JP2001504077A - Multi-channel structure and manufacturing method thereof - Google Patents

Abstract

(57) [Summary] The present invention relates to a method for producing a multi-channel structure suitable for use as a filter or a catalyst carrier. The composite rod (11) having a shell (12) and an inner core (13) is each formed from a mixture of powders. Mixtures for the shell include materials of sinterable powder structure such as, for example, ceramics, metals, alloys and powder binders. The inner core includes a powder channel forming filler material that can be specifically removed from the structural material of the shell. The composite rod (11) may be deformed by extrusion to reduce its diameter. The bundle (14) of the composite rod (11A) is collected and deformed by extrusion to reduce the diameter of the bundle (14) and its component composite rods. Furthermore, the bundle (17) of the reduced diameter bundle (14A) of composite rods may be similarly deformed by extrusion to further reduce the diameter of the component composite rods of the continuous bundle, whereby: The number of rods per given cross-sectional area of the bundle also increases. The final assemblage of the bundle (17A) is consolidated and the binder is removed by heating and possibly by subsequently removing the inner core of the composite rods of the assemblage of the bundle and sintering the residual structure of ceramic or metal. You. In certain embodiments, the core material may be removed by heating the material while heating the structure to perform the sintering step. In other aspects, the binder and / or filler material may be removed by a suitable solvent.

Description

DETAILED DESCRIPTION OF THE INVENTION                   Multi-channel structure and manufacturing method thereof   The present invention relates to a novel method for producing a multi-channel structure and to such a method. Especially suitable for use as filters, catalyst supports, heat exchangers, etc. Structures with small channels or holes with diameters ranging from a few microns to a few millimeters About. Background of the Invention   Various methods for producing channel materials are known. J. Reeman, R.W. Buswel l and D.G. Ainley, "Basic Principles of Powder Metallurgy" (Edited by W.D. Jones, Edward Arno ld Pubhsher Limited, London, 1960, p. 341) Cadmium wire was introduced into the blade press and then fired. Removing them during sintering creates cooling passages in the hot turbine blades. It discloses a method of accomplishing this. This method is very labor and time consuming, Producing a micro-channel material having small, uniformly dispersed channels Can not.   A directional solidification method called GASAR is disclosed in US Pat. No. 5,181,5 issued Jan. 26, 1993. To produce a solid with a controlled porosity [1-3] as disclosed in US Pat. Has evolved. The metal is melted in a specific gas (usually hydrogen) atmosphere and Pour into mold and cool. With the solidification of metal, the solubility of dissolved gas sharply decreases Some nuclei of bubbles are generated. Bubbles float in the liquid to form a high-temperature area, and are absorbed again. Will be collected. Bubbles formed at the solid-liquid interface are separated individually depending on the coagulation conditions. Or it becomes a continuous hole. The final microstructure of the porous material is thermodynamic It depends on both the process and the kinetic process. Under GASAR processing conditions It is impossible to form a homogeneous nucleus, and this process does not produce hydrides. Eutectic is highly asymmetric, and is capable of stable eutectic growth. The solidification temperature is limited to a very narrow range. This method is suitable for micro- It is not possible to make long structures that only pass through the channel. Furthermore, this The method is used to produce channels oriented in two or more desired directions. Can not.   Marsha L. on April 4, 1989. U.S. Patent No. 4,818,264 issued to Langhorst Tubes, hollow glass fibers, which can be used in the production of glass polycapillary materials It discloses that it is manufactured by stretching. 7 gauges with outer diameter 1.8mm and inner diameter 1.4mm Place the lath tube in a glass tube with an outer diameter of 8 mm and an inner diameter of 6 mm. The tube was stretched by a tube stretching machine. This patent is issued by H.D. Articles and technical documents by Pierce Jr. `` Method of manufacturing glass multi-capillary column '' (Vol. 17 of chromatography science) , J, 5 / '79, p. 297), as the basis for this study. This method It cannot be applied to ceramics, intermetallic compounds, powders such as carbon, or brittle materials.   An extrusion method for forming a thin-walled honeycomb structure is disclosed in U.S. Pat. As disclosed in U.S. Pat. Developed by Rodney et al. Rodney Have an outlet face with interconnected ejection slots, and An extrusion die having an inlet face with a number of feed ports extending partially through the die. The use is disclosed. Extrudable into a discharge slot connected to the outlet face When extrudable material is supplied to the die under pressure enough to allow the material to flow, Has a number of open paths that are emitted longitudinally from and extend therefrom Before forming the fillet structure, it flows laterally within the slot to form a continuous mass. You. The longitudinally released mass strictly prevents deformation of the path. Disadvantages of this method Is a very complex and very expensive method, with channels less than 0.5-1 mm in diameter and Channel walls with a diameter of 0.2 mm or less cannot be manufactured, and The inability to manufacture structures with oriented channels.   Although not related to the production of channel materials, the present invention may be implemented to produce channel structures. Some methods used for this are described in William S. Coblenz on September 20, 1988. Monolithic fiber as disclosed in issued U.S. Pat.No. 4,772,524 It should be noted that it is also used in manufacturing is there.   Coblenz patent discloses a method for producing a high density fibrous monolithic ceramic structure. Has been disclosed. This method forms multiple coated fibers, each coated fiber Includes a ceramic core with a ceramic coating. Product formed The green body of ceramic material to be plastically deformed by sintering Compressed. However, this patent does not cover the multichannel features disclosed and claimed herein. There is no disclosure or suggestion about the method of manufacturing the flannel structure.   U.S. Pat.No. 4,965,245, issued to Masaru Sugimoto et al. On October 23, 1990, For example, coated metal filaments coated with oxide (which are drawn and oxidized Superconducting cable or coil containing a bundle of It discloses a method of manufacturing a device. However, this patent discloses herein, It does not disclose or suggest a method of manufacturing the channel structure as claimed.                                Summary of the Invention   In accordance with the present invention, a multichamber comprising a body of structural material having multiple channels The tunnel structure is composed of a powdered shell composed of a structural material and a binder, and a movable channel type. Forming a composite rod including a powdered inner core comprising a composite filler and a binder; Forming a first bundle by bundling the composite rods in a parallel relationship, and assembling the first bundle. Strengthening by deformation, reducing the diameter of individual rods of said first bundle, A large number of the deformed first bundles are further combined with the first bundle, and the bundle is strengthened. Manufactured by making the final product. And the binder and shell material Remove from both inner core material. Remove the filling core material, sinter and finish product bundle Channel defined by the removal of filler from the core of each composite rod The final structure is manufactured containing the Binder and filling core material before and during sintering Or after sintering, e.g., evaporation, decomposition, dissolution, infiltration , And is removed by melting accompanied by blowing. Certain charges, such as carbon Filling core material may be removed by oxidation and combustion.   In one embodiment, the structural material is a sinterable ceramic powder, such as alumina; The core channel forming material may be graphite powder or melamine or urea or polyethylene. Polymers such as ren or polypropylene; both core and shell binders Is paraffin or wax.   