JP2007313835A - Composite porous body and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To join a porous body and a frame body with sufficient joining strength without largely reducing the effective use area of the porous body and to provide good sealability to a laminate constituted by laminating and arranging a plurality of composite porous bodies. <P>SOLUTION: The composite porous body 10 is constituted by integrally forming the sheetlike porous body 11 having a three-dimensional reticulated structure and the frame body 12 extending in a surface direction from at least a part of the side part of the porous body 11. The frame body 12 is equipped with the resin part 14 joined to the side part of the porous body 11 and the seal part 13 joined to the outer peripheral part of the resin part 14 and formed of a rubbery elastic material. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a composite porous body used for a filter, a gas diffusion member, a heat radiating member, a water absorbing member, and the like, and a method for producing the same.

A sheet-like porous body having a three-dimensional network structure is applied to various uses such as a filter, a gas diffusion member, a heat radiating member, and a water absorbing member, and is provided in various apparatuses. Since this kind of porous body is generally low in strength and easily deformed, a frame member extending in the surface direction is provided on the side of the porous body, and the porous body and the frame member Is used as a composite porous body formed integrally. The frame member is formed of a thermosetting resin, a thermoplastic resin, a thermoplastic elastomer, or rubber as shown in Patent Document 1 below, or a rubber-like elastic material as shown in Patent Document 2 below. Is formed.
Japanese Patent Laying-Open No. 2005-029806 JP 2003-007328 A

However, in the conventional composite porous body, when the frame member is formed of a rubber-like elastic material, the rubber-like elastic material forming the frame member is made porous in order to ensure the bonding strength between the frame member and the porous body. It was necessary to permeate from the outer periphery of the body to the inside in the surface direction. In this case, many pores of the porous body having a three-dimensional network structure are crushed, the effective use area of the porous body is greatly reduced, each function of the porous body in each of the above applications is reduced, or There is a problem that leads to an increase in the size of the porous body in order to compensate for the reduced amount of pores in the porous body.
On the other hand, when the frame member is formed of a thermosetting resin or a thermoplastic resin, it is possible to ensure the bonding strength with the porous body without greatly reducing the effective use area of the porous body. In a state where a laminated body in which a plurality of composite porous bodies are laminated is incorporated in the apparatus, a fluid such as gas or fuel is caused to flow toward the surface of the porous body and pass in the laminating direction of the laminated body. Sometimes, there is a problem that fluid easily leaks from between these composite porous bodies and it is difficult to provide good sealing properties.

  The present invention has been made in view of the above problems, and can greatly bond the porous body and the frame member with sufficient bonding strength without greatly reducing the effective use area of the porous body. An object of the present invention is to provide a composite porous body capable of providing a laminated body in which a plurality of composite porous bodies are laminated and have good sealing properties, and a method for producing the same.

  In order to solve such problems and achieve the above object, the composite porous body of the present invention includes a sheet-like porous body having a three-dimensional network structure and at least one of the side portions of the porous body. A composite porous body in which a frame member extending in a plane direction from a portion is integrally formed, and the frame member is bonded to a resin portion bonded to a side portion of the porous body and an outer peripheral portion of the resin portion And a seal portion formed of a rubber-like elastic material.

  According to this invention, since the frame member includes the resin portion and the seal portion, it is possible to sufficiently secure the bonding strength between the porous body and the frame member, and a plurality of the composite porous bodies are laminated. Thus, the laminated body arranged can have a good sealing property. That is, since the resin part is bonded to the side part of the porous body, not the seal part formed of the rubber-like elastic material, the bonding strength between the side part of the porous body and the resin part is set to be porous. The effective use area of the body can be ensured without greatly reducing, and the outermost peripheral part of the composite porous body is constituted by a seal part, so that a plurality of layers of this composite porous body are stacked and arranged. It is possible to make the seal portions adjacent to each other in the stacking direction close to each other in the body, and let a fluid such as gas or fuel flow toward the porous body in the stack, and let this fluid pass in the stacking direction of the stack. In this case, the fluid can be prevented from leaking from between the composite porous bodies by the close contact of the seal portion.

  Here, the resin part may contain 5 wt% or more and 60 wt% or less of a fibrous inorganic filler.

