CN104691046B - 表面带有尺寸受控晶粒的金属泡沫体、其制备方法和用途 - Google Patents

表面带有尺寸受控晶粒的金属泡沫体、其制备方法和用途 Download PDF

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CN104691046B
CN104691046B CN201410334584.6A CN201410334584A CN104691046B CN 104691046 B CN104691046 B CN 104691046B CN 201410334584 A CN201410334584 A CN 201410334584A CN 104691046 B CN104691046 B CN 104691046B
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metal
foam body
alloy
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CN104691046A (zh
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R·波斯
S·萨别里
F·戴塞尔
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Ai Lan Rises European Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
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    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10Sintering only
    • B22F3/11Making porous workpieces or articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10Sintering only
    • B22F3/11Making porous workpieces or articles
    • B22F3/1121Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • B22F3/1137Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers by coating porous removable preforms
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
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    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/002Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00Layered products comprising a layer of metal
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    • B32B15/00Layered products comprising a layer of metal
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    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B15/00Layered products comprising a layer of metal
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    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B15/00Layered products comprising a layer of metal
    • B32B15/04Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B32B15/00Layered products comprising a layer of metal
    • B32B15/20Layered products comprising a layer of metal comprising aluminium or copper
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Abstract

本发明涉及一种金属泡沫体,包括:(a)一由至少一种金属或合金A制成的金属泡沫体基材;和(b)一在金属泡沫体基材(a)表面至少一部分上的金属或金属合金B层,其中金属或金属合金A和B的化学组成和/或晶粒尺寸不相同,其中金属或金属合金A和B选自由Ni、Cr、Co、Cu、Ag及这些金属的任意合金组成的组;由包括以下步骤的方法制得:(i)提供一多孔有机聚合物泡沫体;(ii)在多孔有机聚合物泡沫体上沉积至少一种金属或金属合金A;(iii)烧掉多孔聚合物泡沫体,得到金属泡沫体基材(a);和(iv)在金属泡沫体(a)表面至少一部分上通过电镀沉积一金属或金属合金B的金属层(b)。还涉及制备金属泡沫体的方法及其用途。

Description

表面带有尺寸受控晶粒的金属泡沫体、其制备方法和用途
技术领域
本发明涉及表面带有尺寸受控晶粒的金属泡沫体、其制备方法和用途。具体来说,本发明涉及一种金属泡沫体,其包括(a)由至少一种金属或金属合金A制成的金属泡沫体基材;以及(b)在金属泡沫体基材(a)表面的至少一部分上存在的金属或金属合金B层,其中金属或金属合金A和B的化学组成和/或晶粒尺寸不相同;该种金属泡沫体的制备方法及其用途。
背景技术
已知的是泡沫金属可以作为催化剂前体或作为催化剂。事实上,泡沫金属作为催化剂载体或催化剂的潜在优点已经是化学领域重点关注的主题。这些泡沫金属的一些特征是:能促进传质和传热的较大的界面面积、较高的导热性及机械强度。
为了实现这些有利特征,通常采用多孔有机聚合物作为模板,在其上沉积一种或多种需要的金属或金属合金来制成泡沫金属。然后将所述有机聚合物在高温下烧掉以使泡沫金属能够用于各种应用中,包括各种吸附和吸收工艺中;或者本身作为催化材料或其前体。但是,为了烧掉聚合物,需要使用高温。例如,当使用聚氨酯作为模板时,需要在高达850℃的温度下烧掉聚氨酯。在这种温度条件下,很多金属表面发生变化,并且常常出现金属晶粒尺寸增大。最终,金属表面需要的特征受到损害。
并且,已知的是催化活性物质的晶粒尺寸对很多催化工艺都有重大影响。因此,总的来说,需要提供具有催化活性物质晶粒尺寸确定的催化活性材料。所述晶粒尺寸常常在催化反应过程中增大,特别是当反应是在高温下进行时。例如,文章“Herstellung vonFormaldehyd aus Methanol in der BASF”描述了通过在600-700℃下使用银晶体催化剂对甲醇进行氧化脱氢合成甲醛。在该工艺中发现,当银晶体催化剂的温度升高时,由于未转化甲醇的量减少并且形成的副产物一氧化碳和二氧化碳增多,收率降低。这是由于在进行所述的甲醛合成工艺的700℃的高温下,银的晶粒尺寸增大,导致银催化剂的催化活性降低。
因此,本发明的目的在于提供一种金属泡沫体,在该泡沫体表面具有受控晶粒尺寸的金属颗粒,即晶粒尺寸较少依赖于金属泡沫体的合成条件。本发明还有一个目的是提供一种用于制备该种金属泡沫体的工艺。
EP 2650393 A1公开了一种制备至少含有镍和钨的金属多孔体的方法,该方法包括用至少含有镍和钨的合金包覆镍多孔体的步骤;以及在此步骤之后进行热处理以使钨扩散进入镍多孔体的步骤。在一实施例中,通过使用镍包覆已制成的具有导电性的多孔基体、移除所述多孔基体,然后将镍还原,从而获得所述镍多孔体。可以作为多孔基体的材料优选能够镀覆金属并且随后可以通过焚烧除去的材料。从高孔隙率的角度来看,聚氨酯泡沫是特别优选的。优选的各方法步骤的顺序是“电解镍处理”、“电解镀镍-钨镀层处理”以及“热处理”。
JPH 08225866 A公开了一种具有三维网络结构的金属多孔体及其制备方法。将作为具有高孔隙率的树脂,聚氨酯泡沫,浸入含有球形羰基铁粉的浆料中,使其中充满所述浆料。然后将该树脂在室温下干燥并在非氧化性气氛中进行烧结去除该树脂,从而形成具有三维网络结构的铁多孔体。然后在瓦兹浴(一种电镀浴)中在该铁骨架表面镀覆镍。
US 4076888公开了一种制备具有三维丝状形态的细胞状结构的金属和/或金属陶瓷和/或陶瓷海绵的方法,从泡沫聚氨酯海绵开始,该方法包括采用干燥的高温涂层技术(主要包括利用等离子体喷射进行的熔融喷射沉积法(molten-spray deposition))在具有特定孔隙率的金属化聚氨酯海绵上涂覆至少一层涂层,其中的至少一种涂层材料选自包括金属、金属陶瓷及陶瓷材料的组。
WO 2006/111837 A2涉及一种制备金属(尤其是银或金泡沫金属)的方法,包括采用化学方法在聚氨酯泡沫或类似的泡沫金属的泡沫表面沉积薄的第一金属层,如银或金,再采用电解方法在所述银或金泡沫金属的泡沫表面沉积同一金属、厚度更大的第二金属层。
