein the step (d) is performed on the metal foam before the step (b), and
wherein after the step (d) is performed, a porosity of the metal foam is in a range of 30% to 60%.

### Claim 2

A method for manufacturing a composite material, the method comprising steps of:
(a) providing a metal foam;
(b) preparing a mixture comprising the metal foam and a curable polymer;
(c) curing the curable polymer of the mixture to obtain the composite material; and
(d) performing a planarization treatment on at least one of the metal foam before preparing the mixture, the mixture before curing the curable polymer, or the composite material,
wherein the step (d) is performed on the metal foam before the step (b), and
wherein after the step (d) is performed, a surface roughness of the metal foam is 6 μm or less.

### Claim 3 (depends on 1)

The method for manufacturing the composite material according to claim 1, wherein the step (d) is performed by polishing or pressing.

### Claim 4 (depends on 3)

The method for manufacturing the composite material according to claim 3, wherein the pressing is performed by a roll press.

### Claim 5

A method for manufacturing a composite material, the method comprising steps of:
(a) providing a metal foam;
(b) preparing a mixture comprising the metal foam and a curable polymer;
(c) curing the curable polymer of the mixture to obtain the composite material; and
(d) performing a planarization treatment on at least one of the metal foam before preparing the mixture, the mixture before curing the curable polymer, or the composite material,
wherein the step (a) is performed in a manner comprising (a1) a process of manufacturing a green structure using a slurry comprising a metal powder, a binder and a dispersant, and (a2) a process of sintering the green structure.

### Claim 6 (depends on 1)

The method for manufacturing the composite material according to claim 1, wherein a ratio (TA/TB) of a first thickness (TA) of the metal foam after performing the planarization treatment to a second thickness (TB) of the metal foam before performing the planarization treatment is 0.9 or less.

### Claim 7

A method for manufacturing a composite material, the method comprising steps of:
(a) providing a metal foam;
(b) preparing a mixture comprising the metal foam and a curable polymer;
(c) curing the curable polymer of the mixture to obtain the composite material; and
(d) performing a planarization treatment on at least one of the metal foam before preparing the mixture, the mixture before curing the curable polymer, or the composite material,
wherein the step (d) is performed on the metal foam before the step (b), and
wherein a ratio (RA/RB) of a first surface roughness (RA) of the metal foam after performing the planarization treatment to a second surface roughness (RB) of the metal foam before performing the planarization treatment is 0.9 or less.

### Claim 8

A method for manufacturing a composite material, the method comprising steps of:
(a) providing a metal foam;
(b) preparing a mixture comprising the metal foam and a curable polymer;
(c) curing the curable polymer of the mixture to obtain the composite material; and
(d) performing a planarization treatment on at least one of the metal foam before preparing the mixture, the mixture before curing the curable polymer, or the composite material,
wherein the step (d) is performed on the metal foam before the step (b), and
wherein a ratio (KA/KB) of a first thermal resistance (KA) of the metal foam after performing the planarization treatment to a second thermal resistance (KB) of the metal foam before performing the planarization treatment is 0.9 or less.