The viscosity or yield point of the mixture of shell and core at the extrusion temperature should be as close as possible to each other. Preferably.   In a preferred embodiment, the binder is removed by heating. in this case The binder has a melting point or boiling point lower than the melting point or boiling point of the filled core material, or If the material is carbon and heating is performed in an oxidizing atmosphere, the filling core material Should have an oxidation point below the oxidation point of Also, the filling core material removes the binder. It may be removed by heating after leaving or by oxidizing by heating at a high temperature, This can be achieved during heating to perform the sintering step, A higher temperature than the point or boiling point or oxidation point is required.   In another embodiment, the shell structural material is powdered, such as tungsten or iron powder. Formed from metal, the core channel forming filler is a low melting metal powder such as copper. You. In this embodiment, the binder has a substantially lower melting point than the core filler. It may be paraffin or polyethylene or a mixture of several substances.   In another embodiment, the shell construction material is such as FeCrAlY or Hastealloys powder. Formed from an alloy, the core channel forming filler is low carbon, such as melamine Residual polymer. In this embodiment, the binder may be a wax, and the filler and And / or the binder may be partially or completely organic solvent and / or before or during sintering. It may be removed by evaporation.   In yet other embodiments, the core within the composite rod includes a channel-forming filler and Formed from at least one filler-binder rod consisting of The well is formed from a mixture of structural material and binder arranged parallel around the core A number of rods are arranged to form a bundle and the method described above is used, for example, by extrusion. It is formed by forming a composite rod to perform.   In other embodiments, the shell construction is such as, for example, platinum, palladium, etc. Non-carbide forming powdered metals such as noble metals, or magnesium, copper and nickel Non-carbide forming metal powders and non-carbide forming alloys such as nickel aluminides. Formed from gold, the core channel forming filler is powdered carbon. This implementation In embodiments, the binder may have a substantially lower melting point than the carbon core filler. , It may be paraffin or.   In other embodiments using carbon fillers, the resulting structure is heated to bind When removing dust, keep it in a non-oxidizing atmosphere such as nitrogen or argon. This suppresses the oxidation of the carbon filler. The temperature of the structure by melting To maintain structural integrity by maintaining the temperature until the components combine or connect with each other You can also. Ensuring structural integrity through such connections In such cases, the non-oxidizing atmosphere is excluded and the carbonaceous filler is oxidized, for example by combustion. Replaced by an oxidizing atmosphere such as oxygen or air to remove available. This may be separate or independent of heating to the desired temperature during the sintering step. May be performed during the process. Object and effect of the invention   An object of the present invention is to provide powder materials such as ceramics, metals, intermetallic compounds and polymers. To provide a novel method for producing a multi-channel structure made of the material using And   Another object of the present invention is useful as a filter, a catalyst carrier, a heat exchanger, a vent, and the like. With relatively small diameter channels suitable for producing complex structures An object of the present invention is to provide a method for manufacturing a tunnel structure.   The method of the present invention provides a channel having a smaller diameter than that obtained by conventional methods. A new channel having a channel formed with a relatively thin channel wall. Enables production of structures.   The novel method of the present invention provides a structure with multiple channels of relatively small diameter. Compared to a simple single orifice die that can be used to implement the present invention to manufacture Implement the above conventional method which requires relatively expensive equipment including more complex dies Simpler and less complex than   The present invention uses porous ceramics of different types of ceramics, intermetallics and metals. Capillary structures can be manufactured. This method depends on the channel diameter and channel of the final porosity (from a few vol% to over 90 vol%). Controls channel wall thickness (from a few microns to a few millimeters) within narrow tolerances You can control.   This method can not only produce one-dimensional channel structures, but also two- and three-dimensional The same can be applied to the production of a porous structure. Description of the drawings   FIG. 1 is a schematic explanatory view of a manufacturing process of a multi-channel structure of the present invention.   FIG. 2 is an outline of a procedure including a cross-sectional view of another embodiment of the composite rod shown in Step 1 of FIG. FIG.   FIG. 3 shows a hand including a cross-sectional view of yet another embodiment of the composite rod shown in step 1 of FIG. FIG. 3 is a schematic explanatory view of the order, in which a second structural matrix binder mixture 12A is used. Additional layers are inserted between the outer structural matrix binder layer 12 and the inner core 13. You.   FIG. 4 has channels with different diameters oriented in two perpendicular directions Another embodiment of the final assembly of bundle 19 shown in step 4 of FIG. 1 for manufacturing a structure FIG.   5a and 5b show a large channel (FIG. 5) surrounded by a multi-channel structure. a) and a solid core structure (FIG. 5b) surrounded by a multi-channel structure. 4 shows another embodiment of step 4 of FIG. 1 arranged to make. Description of the preferred embodiment   FIG. 1 shows a powdery structural material such as alumina and a binder material such as paraffin. Outer shell 12 formed of the first mixture, and a powder such as melamine or graphite. Mixture comprising a channel-forming filler material in the form of a binder and a binder such as paraffin A cross-sectional view of the composite rod 11 including the inner core 13 formed by is shown.   The composite rod 11 is produced, for example, by extruding a tube of the first mixture, for example by extrusion. To form the outer shell 12. Inner core 13 is a second mixture From, for example, by extrusion. Then insert the inner core 13 into the shell 12 By doing so, the composite rod 11 can be formed.   Separately, a mixture comprising the materials forming the outer shell 12 and the inner core 13 is coaxial The composite rod 11 can be formed by simultaneously extruding using a channel die.   After the composite rod 11 is formed as described above, as shown in FIG. Thus, the diameter can be further reduced by extrusion.   Next, a bundle 14 of composite rods (11 or 11A) is assembled as shown in Step 2 of FIG. Te Here, the composite rod indicated by 11A has cross sections arranged parallel to each other.   A convenient way to manufacture some parallel rods (11A) is before or after reducing the diameter. Will later be cut into segments 11A, forming various parallel rods and forming bundles 14 To produce a long composite rod (11) that can be formed.   The assembled bundle of rods 14 is assembled into a die having an appropriate diameter in Step 2 as shown in a cutaway view. The bundle 14 is extruded and deformed by the extruder 15 having the diameter of the bundle 14 as shown in the bundle 14A. Deformed to the diameter of the individual composite rod 11A with the smaller diameter bundle 14A, Be reduced.   As shown in step 3 of FIG. 1, a further bundle 17 is combined with a smaller diameter composite. Assemble from a large number of parallel bundles 11A including the joining rods 11B. This further bundle 17 The bundle 17 is further deformed by an extruder 18 having a die having an appropriate diameter to reduce the diameter of the bundle 17. As shown in step 3, make smaller diameter 17A. Of course, steps 1, 2 or 3 The extruder used in (1) is appropriately equipped with an extrusion die having a desired diameter for each step. The same device may be used.   