EP 1477578 A1公开了一种制备泡沫金属的方法,包括步骤:提供一含有第一金属或合金的开孔泡沫金属芯,在该泡沫金属芯上涂覆第二金属或合金,其是在液态下涂覆到泡沫金属芯上的。所述第一金属或合金的熔点比第二金属或合金的熔点高。
发明内容
本发明目的是通过金属泡沫体、制备该种金属泡沫体的方法和该种金属泡沫体的用途实现。该金属泡沫体、其制备方法和用途的优选实施方式在下述描述。即使没有明确指出,但本发明金属泡沫体、其制备方法和用途的优选实施方式相当于其他发明类别中的优选实施方式。
如前所述,本发明涉及一种金属泡沫体,包括:
(a)一金属泡沫体基材,其由至少一种金属或合金A制成;和
(b)一金属或金属合金B层,其位于金属泡沫体基材(a)表面的至少一部分上,其中金属或金属合金A和B的化学组成和/或晶粒尺寸不相同,并且其中金属或金属合金A和B选自由Ni、Cr、Co、Cu、Ag及这些金属的任意合金组成的组;
其由包括以下各步骤的方法制备得到:
(i)提供一多孔有机聚合物泡沫体;
(ii)在所述多孔有机聚合物泡沫体上沉积至少一种金属或金属合金A;
(iii)烧掉所述多孔聚合物泡沫体,得到所述金属泡沫体基材(a);以及
(iv)在所述金属泡沫体(a)表面的至少一部分上通过电镀沉积一金属或金属合金B的金属层(b)。
步骤(ii)中,在多孔有机聚合物泡沫体上沉积至少一种金属或金属合金A可以通过多种方法实现,例如通过电镀、CVD、金属-有机CVD(MOCVD),通过拉浆法或其他方法。如果待实施的方法是电镀,需要预先使所述多孔聚合物具有导电性,从而使其适于使用电镀法。
因此,优选地,步骤(ii)包括:
(ii1)通过化学或物理气相沉积法沉积含金属或金属合金A1的第一金属层;和
(ii2)通过电镀沉积含金属或金属合金A2的第二金属层;
其中所述金属或金属合金A1和A2选自由Ni、Cr、Co、Cu、Ag及这些金属的任意合金组成的组,并且其中A1和A2相同或不同。在本发明的上下文中,A的含义包括A1和A2。
在步骤(ii1)中,可以使用各种不同的化学或物理气相沉积法。优选地,使用溅射法。
第一金属层的主要目的是使多孔有机聚合物的表面具有导电性。因此,第一金属层可以足够薄,只要其能提供足够的导电性即可。一般来说,该第一金属层的厚度为大约几原子的级别就足够了。优选地,第一金属层的平均厚度可达0.1μm,第二金属层的平均厚度为5-50μm。
在制备本发明的金属泡沫体时,很多多孔有机聚合物可以使用。优选地,使用带有开孔的有机聚合物。一般来说,所述多孔有机聚合物泡沫体选自由聚氨酯(PU)泡沫、聚乙烯泡沫和聚丙烯泡沫组成的组。更优选地,使用多孔聚氨酯(PU)泡沫。使用多孔聚氨酯(PU)泡沫特别有利于制得开孔金属泡沫体。
在一特别优选的金属泡沫体实施例中,金属泡沫体基材(a)中的孔筋(strut)的厚度范围为5-100μm。
优选地,金属或金属合金B的层(b)的平均厚度为5-200μm。
在本发明的金属泡沫体中,金属或金属合金A、A1、A2和/或B选自由Ni、Cr、Co、Cu、Ag及这些金属的任意合金组成的组。在一特别优选的实施例中,A2和B是银。在该实施例中,A1也可以是银或者一种不同的金属或金属合金。金属或金属合金的选择在某些程度上依赖于金属泡沫体的预期应用。为了某些催化目的的,不同金属的存在可能使银的催化作用减弱(poison)。
至于在本发明中,晶粒大小采用电子显微镜确定。在本发明的金属泡沫体中,所述金属或金属合金A的金属泡沫体基材(a)中的晶粒大小范围优选为1μm-100μm。此外,金属或金属合金B的层(b)中的晶粒大小范围优选为1nm-50μm。
本发明的金属泡沫体的孔径大小优选为100-5000μm,孔筋厚度范围优选为5-100μm,表观密度范围优选为300-1200kg/m3,几何比表面积范围优选为100-20000m2/m3,孔隙率范围优选为0.50-0.95。
所述孔径大小一般通过由Recticel提出的Visiocell分析方法(Visiocellanalysis method)确定,该方法在“The Guide 2000of Technical Foams”第4册第4部分33-41页中有描述。具体来说,孔径大小通过采用叠加的校准环对选定的孔进行光学测量孔径并打印在一透明纸上确定。至少对上百个不同的孔进行孔径大小测量以得到平均孔径值。
表观密度是根据ISO 845确定每单位体积的重量。
所述金属泡沫体的几何比表面积(GSA)采用2-D泡沫扫描(2-D foam scans)和数值方法确定。具体来说,GSA通过采用下述成像技术确定:将带有硬化剂(混合物中树脂和环氧树脂硬化剂的重量比是10:3)的泡沫样品(20×20mm)放置在一容器(holder)中。所述样品在炉温70℃下硬化30分钟。使用抛光盘和水对泡沫样品进行抛光。采用“Inner View”软件进行图像捕捉和处理。捕捉36个区(一个区为1.7×2.3mm)的图像,并用该软件对捕捉的图像进行分析。去掉3个最大值和3个最小值,并基于30个区的值根据下述方程估得GSA的值:
