Enhanced heat transfer device manufacture

Claim 1

A method for manufacturing an enhanced heat transfer device consisting of a metal substrate and randomly distributed metal bodies bonded to said substrate comprising the steps of: (a) providing base metal powder with particles of major dimensions less than 0.1 inch; (b) mixing said base metal powder with first liquid binder and in proportion such that the weight ratio of base metal powder to first liquid binder is between 20:1 and 30:1, so as to form an adherent mass; (c) providing braze metal powder having a melting point lower than said base metal powder and with particles of major dimensions such that the major dimension ratio of braze metal powder to base metal powder is between 1:60 and 1:3, and mixing said braze metal powder and said adherent mass in weight proportion such that said braze metal powder is between 10 and 30 percent of the braze metal powder plus the base metal powder, so as to form braze metal-coated mass; (d) applying a second liquid binder on said metal substrate; (e) applying said braze metal-coated mass on the second liquid binder coated metal substrate; and (f) heating the braze metal coated mass-metal substrate sufficiently to remove said first and second binders, melt said braze metal and metal bond said base metal to said metal substrate thereby forming said metal bodies.

Claim 2

A method for manufacturing an enhanced heat transfer device consisting of a metal substrate and randomly distributed metal bodies bonded to said substrate comprising the steps of: (a) providing base metal powder with particles of major dimensions less than 0.1 inch; (b) mixing said base metal powder with first liquid binder and in proportion such that the weight ratio of base metal powder to first liquid binder is between 20:1 and 30:1, so as to form an adherent mass; (c) providing braze metal powder having a melting point lower than said base metal powder and with particles of major dimensions such that the major dimension ratio of braze metal powder to base metal powder is between 1:60 and 1:3, and mixing said braze metal powder and said adherent mass in weight proportion such that said braze metal powder is between 10 and 30 percent of the braze metal powder plus the base metal powder, so as to form braze metal-coated mass; (d) applying a second liquid binder on said metal substrate; (e) applying said braze metal-coated mass on the second liquid binder coated metal substrate; and (f) heating the braze metal coated mass-metal substrate sufficiently to remove said first and second binders, melt said braze metal and metal bond said base metal to said metal substrate thereby forming said metal bodies.

Claim 12

A method for manufacturing an enhanced heat transfer device consisting of a metal substrate and randomly distributed metal bodies individually bonded to said substrate in a single layer and spaced from each other and substantially surrounded by said substrate comprising the steps of: (a) providing base metal powder with particles of major dimensions between 0.006 and 0.060 inch; (b) mixing said base metal powder with first liquid binder comprising a low volatility, high molecular weight organic polymer component and a high volatiltiy solvent component, and in proportion such that the weight ratio of base metal powder to first liquid binder is between 20:1 and 30:1, so as to form an adherent mass; (c) providing braze metal powder having a melting point lower than said base metal powder and with particles of major dimensions such that the major dimension ratio of braze metal powder to base metal powder is between 1:30 and 1:3 and mixing said braze metal powder and said adherent mass in weight proportion such that said braze metal power is between 15 and 25 percent of the braze metal powder plus the base metal powder, so as to form braze metal-coated mass; (d) applying a second liquid binder comprising a low volatility, high molecular weight organic polymer component and a high volatility solvent compound on said metal substrate; (e) applying said braze metal-coated mass on the second liquid binder coated metal substrate; and (f) heating the braze metal-coated mass-metal substrate sufficiently to completely remove said first and second binders, melt said braze metal and metal bond said base metal to said metal substrate thereby forming said metal bodies.

Claim 13

A method for manufacturing an enhanced heat transfer device consisting of a metal substrate and randomly distributed metal bodies individually bonded to said substrate in a single layer and spaced from each other and substantially surrounded by said substrate comprising the steps of: (a) providing base metal powder with particles of major dimensions between 0.006 and 0.060 inch; (b) mixing said base metal powder with first liquid binder comprising a low volatility, high molecular weight organic polymer component and a high volatiltiy solvent component, and in proportion such that the weight ratio of base metal powder to first liquid binder is between 20:1 and 30:1, so as to form an adherent mass; (c) providing braze metal powder having a melting point lower than said base metal powder and with particles of major dimensions such that the major dimension ratio of braze metal powder to base metal powder is between 1:30 and 1:3 and mixing said braze metal powder and said adherent mass in weight proportion such that said braze metal power is between 15 and 25 percent of the braze metal powder plus the base metal powder, so as to form braze metal-coated mass; (d) applying a second liquid binder comprising a low volatility, high molecular weight organic polymer component and a high volatility solvent compound on said metal substrate; (e) applying said braze metal-coated mass on the second liquid binder coated metal substrate; and (f) heating the braze metal-coated mass-metal substrate sufficiently to completely remove said first and second binders, melt said braze metal and metal bond said base metal to said metal substrate thereby forming said metal bodies.