By making a bundle of composite rods and extruding this bundle, the diameter of the bundle and its To reduce the diameter of the composite rod, thereby reducing the diameter of each core 13. The operation of reducing the number and increasing the number per unit volume This can be performed until a channel-forming core is obtained.   Due to the deformation of the assembled bundle of composite rods, many bundles are integrated and have a circular cross section or Will be a rod of rectangular cross section or other shaped cross section. But push out the final bundle In some cases, it is desirable to have a large assembly that is not easily integrated. in this case , The final assembly of bundle 17A is compressed in die 21 by plunger 22 in step 4, for example. It consists of a large bundle that is shrunk and integrated.   The integrated bundle 19 is then subjected to a heat treatment in step 5 to remove the binder and fill. The filler material is removed and the remaining multi-channel unfired (gre en) The structure is fired.   The choice of filler depends greatly on the type of structural material, and the filler is In place until adequate mechanical integrity develops and the properties of the structural material are inferior. It must be one that can be removed under conditions that do not render it inactive. Also, filler The material must be chemically compatible with the structural material over the temperature range in which both are present. is there. Fillers that remain at relatively high temperatures before being removed, Has a wide range of applications. For example, MgO, CaO, etc. are removed during the firing process. The shape of the channel can be maintained during firing, and can be removed by dissolution after firing. You. Therefore, they are used at high temperatures of 800-1200 ° C. for the development of sufficient structural integrity of the shell. Can be used as a filler for high temperature refractory metals such as W, Ta, etc. Wear. Filler materials should not form new undesirable compounds with structural materials Needless to say. Structural material is removed before developing sufficient mechanical integrity When using low temperature polymers such as these, the multichannel structure is unstable and collapses. You. Lower melting point fillers can be used, in which case the powder bed supporting the structure is It is necessary to remove the filler very slowly in the furnace.   Compared with alumina, silicon carbide, nickel, etc., to achieve sufficient mechanical integrity Structural materials that require relatively high temperatures, especially nickel, are There are advantages. Carbon fillers are used to remove binders unless their presence is foreseen. Does not form carbides or other compounds during firing, and filler removal It can be used with these structural materials.   The chemical composition of the channel structure material is typically used to form a composite rod Of the starting structural powder material. However, the desired chemical composition of the structural material is It is also possible to start with a mixed structural powder and react the powder during or after sintering, By forming the composition of For example, metal alloys such as FeCrAlY Gold is an alloy with high room temperature ductility, extraordinary cyclic oxidation resistance, and excellent impact resistance These properties make this alloy an excellent catalyst support for high temperature applications. The metal alloy is manufactured from the corresponding alloy powder or Mix the corresponding elemental metal powdered components of the alloy in stoichiometric proportions and allow After that, in-situ heat is applied to form the elemental metal components into the desired alloy. Thus, an alloy can be formed. When the FeCrAlY multi-channel structure is formed, platinum Apply a catalyst such as by dip coating or electroplating to convert the catalyst Catalyst products for such applications. Furthermore, it's platinum Such a catalyst is a component of the powdery component of the structural material used to form the composite rod. It can be incorporated as one of them. Apply the same method to Desired intermetallics such as nickel aluminide from Kel and aluminum powder Compounds can be formed. Similarly, using this method, with multi-channel structural materials, Ceramic compositions can be formed, for example, silicon carbide from silicon and carbon powder. The technology starts with less expensive raw materials having desired properties such as molecular size. Can be   The method of the invention comprises the following steps (FIG. 1): Step 1-For example, shell (alumina + binder) and core (filler + binder) Of bi-material rod (11) consisting of   The shell consists of alumina powder and a binder additive (wax, paraffin or ethylene). Certain thermoplastic polymers such as vinyl acetate and ethylene ethyl acrylate) Consisting of a mixture of The core is combined with the binder by later evaporation, melting, melting and oxidation. And a mixture with the powder of the channel-forming filler which can be removed by the method. Carbon (graphite or (Such as amorphous carbon) and other organic substances (such as urea, melamine, and polymers) Alternatively, a powder of an inorganic substance (CaO, MgO, metal) can be used as the filler. Desirable rods with diameters in the range of 0.1-10mm are larger diameters (20-200mm) It is produced by extrusion of a two-component material rod 11. Step 2-Assemble rod into bundle and re-extrude bundle   As a result of this stage, the matrix (alumina + binder) and channel Composite blanks (rods) consisting of fiber forming fibers (filler + binder) It is. However, the fibers produced by this stage of extrusion are still too large. Threshold diameter, i.e., hundreds of microns, and therefore, A further reduction may be necessary. Step 3-Repeat step 2 for further purification of channel size   At the end of this step, depending on the extrusion ratio, a 10-100 micron diameter Rods obtained with flannel forming fibers have a diameter of 0.1 to 10 mm. If necessary, The steps can be repeated to obtain smaller diameter fibers. Step 4-Step 3 to obtain the desired green density prior to heat densification Assembling into a bundle of rods manufactured and cold isostatic pressing in a die or Solidification by cold extrusion and cold rolling Step 5-densification   This step involves (1) binder removal, (2) filler removal, and (3) Includes sintering of multi-channel alumina green bodies. Sintering avoids thermally induced cracks And high density of the channel walls to obtain high filter strength. Offer. If paraffin is used as a binder, its removal can take place at 150-350 ° C. This. To remove urea or melamine or carbon filler, temperature of about 300-500 ° C Is necessary. Alumina sintering occurs at 1500-1700 ° C. Microstructure design and By processing this type of multi-channel product with control and control, Various ceramic metallic or intermetallic compounds with tailored properties Products can be manufactured. For example, a product with a channel diameter of 20 micrometers If necessary, on stage 1, a component having a core diameter of 0.5 mm and a shell diameter of 1 mm A material rod can be obtained. Then, in stage 2, these locks are 1000 bundles are collected and extruded from 36 mm in diameter to 1 mm in diameter. After this, the filler + binder mixture of this rod (and hence the future The fibers from Nell) have a diameter of 2020 micrometers. Step 3 Case can be excluded. In step 2, the resulting rods are bundled, pressurized (s Step 4) and sinter (Step 5). Where smaller diameter channels are needed If so, step 3 may be included again.   Thus, the method of the present invention provides for the removal of a mixture of filler and binder powder. Rod structure consisting of a possible inner core, binder powder and sinterable structural powder Using repeated coextrusion with an outer shell of the mixture, the fiber reinforced ceramic To form a green matrix blank, and then the fibers fixed by the filler The fibers are decoupled and removed and the matrix is calcined. In this way, it is adjusted Multi-channel structure with a rounded diameter and a straight distribution of microchannels It is formed.                                  