High porosity body mfr. - by sintering encrusted powders on surfaces of physically or chemically removable supports

摘要

Highly porous bodies, fleeces or felts are formed by sintering organic or inorganic support structures which have been encrusted with metal or ceramic powder, with the support normally removed by physical methods (heating) or chemically during sintering. The support is pref. material such as plastic which softens at temps. below the sintering temp. to aid encrustation, or is chemically softened. The softening heat may be provided by heating the powder. The support may be made of fibre, esp. hollow fibre and can be shaped into desired forms before, during or after encrustation/sintering. Process makes filters, catalysts and their supports, electrodes, sound absorbers etc. and produces bodies of uniform structure and appearance without the difficulties involved in classifying metal wires/fibres/powders. Final product density may be only 1% of the solid material value.