A method of manufacturing a porous material

摘要

A porous material is manufactured by weaving polycarbonate fibres through a tow of carbon fibres which has been pre-impregnated with an epoxy resin. A second layer of pre-impregnated carbon fibres are superimposed on the woven layer and the epoxy resin is cured to bond the fibres together. A ceramic slurry is applied and allowed To penetrate through the second layer of fibres and part way through the woven layer of fibres to a controlled depth before being dried to form a mask. A thermoplastic powder is then applied to the unmasked region of the woven layer of fibres and sintered. Finally the mask and the polycarbonate fibres are removed chemically to produce a porous material which comprises a sintered thermoplastic layer reinforced with carbon fibres through which channels are provided.