Example Example 1   Step 1-85% by weight of alumina powder (average particle diameter 1.3 μm) and 15% by weight A first mixture of paraffin and binder was prepared. Bring this first mixture to 90 ° C Heat and blend.   Step 2-79% by weight of melamine powder (average particle size 2.5 μk) and 21% by weight Prepare a second mixture with paraffin binder as the mixture in step 1 did.   Step 3—Two channels prepared in Step 1 and Step 2 It was loaded into an extruder and extruded at 45 ° C. As a result, it has a core with a diameter of 1 mm A bi-material rod with a 2 mm diameter sheath was made. This core Consists of a second mixture of melamine powder and paraffin and the sheath is aluminum It consisted of a first mixture of powder and paraffin.   Step 4—Cut the composite rod obtained in Step 3 into 100 mm pieces This bundle of 631 pieces is assembled, and the Inserted into a stamping die having a container with a 90 mm diameter and 3 mm diameter outlet hole and extruded . As a result, the matrix and the matrix of the mixture of the alumina powder and the paraffin binder are obtained. Fiber reinforced with 631 fibers consisting of a mixture of lamin powder and paraffin binder A 3 mm diameter rod with a fiber structure was made. Each fiber diameter is about 60 mics Meters.   Step 5-Cut the rod bundle obtained in Step 4 into 50 mm long pieces , Such 300 pieces are stacked in parallel in a 50x90mm square die (10 layers , Each layer is 30 pieces), and the stack is compressed at 40 ° C. (pressure 1500 N / cm^Two) Rod Hardened tack. The result is a square green (su) with 189,300 fibers. That is, an uncured) composite structure was obtained.   Step 6-The immature structure obtained in step 5 was heated and sintered. Heat treatment The order was as follows:   Raise the temperature from 20 ° C to 250 ° C at a rate of 5 ° C / hour and heat for 0.5h at the higher temperature Maintain, increase the temperature to 350 ° C at a rate of 15 ° C / hour, continue heating, and For 1 hour, raise the temperature to 540 ° C, continue heating and maintain for 1 hour, 100 ° C / hour Heat to 815 ° C at a rate between and maintain for 1 hour, heat to 1090 ° C at a rate of 100 ° C / hour And maintained for 1 hour. This results in a 189,300 series of approximately 40 micrometers in diameter A square multi-channel sintered alumina product with parallel ducts was obtained. Example 2   Step 1-Tungsten powder (average particle size-5 micrometers) and 48 Volume% binder (34% paraffin wax, 33% polyethylene wax and 33% % Beeswax) and a 1 mm outer diameter shell containing a first mixture of 2.5 mm diameter core containing a second mixture of copper powder and 60% by volume of the same binder Extrudes a composite material rod consisting of a 60 mm diameter composite material immature structure to a diameter of 4 mm. It was produced by molding.   Step 2-The 169 composite rods obtained in step 1 are substantially parallel Put it into a bundle, insert it into a 60 mm barrel, and pass it through a 2 mm diameter die. And extruded. The result of this step is the (W + binder) matrix and diameter About 2mm diameter immature composite rod containing 169 (Cu + binder) fibers of about 0.1mm A bunch was obtained.   Step 3-A bundle of 2 mm rods produced in step 2 is a 50 mm long piece And put the bundle of these pieces in a 50x50 mm square die, and weigh 6000 kgf. The assembled rod was compacted by force.   Step 4-The green body obtained in step 3 (ie, the uncured structure H) for binder removal_TwoIn an atmosphere, the temperature is increased from 20 ° C to 500 ° C at a rate of 0.2 ° C / min. Heat, then raise the temperature from 500 ° C to 1280 ° C at a rate of 5 ° C / min and heat in a hydrogen atmosphere. Heated. During the heating process, copper begins to melt at 1083 ° C, penetrates the W matrix, Leave the channel in place of the fiber. The resulting channel wall, including the resulting structure, is W-Cu It is made of pseudo alloy. Example 3   Step 1-Carbonyl Fe powder and 40% by volume binder (85% paraffin and 15% % Beeswax) and a 1 mm outer diameter shell containing the first mixture with melamine powder and 50 volumes Of a core with a diameter of 0.81 mm containing a mixture with the same binder The unfired composite material with a diameter of 60 mm (a core of melamine and binder with a diameter of 54 mm) And a 60 mm diameter shell of Fe and binder) by extrusion molding to a diameter of 1 mm. I got it.   Step 2-Cut the rod obtained in Step 1 into pieces having a length of 100 mm, The bundle of the composite material pieces of No. 027 was bundled into a bundle of parallel rods, and this was And compressed to solidify the assembled rod.   Step 3-The green body of φ30 mm obtained after step 2 is H to remove lamin_TwoThe temperature is increased from 20 ° C to 500 ° C at a rate of 0.2 ° C / min in the atmosphere. And heat, then H_TwoRaise the temperature from 500 ℃ to 1200 ℃ at 5 ℃ / min in the atmosphere Sintering was maintained at 1200 ° C. for 2 hours. As a result, about 87mm long after sintering And an iron structure with a diameter of 25 mm and 1027 channels of 0.66 mm diameter Was done. Example 4   Step 1-63 volume% alumina powder (average particle size about 1.3μm) and 37 volume A first mixture of 1% binder (80% paraffin + 20% polyethylene) was prepared. .   Step 2-60% by volume magnesium oxide powder (average particle size about 1.8 μm) And a second mixture of 40% by volume binder (80% paraffin + 20% polyethylene) Prepared.   Step 3-The two mixtures prepared in steps 1 and 2 are extruded in a 2-channel extruder And the first mixture is extruded as a shell over the second mixture as a core. And extruded at 55 ° C. As a result, a core having a diameter of 2 mm and a diameter of 4 mm A composite rod with a mm shell was made. The core is the second mixture (Magnesium oxide + binder), and the shell is composed of a first mixture (alumina + Binder).   Step 4-The composite material rod obtained in Step 3 is bundled to have a diameter of 90 mm, It was inserted into a die having a container with an outlet hole diameter of 20 mm and extruded. The result As a result, an unfired 20 mm diameter roast having 91 future channels A pad structure was produced.   Step 5-The green body obtained in Step 4 was heated and sintered. Heat treatment The order is as follows:   Heat from 20 ° C to 500 ° C at a rate of 5 ° C / hour and then 500 ° C at a rate of 60 ° C / hour. Heated at 1100 ° C, maintained at the higher temperature for 1 hour, and then 1100 ° C at a rate of 30 ° C / hour. C. to 1500.degree. C. and maintained for 1 hour.   Step 6-Cut the sintered structure piece obtained in step 5 into 20 mm long pieces Then, this piece is HNO at 60 ° C._ThreeAnd kept there for 6 hours. MgO fiber is the structure A channel about 1 mm in diameter that melted out of the structure was left in the remaining structure. Example 5   To produce an alumina multi-channel structure, an aperture having a grain size of 1.3 μm was used. Lumina powder is mixed with 50% by volume of a binder (paraffin wax / beeswax) A viscous mixture was obtained at ５０45-50 ° C. In the next step, this mixture is Extruded through a 12 mm die connected to a 0 mm container. 12mm as a result Rods are made from the alumina-binder mixture and are reduced to smaller pieces (~ 100 mm each). It was cut.   Using the same technique, the filler-binder mixture is added to the melamine powder (50% by volume). ) And a binder (paraffin wax / beeswax); The mixture was extruded into 12 mm rods of the same size.   In the next step, alumina-binder and filler-binder rods are bundled Arrayed with one filler-binder rod in the center and two concentric Layer, the first layer contains filler-binder rods, the second (outer) layer is aluminum Including a rod of a binder. Push this bundle through the same 12mm die After release, the raw body structure formed by the two material rods Obtained with filler and binder in the shell and center. In the next step, the rod Cut into 00mm pieces, which are assembled into bundles of parallel rods and die with 12mm Loaded into 60mm container for re-extrusion. As a result of this process, Alumina-Binder Matrix and Filler of Nineteen- Filling Path with Binder The resulting rod assembly was obtained.   