(As/V)=Σl(Ps/A)l/l
·截面积(A)
·每截面积的孔筋面积(As)
·每截面积孔筋的周长(Ps)
孔隙率(%)通过下述方程计算得到:
孔隙率(%)=100/VT×(VT–W(1000/ρ),
其中,VT是泡沫片样品体积,单位[mm3];W是泡沫片样品重量,单位[g];ρ是泡沫材料密度。
孔筋厚度采用电子显微镜测量。具体来说,孔筋厚度采用Salvo等人(cf.Salvo,L.,Cloetens,P.,Maire,E.,Zabler,S.,Blandin,J.J.,Buffière,J.Y.,Ludwig,W.,Boller,E.,Bellet,D.and Josserond,C.2003,“X-ray micro-tomography as anattractive characterization technique in materials science”,NuclearInstruments and Methods in Physics Research B 200 273-286)的X射线微断层扫描技术测得平均值,其提供了泡沫微观结构的3D可视化。对于每个孔筋,等效水力直径(直径相当于相同截面积的圆柱体)是在大量孔筋基础上计算并统计均值得到的。
然后根据前述提到的Salvo等人的方法从等效水力直径得到孔筋厚度,如下所述,采用Ni泡沫体作为解说示例:
泡沫面积密度(AD)[kg Ni/m2泡沫]/泡沫厚度(FT)[m]=X(kg Ni/m3泡沫)
X[kg Ni/m3泡沫]/镍密度[kg Ni/m3固体Ni]=Y[无量纲]
几何比表面积(GSA)=m2/m3
·泡沫孔筋厚度[m]=Y/GSA
所述金属或金属合金B的层可以位于金属泡沫体基材(a)的一部分表面上或整个表面上。不过优选地是,所述金属或金属合金B位于金属泡沫体基材(a)的整个表面上。此外,优选地是,金属泡沫体基材(a)上的层(b)具有均一的厚度。
另外,本发明涉及制备金属泡沫体的方法,其中所述金属泡沫体包括:
(a)一金属泡沫体基材,其由至少一种金属或合金A制成;和
(b)一金属或金属合金B层,其位于金属泡沫体基材(a)表面的至少一部分上,其中金属或金属合金A和B的化学组成和/或晶粒尺寸不相同,并且其中金属或金属合金A和B选自由Ni、Cr、Co、Cu、Ag及这些金属的任意合金组成的组;
包括步骤
(i)提供一多孔有机聚合物泡沫体;
(ii)在所述多孔有机聚合物泡沫体上沉积至少一种第一金属或金属合金A;
(iii)烧掉所述多孔聚合物泡沫体,得到所述金属泡沫体基材(a);以及
(iv)在所述金属泡沫体基材(a)表面的至少一部分上通过电镀沉积一金属或金属合金B的金属层(b)。
优选的方法包括步骤:
(i1)提供一多孔聚氨酯泡沫体;
(ii3)在聚氨酯泡沫体上沉积厚度5-50μm的Ag;和
(iii1)在300-850℃的温度范围下烧掉聚氨酯泡沫体,得到金属泡沫体基材(a);和
(iv1)在步骤(iii1)中得到的金属泡沫体基材(a)上通过电镀沉积厚度1-200μm的Ag,优选地厚度为5-50μm。
更优选的方法包括步骤:
(i1)提供一多孔聚氨酯泡沫体;
(ii4)通过溅射沉积Ni或Ag使聚氨酯泡沫体具有导电性;
(ii5)在步骤(ii4)中得到导电聚氨酯泡沫体上通过电镀沉积厚度5-50μm的Ag;和
(iii1)在300-850℃的温度范围下烧掉聚氨酯泡沫体;和
(iv1)在步骤(iii1)中得到的金属泡沫体基材(a)上通过电镀沉积厚度1-200μm的Ag,优选地厚度为5-50μm。
在进一步的内容中,本发明涉及本文描述的金属泡沫体在物理吸附或吸收工艺或在化学工艺中的应用。
示例是从制药、精炼和工业应用的废液流中去除及回收金属。
本发明的金属泡沫体也能够在特别涉及有机化合物的多种催化化学反应(例如氢化、异构化、水合作用、氢解、还原胺化、还原烷基化、脱水、氧化、脱氢、重排和其他反应)中作为催化剂的一种组分使用。
在优选的用途中,所述金属泡沫体在通过氧化甲醇制备甲醛的工艺中作为催化剂前体或催化剂使用。
本发明的金属泡沫体孔隙率高、质量轻,并且具有较大的表面积。另外,它们还表现出良好的结构均质性。关于流体传递、传质和传热性能,表面改性的泡沫金属具有较低的压降、增强的流体混合性、较高的传热和传质速率、较高的导热性以及较低的扩散阻力。
本发明具有若干优点。本发明制得了一种可以在化学工艺中使用的催化剂或催化剂组分,其具有较高的机械稳定性,并且由于泡沫体表面的金属颗粒的晶粒大小能够控制,因此可以得到非常明确的表面结构。也就是说,与已知的泡沫体相比,晶粒大小较少依赖于金属泡沫体的合成条件。
