Abstract A porous laminate is disclosed consisting of a plurality of lamina each having a parallel slot series formed therein, stacked with the respective adjacent slot series overlapping and extending transversely to each other and bonded to each other to form the porous laminate. Variations disclosed include tapering the slots in one or more of the lamina to create a variable porosity and the inclusion of tying sections at intermediate points along the slots for reinforcement purposes. The disclosed process includes the steps of photoetching metal sheets to create the slot pattern, stacking a plurality of the sheets together with the slots in adjacent sheets extending transversely to each other, diffusion bonding the stacked sheets to form a porous laminate, and calendering the finished sheet to modify or adjust permeability.
A POROUS LAMINATE COMPRISING: A PLURALITY OF LAMINA HAVING SLOT PATTERNS FORMED THEREIN. SAID LAMINA STACKED IN INTIMATE CONTACT WITH EACH OTHER WITH SAID SLOT PATTERNS OF ADJACENT LAMINA OVERLAPPING AND EXTENDING TRANSVERSELY TO EACH OTHER TO PROVIDE INTERSECTING SLOT PATTERNS, SAID STACKED LAMINA BEING BONDED TO EACH OTHER TO FORM SAID LAMINATE, WHEREBY SAID INTERSECTING SLOT PATTERNS FORM FLUID FLOW PASSAGES THROUGH SAID LAMINATE.
Claim 2
Dependent Claim
65 words
A POROUS LAMINATE COMPRISING: A PLURALITY OF LAMINA HAVING SLOT PATTERNS FORMED THEREIN. SAID LAMINA STACKED IN INTIMATE CONTACT WITH EACH OTHER WITH SAID SLOT PATTERNS OF ADJACENT LAMINA OVERLAPPING AND EXTENDING TRANSVERSELY TO EACH OTHER TO PROVIDE INTERSECTING SLOT PATTERNS, SAID STACKED LAMINA BEING BONDED TO EACH OTHER TO FORM SAID LAMINATE, WHEREBY SAID INTERSECTING SLOT PATTERNS FORM FLUID FLOW PASSAGES THROUGH SAID LAMINATE.
Claim 3
Dependent Claim
21 words
The laminate of claim 1 wherein said slot patterns comprise a parallel series of uniform width slots formed in said lamina.
Claim 4
Dependent Claim
40 words
The laminate of claim 1 wherein said slots formed in said lamina are tapered in the plane of the lamina and said lamina are stacked with the larger end of said slots overlapping, whereby a variable porosity laminate is provided.
Claim 5
Dependent Claim
20 words
The laminate of claim 1 wherein said slots in said slot patterns have spaced tie sections formed along their lengths.
Claim 6
Dependent Claim
39 words
The laminate of claim 1 wherein each of said lamina have solid areas formed extending around said slot patterns and wherein said solid areas as aligned in said stack, whereby said laminate is formed with a solid peripheral border.
Claim 7
Dependent Claim
36 words
The laminate of claim 1 wherein said slots in alternate lamina in said stack extend parallel to each other but are at least partially offset from each other to form lateral flow passages in said laminate.
Claim 8
Independent Claim
52 words
A METHOD OF MANUFACTURING A POROUS MATERIAL COMPRISING: FORMING A SLOT PATTERN IN A PLAURALITY OF LAMINA, STACKING SAID LAMINA IN INTIMATE CONTACT WITH EACH OTHER WITH SAID SLOT PATTERNS OF ADJACENT LAMINA OVERLAPPING AND EXTENDING TRANSVERSELY TO EACH OTHER, AND BONDING SAID LAMINA TO EACH OTHER TO FORM A POROUS LAMINATE.
Claim 9
Independent Claim
52 words
A METHOD OF MANUFACTURING A POROUS MATERIAL COMPRISING: FORMING A SLOT PATTERN IN A PLAURALITY OF LAMINA, STACKING SAID LAMINA IN INTIMATE CONTACT WITH EACH OTHER WITH SAID SLOT PATTERNS OF ADJACENT LAMINA OVERLAPPING AND EXTENDING TRANSVERSELY TO EACH OTHER, AND BONDING SAID LAMINA TO EACH OTHER TO FORM A POROUS LAMINATE.