After being cut into smaller pieces, the uncooked rod consisting of a 12 mm rod and 19 blocked passages The body structure was fixed in fine alumina powder and heat-treated in air. This al Mina powder liquefies by capillary action during heat treatment to melt wax binder Excluded binder. This debinding method uses a heating rate of 5 to 6 ° C./hour, A holding time of 2 hours was performed, and the sample was then oven-heated to 1100 ° C at 30-35 ° C / Heat at the heating rate of time, hold for 2 hours, and cool. Burying the sample After removal from the powder, it is sintered at 1400 ° C. at a slower heating rate. And held for 2 hours. Carbon instead of alumina powder to suck up liquefied binder It should be noted that powders can also be used.   As a result, an alumina structure sample including 19 channels was produced. After sintering OD is 9.3mm, channel size is ~ 1.6mm, volume fraction of channel is about 69%, The wall thickness between the channels was 1 mm. Example 6   Fabricates multi-channel structures formed from zirconia stabilized with yttria For this purpose, zirconia powder stabilized with yttria was used. Particle size is 1-5 It was in the range of μm. 55% by volume of the stabilized zirconia powder at 55-60 ° C. Mix with binder (paraffin wax / beeswax) to produce uniform consistency material Built. Using the same technique as described in Example 5, two 12 mm rods, 1 One is “ZrO_Two/ Y_TwoO_Three-Binder "and the other" filler "of Example 5 -Binder "is formed and re-extruded together (at 750 ° C) rO_Two/ Y_TwoO_Three12m with a shell containing and a core containing filler-binder material m two-material rods were produced. In the next step, cut the two material rod into 19 pieces And one central filler-binder rod and two concentric layers, And 12 bundles. The first concentric layer is The second (outer) layer consists of filler-binder rods and ZrO_Two/ Y_TwoO_Three-Ba Made of Indah rod. The bundle is inserted into a 60mm container and 12mm Extruded through the die, ZrO_Two/ Y_TwoO_ThreeMatrix and filler matrix A rod structure containing 19 2.4 mm passages filled with stainless steel was manufactured. In the next step, The rod structure thus obtained was further cut into 19 pieces and re-extruded as described above._Two / Y_TwoO_Three19 × 19 = 36 packed with matrix and filler material matrix A 12 mm rod having one passage (〜0.45 mm diameter) was produced.   After cutting to the required length, these rod structures were described in Example 5. And a final sintering at 1500 ° C.   As a result, ZrO containing 361 channels_Two/ Y_TwoO_ThreeThe structure was manufactured. After sintering OD is reduced to about 9.8 mm, channel size is about 0.3 mm, and wall thickness is 0.25 mm The channel porosity was 58%. Example 7   High temperature metal alloy (Fe) with 85% volume loading of the channel and a channel diameter of ~ 0.5 mm (CrAlY) multi-channel rods were produced in the following manner.   Fe-25Cr-5Al-0.5Y powder was mixed with 45% by volume of a binder (paraffin Wax / beeswax) and extruded the mixture through a 5 mm die. Was cut into pieces having a length of 100 mm and a diameter of 5 mm.   Using the same technique, the filler-binder mixture is mixed with melamine powder (50% by volume) and Prepared from binder (paraffin wax / beeswax). After extrusion, this filler A 55 mm diameter rod of binder mixture was obtained.   The parallel rods of FeCrAlY-binder and filler-binder are filled with 1 1 including filler-binder rod and fecr alloy-binder rod around it The concentric outer layers were arranged in parallel bundles. 45 through this 0.75mm die After extruding at 0 ° C, a FeCrAlY-binder shell and a filler-bine in the center A two-material rod with a damper was obtained. In the next step, the rod was Cut into pieces, collect in bundles of 1000 parallel pieces, and divide the bundles into square sections It was loaded on a die with a face of 40 × 30 mm and compressed at a temperature of 45 ° C. under a pressure of 15 MPa. As a result of this process, a uniform FeCrAlY-binder matrix and 1000 40 × 30 × 12 mm raw body with distributed parallel filler-binder fibers was gotten. Debinding and sintering to remove binder and filler As a result, pre-designated with 1000 channels stretched perpendicular to the plane 40 × 12 mm The resulting multi-channel FeCrAlY structure is obtained.   Debinding is carried out slowly (0.1 ° C./min) to 350 ° C. and then 1 The sintering is carried out at 0.2 ° C. in an ultra-high purity hydrogen atmosphere. Per minute by heating from 350 ° C. to 1400 ° C. C. for 2 hours. Example 8   In substantially the same manner as described in the previous example, a superalloy (superall oy) 40 × 30 × 12 mm multi-channel unfired bar of Heysteroy X (Green bar). It is a 0.5 mm diameter chamber with a volume fraction of 85%. Flannel. Powder mixture: Ni-45%, Cr-22%, Fe-18%, Mo-9%, Co-1.5%, W-0.5% were used as structural materials. 85 % Paraffin and 15% beeswax by mixing with 50% by volume of a binder. The compound was used as a bi-material rod. The core of the rod is , 55% melamine + 50% of the same binder. Unfired bar (green bar) was manufactured in the same manner as in Example 8. Example 9   1.3 micron average particle size to produce multi-channel alumina structure Was mixed with a mixture of paraffin + beeswax binder. The binder It contained 90% paraffin and 10% beeswax. The mixture is 50% binder And 50% alumina powder.   The filler mixture is composed of graphite powder having an average particle size of 20 microns and the same binder as described above. Was mixed.   A tube of the first mixture was extruded with an outer diameter of 60 mm and an inner diameter of 30 mm.   A rod of the second mixture was extruded with a diameter of 30 mm. Is this the first mixture Was inserted into the tube manufactured by the company.   The composite rod comprises an alumina-binder tube and a core forming a shell. It consists of a graphite-binder rod to be formed. Extrude this into a die, 2m m composite rods were formed.   2 mm composite rods were cut into 100 mm long segments. 631 Seg A bundle of the vessel, a container and a 90 mm diameter cavity and a 30 mm exit hole (Outgoing hole) and extruded. As a result, a diameter of. Uncured, 30 mm outer diameter with 631 graphite and binder fibers of 3 mm A (composite) structure was obtained.   For debinding, the composite structure is brought to room temperature at a rate of 0.1 ° C./min. To 400 ° C.   The composite structure is then heated from 400 ° C. to 1600 ° C. at a rate of 1.0 ° C./min. Maintained at 1600 ° C for 2 hours for burning graphite filler and sintering alumina structure did. Example 10   To produce a multi-channel silicon carbide structure, the first mixture is treated with a particle size . 52% by volume and 70% by weight polyethylene of 5 micron sintered silicon carbide powder Wax consisting of wax, 25% paraffin wax and 5% beeswax 48% by volume of the material was produced. The second mixture is 50% by volume graphite powder (Asbury brand, grade number: Micro 850, particle size: 325 (Mesh) and 50% by volume of the same binder.   Extruding the first mixture through a 20 mm die connected to a 60 mm container; A 20 mm rod was produced. The second mixture is similarly extruded and the same 20 mm A rod was manufactured. In the next step, the rods were collected in a bundle consisting of seven rods . It consists of a rod made of the second mixture in the center and the first mixture around it. Fee 6 rods were surrounded. Insert this into a 60mm container and attach Extruded through a drawn 20 mm die. In the next step, The resulting composite rod was cut into 7 pieces of the obtained length, collected in a bundle, and placed in a 60 mm container. And extruded again through the attached die, a rod with composite structure: A matrix made of silicon carbide mixed with a binder and mixed with a binder Seven fibers made of the graphite powder were manufactured. In the next step, The die is similarly cut into seven pieces, bundled, inserted into a die container and pushed through a similar die. I started. The result of this step is a silicon carbide / binder matrix and 49 graphite / An uncured product containing a binder fiber was produced.   The heat treatment was composed of the following two steps. (1) Heating rate of 5-6 ° C / hour For 5 hours at 350 ° C (embedding of medium-graphite) at a heating rate of 10 to 12 ° C / hour Gradual heating to 1100 ° C. at a temperature, followed by maintaining at the same temperature for 2 hours, (2) 10 Final sintering (argon) in argon at a heating rate of 12 ° C./hour at 2100 ° C. for 2 hours No body burial). In the final step, the sample is heated to 1400 ° C. in air and Burned lead.   As a result, a silicon carbide structure having 49 channels was produced.