此外,当传递物质能够与催化部位接触时,本发明的金属泡沫体可以很好地通过它使物质传递。此外,本发明的泡沫体的使用避免了沟流形成。
下述示例用于解释说明本发明,并且不用于限定本发明。晶粒大小和层厚度通过扫描电子显微镜确定。
具体实施方式
实施例
首先,通过提供一平均孔隙率为450μm的1.6mm多孔聚氨酯泡沫片制备金属泡沫体。所述聚氨酯泡沫经历溅射镀Ni(或者Ag),以使聚氨酯泡沫导电。然后电镀银,其平均厚度为20μm。接着,700℃下,在空气中烧掉所述聚氨酯泡沫。在烧掉所述聚氨酯泡沫后,晶粒大小增加超过沉积银层后直接得到的晶粒大小。然后,镀上平均厚度为20μm的第二银层。最后的金属泡沫体的晶粒大小近似于烧掉聚氨酯泡沫前、沉积银层后直接得到的晶粒大小。
对比例
重复上述实施例,除了在聚氨酯进行导电化后电镀的银层的平均厚度为40μm。最后的金属泡沫体的晶粒大小大于上述实施例最后的金属泡沫体的晶粒大小。

Claims (11)

1.金属泡沫体,包括:
(a)一金属泡沫体基材,其由至少一种金属或金属合金A制成;和
(b)一金属或金属合金B层,其位于金属泡沫体基材(a)表面的至少一部分上,其中金属或金属合金A和B的晶粒尺寸不相同,并且其中金属或金属合金A和B选自由Ni、Cr、Co、Cu、Ag及这些金属的任意合金组成的组;
其由包括以下各步骤的方法制备得到:
(i)提供一多孔有机聚合物泡沫体;
(ii)在所述多孔有机聚合物泡沫体上沉积至少一种金属或金属合金A;
(iii)烧掉所述多孔有机聚合物泡沫体,得到所述金属泡沫体基材(a);以及
(iv)在所述金属泡沫体(a)表面的至少一部分上通过电镀沉积一金属或金属合金B的金属层(b);
其中步骤(ii)包括步骤:
(ii1)通过化学或物理气相沉积法沉积含金属或金属合金A1的第一金属层;和
(ii2)通过电镀沉积含金属或金属合金A2的第二金属层;
其中所述金属或金属合金A1和A2选自由Ni、Cr、Co、Cu、Ag及这些金属的任意合金组成的组,其中A1和A2相同或不同,其中A2和B是银。
2.根据权利要求1所述的金属泡沫体,其中所述第一金属层的平均厚度为0.1-3μm,所述第二金属层的平均厚度为5-50μm。
3.根据权利要求1所述的金属泡沫体,其中所述多孔有机聚合物泡沫体选自由聚氨酯(PU)泡沫、聚乙烯泡沫和聚丙烯泡沫组成的组。
4.根据权利要求1所述的金属泡沫体,其中所述金属泡沫体基材(a)中的孔筋的厚度范围为5-100μm。
5.根据权利要求1所述的金属泡沫体,其中所述金属或金属合金B的层(b)的平均厚度为5-200μm。
6.根据权利要求1所述的金属泡沫体,其中该金属泡沫体的孔径大小为100-5000μm,孔筋厚度范围为5-100μm,表观密度范围为300-1200kg/m3,几何比表面积范围为100-20000m2/m3,孔隙率范围为0.50-0.95。
7.根据权利要求1所述的金属泡沫体,其中所述金属或金属合金B的层(b)位于金属泡沫体基材(a)的整个表面上。
8.制备金属泡沫体的方法,其中所述金属泡沫体包括:
(a)一金属泡沫体基材,其由至少一种金属或金属合金A制成;和
(b)一金属或金属合金B层,其位于金属泡沫体基材(a)表面的至少一部分上,其中金属或金属合金A和B的晶粒尺寸不相同,并且其中金属或金属合金A和B选自由Ni、Cr、Co、Cu、Ag及这些金属的任意合金组成的组;
包括步骤
(i)提供一多孔有机聚合物泡沫体;
(ii)在所述多孔有机聚合物泡沫体上沉积至少一种第一金属或金属合金A;
(iii)烧掉所述多孔有机聚合物泡沫体,得到所述金属泡沫体基材(a);以及
(iv)在所述金属泡沫体基材(a)表面的至少一部分上通过电镀沉积一金属或金属合金B的金属层(b);
其中步骤(ii)包括步骤:
(ii1)通过化学或物理气相沉积法沉积含金属或金属合金A1的第一金属层;和
(ii2)通过电镀沉积含金属或金属合金A2的第二金属层;
其中A1和A2相同或不同,并且其中A2和B是银。
9.根据权利要求8所述的方法,包括步骤:
(i1)提供一多孔聚氨酯泡沫体;
(ii3)在聚氨酯泡沫体上沉积厚度5-50μm的Ag;和
(iii1)在300-850℃的温度范围下烧掉聚氨酯泡沫体,得到金属泡沫体基材(a);和
(iv1)在步骤(iii1)中得到的金属泡沫体基材(a)上通过电镀沉积厚度1-200μm的Ag。
10.权利要求1-7中任一项所述的金属泡沫体在物理吸附或吸收工艺,或在化学工艺中的用途。
11.根据权利要求10所述的用途,其中权利要求1-7中任一项所述的金属泡沫体在通过氧化甲醇制备甲醛的工艺中作为催化剂前体或催化剂使用。
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