────────────────────────────────────────────────── ─── Continuation of front page    (81) Designated countries EP (AT, BE, CH, DE, DK, ES, FI, FR, GB, GR, IE, IT, L U, MC, NL, PT, SE), AU, CA, JP, K R (72) Inventor Maria Robert A             85715 US Arizona             Johnson North Fontaine Park             2001 [Continuation of summary] Removed by In certain embodiments, the inner core The material is heated while heating the structure to perform the sintering process. May be removed by heating the material. Other forms In one embodiment, the binder and / or filler material is a suitable solvent May be removed.

Claims (1)

[Claims] 1. Solid multichannel formed from structural material with multiple channels inside A method of manufacturing a structure,   a. preparing a first mixture including a powder form of the structural material and a binder material; ,   b. providing a second mixture including the powder form of the channel forming filler and the binder material; Process,   c. deforming the second mixture to form a core, and deforming the first mixture to form the core; A shell formed from the first mixture by forming the shell surrounding the core. Forming a composite rod comprising a shell and an inner core formed from the second mixture. About   d. assembling a first bundle including a plurality of said composite rods in a substantially parallel relationship with each other; Compacting the first bundle and deforming the bundle to form individual locks in the first bundle. The process of reducing the diameter of the   e. assembling a plurality of said deformed bundles into yet another bundle comprising a final assembly of the desired configuration Process,   f. maintaining the filler and binder of the composite rod of the assembly in place, Consolidating yet another bundle containing the final assembly;   g. Both the core and shell material of the composite rod containing the final consolidated assembly then Removing the binder from the   h. The resulting structure including the remaining structural material of the composite rod shell of the final assembly The channel is formed from the inner core of the composite rod containing the sintered and consolidated final assembly Removing the composite filler, thereby forming the core of the composite rod containing the final assembly structure A solid structure having a plurality of channels formed by the removed filler material. Process of making A method for manufacturing a multi-channel structure, comprising: 2. Claims wherein removal of the channel-forming filler in step (h) is performed by sintering step (h). 2. The method according to item 1. 3. Step (i) in which removal of the channel-forming filler in step (h) is separate from sintering step (h) The method according to claim 1, which is performed by: 4. After deforming said bundle in step (d), individual rods of said first bundle of composite rods Of the reduced diameter deformed bundle before the diameter of the deformed bundle is mixed into the final assembly of step (e). Further by at least one additional step of deformation in a further bundle comprising parallel bundles The method of claim 1 wherein the method is reduced. 5. A composite rod extrudes the second mixture through an internal orifice and mixes the first mixture. The compound is extruded through an outer annular orifice to form the shell surrounding the core. By forming the first mixture and the second mixture in step (c). A method according to claim 1, wherein the method comprises: 6. A composite rod extrudes the second mixture through an internal orifice and mixes the first mixture. The compound is extruded through an outer annular orifice to form the shell surrounding the core. By forming the first mixture and the second mixture in step (c). 5. The method of claim 4, wherein the method comprises: 7. Reducing the diameter of individual rods in the first bundle by deforming the bundle Step (d) pushes the bundle through an orifice smaller than the first circumference of the first bundle. A method according to claim 1, which comprises issuing. 8. Reducing the diameter of individual rods in the first bundle by deforming the bundle Step (d) pushes the bundle through an orifice smaller than the first circumference of the first bundle. 6. The method of claim 5, which includes issuing. 9. Additional deformation of the bundle of rods to reduce the diameter of individual rods 5. The method of claim 4 which involves the extrusion of yet another bundle of cladding. Ten. Additional deformation of the bundle of rods to reduce the diameter of individual rods 9. A method according to claim 8 involving the extrusion of yet another bundle of bars. 11． The binder material of the first mixture and the binder material of the second mixture are thermoplastic. 2. The method of claim 1, comprising a conductive material. 12． The binder material of the first mixture and the binder material of the second mixture are thermoplastic. 5. The method of claim 4, wherein the method is sexual. 13. The channel forming material of the second mixture is a mixture of both the first mixture and the second mixture. A thermoplastic material having a melting point above the melting point of the thermoplastic material of the indah material 12. The method according to item 11, wherein 14. The channel forming material of the second mixture is a mixture of both the first mixture and the second mixture. A thermoplastic material having a melting point above the melting point of the thermoplastic material of the indah material Item 13. The method according to Item 12, wherein 15． The channel forming material of the second mixture has a boiling point higher than that of the material of the binder material. The method according to claim 1, wherein the material has a material. 16． The structural material of the first mixture is a sinterable ceramic powder. Item 2. The method according to item 1. 17． The structural material of the first mixture is a sinterable ceramic powder. Item 5. The method according to Item 4. 18． The structural material of the first mixture is a sinterable ceramic powder. 11. The method according to item 11. 19. The structural material of the first mixture is a sinterable ceramic powder. 12. The method according to item 12. 20. The structural material of the first mixture is a sinterable ceramic powder. 13. The method described in the section. twenty one. The structural material of the first mixture is a sinterable ceramic powder. 14. The method according to item 14. twenty two. 2. The method according to claim 1, wherein the ceramic powder structural material of the first mixture is alumina. Item 6. The method according to Item 5. twenty three. 2. The method according to claim 1, wherein the ceramic powder structural material of the first mixture is alumina. Item 8. The method according to Item 7. twenty four. 2. The method according to claim 1, wherein the ceramic powder structural material of the first mixture is alumina. Item 9. The method according to Item 8. twenty five. 2. The method according to claim 1, wherein the ceramic powder structural material of the first mixture is alumina. Item 10. The method according to Item 9. 26. 2. The ceramic powder structure material of the first mixture is alumina. The method according to item 0. 27. 2. The ceramic powder structure material of the first mixture is alumina. Item 2. The method according to item 1. 28. Whether the channel-forming filler of the second mixture is in urea, melamine and polymer 12. The method according to claim 11, which is a substance selected from the group consisting of: 29. The evaporation temperature of the channel forming filler is higher than the sintering temperature of the structural material of the first mixture. 2. The method of claim 1, wherein said method is also low. 30. Whether the channel-forming filler of the second mixture is in urea, melamine and polymer 13. The method according to claim 12, which is a substance selected from the group consisting of: 31. The channel-forming filler of the second mixture is a carbonaceous material, CaO, MgO and metal. 12. The method according to claim 11, which is a substance selected from the group consisting of: 32. The channel-forming filler of the second mixture is a carbonaceous material, CaO, MgO and metal. 13. The method according to claim 12, which is a substance selected from the group consisting of: 33. 3. The method according to claim 3, wherein the binder of the first mixture is wax or paraffin. Item 2. The method according to item 1. 34. 3. The method according to claim 3, wherein the binder of the first mixture is wax or paraffin. Item 3. The method according to Item 2. 35. The binder of claim 2 wherein the binder of the second mixture is also wax or paraffin. 33. The method according to paragraph 33. 36. The step (e) of assembling the extruded bundles into the final assembly substantially separates the respective bundles from each other In a layer which is parallel to the sintering step (h). The body structure includes a plurality of parallel channels in layers that are in a substantially parallel relationship, The method of claim 1 including a plurality of parallel channels from one side to another. Law. 37. The step (e) of assembling the extruded bundles into the final assembly brings the respective bundles into a parallel relationship. The solid structure resulting from the sintering step (h) is one of the structures 5. The method of claim 4 including a plurality of parallel channels from one side to another. 38. The step (e) of assembling the extruded bundles into the final assembly substantially separates the respective bundles from each other In a layer which is parallel to the sintering step (h). A plurality of parallel chips in a layer where the body structure is substantially parallel from one side of the structure to another side. 6. The method of claim 5, including a channel. 39. The step (e) of assembling the extruded bundles into the final assembly involves alternating the respective bundles with one another. Solid structure resulting from the sintering step (h) 2. The method of claim 1 wherein the structure includes a plurality of parallel channels in layers alternating with each other. The method described in. 40. The step (e) of assembling the extruded bundles into the final assembly involves alternating the respective bundles with one another. Solid structure resulting from the sintering step (h) 5. The structure of claim 4 wherein the structure includes a plurality of parallel channels in layers alternating with each other. The method described in. 41. The step (e) of assembling the extruded bundles into the final assembly involves alternating the respective bundles with one another. Solid structure resulting from the sintering step (h) 6. The structure of claim 5, wherein the structure includes a plurality of parallel channels in layers alternating with each other. The method described in. 42. A solid multi-channel structure manufactured by the method according to claim 36. . 43. A solid multi-channel structure manufactured by the method according to claim 37. . 44. A solid multi-channel structure manufactured by the method according to claim 38. . 45. A solid multi-channel structure manufactured by the method according to claim 39. . 46. A solid multi-channel structure manufactured by the method according to claim 40. . 47. A solid multi-channel structure manufactured by the method according to claim 41. . 48. Claims wherein the channels of the final assembly have a diameter in the range of 10-100 microns 43. A solid multi-channel structure manufactured by the method according to claim 42. 49. Claims wherein the channels of the final assembly have a diameter in the range of 10-100 microns. A solid multi-channel structure manufactured by the method according to Item 43. 50. Claims wherein the channels of the final assembly have a diameter in the range of 10-100 microns. 45. A solid multi-channel structure manufactured by the method according to item 44. 51. Claims wherein the channels of the final assembly have a diameter in the range of 10-100 microns. 46. A solid multi-channel structure manufactured by the method according to item 45. 52. Claims wherein the channels of the final assembly have a diameter in the range of 10-100 microns. A solid multi-channel structure manufactured by the method according to Item 46. 53. Claims wherein the channels of the final assembly have a diameter in the range of 10-100 microns. 50. A solid multi-channel structure manufactured by the method according to item 47. 54. The binder material of the first mixture and the second mixture is paraffin, and the filler Is urea or melamine and the core and shell materials of the consolidated final assembly Exposing the compacted final assembly to heat in the range of 150 ° C to 350 ° C The step (I) of removing the filler from the compacted final assembly is accompanied by compaction. Exposing the final assembly to heat in the range of 300 ° C. to 500 ° C., the curing step (I) By exposing the remaining structures of the final assembly to heat in the range of 1500 ° C to 1800 ° C. 12. The method according to claim 11, which comprises sizing. 55. The metal powder structural material of the first mixture consists essentially of powdered metal. 2. The method according to claim 1. 56. The metal powder structural material of the first mixture consists essentially of powdered metal. Item 5. The method according to Item 4. 57. The metal powder structural material of the first mixture consists essentially of powdered metal. Item 6. The method according to Item 5. 58. The channel-forming filler of the second mixture is substantially the powder metal of the first mixture Claim 55 comprising a separate powdered metal having a melting point lower than the melting point of the structural material The described method. 59. The channel-forming filler of the second mixture is substantially the powder metal of the first mixture Claim 57 comprising another powdered metal having a melting point lower than the melting point of the structural material. The described method. 60. The channel-forming filler of the second mixture is substantially the powder metal of the first mixture Claim 57 comprising another powdered metal having a melting point lower than the melting point of the structural material. The described method. 61. Claiming to remove channel-forming filler from the inner core of the composite rod of the final assembly Step (h) according to claim 1, wherein said consolidated final assembly is powdered with said assembling rod. High enough to melt the metallic binder core material, but not Exposure to heat at a temperature that is not high enough to melt the structural material forming the The molten metal binder material contains the metal of the shell of the assembled rod. Infiltrate the matrix, thereby replacing the melted core material with chips in the final assembly. 59. The method of claim 58, wherein said channel is provided. 62. Claiming to remove channel-forming filler from the inner core of the composite rod of the final assembly Step (h) according to claim 1, wherein said consolidated final assembly is powdered with said assembling rod. High enough to melt the metallic binder core material, but not Exposure to heat at a temperature that is not high enough to melt the structural material forming the The molten metal binder material contains the metal of the shell of the assembled rod. Infiltrate the matrix, thereby replacing the melted core material with chips in the final assembly. 59. The method of claim 58, wherein said channel is provided. 63. Claiming to remove channel-forming filler from the inner core of the composite rod of the final assembly Step (h) according to claim 1, wherein said consolidated final assembly is powdered with said assembling rod. High enough to melt the metallic binder core material, but not Exposure to heat at a temperature that is not high enough to melt the structural material forming the The molten metal binder material contains the metal of the shell of the assembled rod. Infiltrate the matrix, thereby replacing the melted core material with chips in the final assembly. 60. The method according to claim 59, wherein said channel is provided. 64. Claims wherein the powdered metal structural material of the first mixture consists essentially of tungsten. Clause 58. The method of clause 58. 65. The method of claim 64, wherein the powder metal channel forming filler consists essentially of copper. the method of. 66. Claims wherein the powdered metal structural material of the first mixture consists essentially of tungsten. 60. The method according to paragraph 59. 67. The method of claim 66, wherein the powder metal channel forming filler consists essentially of copper. the method of. 68. Claims wherein the powdered metal structural material of the first mixture consists essentially of tungsten. Clause 58. The method of clause 58. 69. 70. The method of claim 68, wherein the powder metal channel forming filler consists essentially of copper. the method of. 70. Claims wherein the channel-forming filler of the second mixture consists essentially of an organic material. The method according to paragraph 55. 71. 71. The method according to claim 70, wherein the organic substance is melamine powder. 72. Claims wherein the channel-forming filler of the second mixture consists essentially of an organic material. Paragraph 56. The method of Paragraph 56. 73. 73. The method according to claim 72, wherein the organic substance is melamine powder. 74. Claims wherein the channel-forming filler of the second mixture consists essentially of an organic material. 60. The method according to paragraph 57. 75. 75. The method according to claim 74, wherein the organic substance is melamine powder. 76. The powder metal of the first mixture consists essentially of powdered carbonyl iron. Clause 55. The method of clause 55. 77. The powder metal of the first mixture consists essentially of powdered carbonyl iron. 56. The method according to paragraph 56. 78. The powder metal of the first mixture consists essentially of powdered carbonyl iron. 56. The method according to paragraph 57. 79. The powder metal of the first mixture consists essentially of powdered carbonyl iron. Clause 75. The method of clause 75. 80. The powder metal of the first mixture consists essentially of powdered carbonyl iron. Clause 71. The method of clause 71. 81. The powder metal of the first mixture consists essentially of powdered carbonyl iron. The method according to paragraph 77. 82. The powder metal of the first mixture consists essentially of powdered carbonyl iron. Paragraph 62. A method according to Paragraph 62. 83. The powder metal of the first mixture consists essentially of powdered carbonyl iron. Clause 63. The method of clause 63. 84. The powder metal of the first mixture consists essentially of powdered carbonyl iron. Clause 64. The method of clause 64. 85. A solid multi-channel structure manufactured by the method according to claim 34 . 86. A solid multi-channel structure manufactured by the method according to claim 21. . 87. A solid multi-channel structure manufactured by the method according to claim 22 . 88. A solid multi-channel structure manufactured by the method according to claim 28. . 89. 32. A solid multi-channel structure manufactured by the method according to claim 31. . 90. A solid multi-channel structure manufactured by the method according to claim 35. . 91. A solid multi-channel structure manufactured by the method according to claim 1. . 92. A solid multi-channel structure manufactured by the method according to claim 2. . 93. A solid multi-channel structure manufactured by the method according to claim 3. 94. A solid multi-channel structure manufactured by the method according to claim 4. . 95. 70. A solid multi-channel structure manufactured by the method of claim 69 . 96. 84. A solid multi-channel structure manufactured by the method of claim 84. body. 97. Claims wherein the channels of the final assembly have a diameter in the range of 10-100 microns. 90. The solid multi-channel structure according to item 85. 98. Claims wherein the channels of the final assembly have a diameter in the range of 10-100 microns. 90. The solid multi-channel structure according to item 86. 99. Claims wherein the channels of the final assembly have a diameter in the range of 10-100 microns. 90. The solid multi-channel structure according to item 87. 100. The claim of claim 1, wherein the channels of the final assembly have a diameter in the range of 10-100 microns. 90. The solid multi-channel structure according to item 88. 101. The channel of the final assembly having a diameter in the range of 10-100 microns. 2. The solid multi-channel structure according to 1. 102. The channel of the final assembly having a diameter in the range of 10-100 microns. 5. The solid multi-channel structure according to 4. 103. The first mixture containing the structural material in powder form comprises a catalyst. The method described in. 104. The first mixture containing the structural material in powdered form comprises a catalyst. The method described in. 105. The channel forming filling material is acid-soluble, the structural material is acid-insoluble, Is removed in step (h) by subjecting the filler material to an acid solution. The method described in. 106. The channel-forming filling material is an acid-soluble metal, and the structural material is alumina. 108. The method of claim 105. 107. The method of claim 106, wherein the channel forming fill material is copper. 108. The method of claim 106, wherein the channel forming fill material is iron. 109. The method according to claim 107, wherein the acid is hydrochloric acid. 110. The method according to claim 108, wherein the acid is sulfuric acid. 111.From the first mixture forming the shell and the second mixture forming the inner core Step (c) of forming a composite rod comprising (I) forming a plurality of structure-binder rods comprising the first mixture; (Ii) forming at least one filler-binder rod comprising said second mixture; Performing the process, and (Iii) collecting the bundle of parallel rods to form the composite rod of step (c) of claim 1 Wherein the core of the rod comprises at least one filler-binder lock. A plurality of said structures-binders disposed around said core. And the bundle of parallel rods collected is deformed in step (c) to form a composite rod. The method of claim 1, comprising forming a pad. 112. The composite rod of step (c) (iii) is used to extrude the bundle of collected parallel rods. 112. The method according to claim 111, formed by such deformation. 113. The structural material of the first mixture is a sinterable ceramic powder. 12. The method according to 11. 114. The method of claim 113, wherein the sinterable ceramic powder is alumina. . 115. The channel-forming filler of the second mixture comprises melamine and a polymer. 115. The method of claim 114, wherein the substance is selected. 116. Sinterable ceramic powder is a zirconia powder stabilized with yttria 114. The method according to claim 113. 117. The channel-forming filler of the second mixture is a melamine and a polymer. 117. The method of claim 116, wherein the substance is selected. 118. The composite rod formed in step (c) is provided with an intermediate layer between the shell and the inner core. Comprising a third mixture of a second structural material and a binder material in powder form, As an additional preliminary step, (iv) forming a plurality of rods of the catalyst-binder material (V) disposing a plurality of the second structural material-binder rods in parallel with the core. Structure comprising a core and a shell of bundles of parallel rods placed and assembled-binder Collecting the bundle of parallel rods arranged in parallel between the rods. Clause 111. The method of clause 111. 119. The method according to claim 118, wherein the second structural material is a catalyst powder. 120. The channel-forming filler of the second mixture is selected from melamine and a polymer. 120. The method of claim 119, wherein the substance is selected. 121. A parallel channel in which each bundle has a different diameter than the channel diameter of the other bundles   37. The method of claim 36, comprising: 42. The channel of claim 39, wherein the channels of every other lateral layer are of different diameters.   the method of. 123. The method of claim 55, wherein the powdered metal is an alloy powder. 124. The method of claim 56, wherein the powdered metal is an alloy powder. 125. The structural material is FeCrAlY, and the corresponding elemental metal powder mixture   Mixing the elemental metal powders in a suitable stoichiometric ratio and stirring or stirring the alloy.   124. The method of claim 123 formed by forming after stirring. 126. The method of claim 125, wherein said FeCrAlY is a catalyst support. 127. The method of claim 126, wherein a catalyst is coated on the FeCrAlY catalyst support.   the method of. 128. The channel-forming filler of the second mixture is carbon, and is suitable for step (h).   Removing the channel-forming filler material is achieved by oxidizing carbon;   The method of claim 1. 129. Oxidation of the carbon filler material is achieved by heat applied during the sintering step (h).   129. The method of claim 128, wherein 130. Oxidation of the carbon filler material heats the final assembly to remove binder   While maintaining the material in a non-oxidizing atmosphere, and then the structural integrity of the final assembly   But after being secured by the binding of its components, to burn out the carbon filler   130. The method is controlled by replacing a non-oxidizing atmosphere with an oxidizing atmosphere.   The method described in. 131. The method according to claim 128, wherein said carbon filling material is graphite carbon. 132. The method of claim 128, wherein the carbon-filled material is amorphous carbon. 133. The structural material of the first mixture is a sinterable ceramic powder.   28. The method according to 28. 134. The method according to claim 133, wherein the sinterable ceramic powder is alumina.   the method of. 135. The ceramic powder of claim 133, wherein the sinterable ceramic powder is silicon carbide powder.   The method described. 136. The method of claim 128, wherein the structural material of the first mixture consists essentially of powdered metal.   The described method. 137. The method of claim 136, wherein the powdered metal consists essentially of powdered copper. 138. The method of claim 136, wherein the powdered metal consists essentially of powdered nickel.   Law. 139. The powder metal is essentially a powder selected from Pt, Pd, Ag and Au   138. The method of claim 136. 140. The method of claim 136, wherein the powdered metal consists essentially of powdered magnesium. the method of.