In this case, since the resin portion contains an inorganic filler, the strength of the resin portion itself can be increased, whereby the strength of the composite porous body can be increased, and the handleability can be further improved.
In addition, when the resin part is formed by insert molding using, for example, a porous body as an insert product, in the case where molten resin is about to flow into the inside of the porous body from the pores opened to the side of the porous body However, the inorganic filler is entangled with the mesh defining the pores, and the opening area of the pores in the side portion of the porous body is reduced. Therefore, at the time of insert molding, it is possible to prevent the molten resin from flowing into the porous body without any restriction, and it is possible to further suppress the decrease in the effective use area of the porous body. Furthermore, as described above, since the inorganic filler entangles with the mesh defining pores opened in the side portion of the porous body during the insert molding, the molten resin is cured in this state, and the molten resin Although the inflow to the inside of the porous body is suppressed to the minimum, the resin part and the porous body can be firmly joined.
Further, since it becomes possible to suppress the inflow of the molten resin into the porous body, the porous body generated by the curing shrinkage of the molten resin when the resin portion is formed on the side portion of the porous body and bonded. It is possible to reduce the warpage.

The seal portion may protrude outward in the thickness direction with respect to the surfaces of the porous body and the resin portion.
In this case, in the laminated body in which a plurality of composite porous bodies are laminated, it is possible to reliably bring the seal portions adjacent in the laminating direction into close contact with each other, flowing a fluid toward the porous body, This fluid can be prevented from leaking between the composite porous bodies when trying to pass in the stacking direction of the stack.

Furthermore, a protrusion that extends outward in the surface direction may be provided on the outer peripheral portion of the resin portion, and the protrusion may be covered with a seal portion.
In this case, the bonding strength between the resin portion and the seal portion can be improved.

  Further, in the method for producing a composite porous body of the present invention, a sheet-like porous body having a three-dimensional network structure and a frame member extending in a plane direction from at least a part of a side portion of the porous body are integrated. A method for producing a composite porous body, wherein the porous body is used as an insert part and insert molding is performed by injection molding a resin portion joined to a side portion of the porous body, and then transfer molding is performed. A composite porous body is formed by forming a frame member having a seal portion and a resin portion by forming a seal portion made of a rubber-like elastic material joined to the outer peripheral portion of the resin portion.

  In this case, in addition to being able to reliably form a composite porous body that exhibits the above-described effects, the resin portion and the porous body are integrated by joining the resin portion to the side of the porous body. Since the seal portion is formed by transfer molding after the formation, it is possible to use one member for positioning with respect to the cavity of the mold at the time of molding, and the seal portion can be formed with high accuracy.

  According to the present invention, the porous body and the frame member can be bonded with sufficient bonding strength without greatly reducing the effective use area of the porous body, and a plurality of composite porous bodies are laminated. The arranged laminate can be provided with good sealing properties.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
As shown in FIG. 1, the composite porous body 10 of the present invention includes a sheet-like porous body 11 and a frame member 12 that extends in the plane direction from at least a part of the side of the porous body 11. The formed thin plate is rectangular in plan view.

The porous body 11 is a rectangular thin plate having a three-dimensional network structure, and has air permeability and water absorption due to pores opened in the side portions in each direction, and is lightweight and has a large surface area. have. The porous body 11 may be made of metal, crystalline carbon, carbonaceous material containing amorphous carbon that is not crystalline, or a metal cloth.
Moreover, in this embodiment, the side part of the porous body 11 is comprised by the four flat plate parts 11b, and comprises the outer periphery of the porous body 11 made into the planar view rectangle by these flat plate parts 11b. . That is, the side part of the porous body 11 is configured such that end portions in the length direction of the flat plate parts 11b adjacent to each other in the direction along the outer peripheral edge of the porous body 11 are connected to form a ridge line.

  The frame member 12 has a thin plate shape, and is joined to the side of the porous body 11 with no difference in level with respect to the front and back surfaces of the porous body 11 with the same thickness as the porous body 11. The composite porous body 10 in which the porous body 11 and the frame member 12 are integrally formed as described above is formed as a single thin plate member as a whole, and a plurality of composite porous bodies 10 are stacked and arranged. In a state where the laminated body is incorporated in the apparatus, a fluid such as gas or fuel is flowed toward the surface of the porous body 11 and is passed through in the laminating direction of the laminated body.

Here, the porous body 11 can be manufactured by various methods. For example, the porous body 11 can be manufactured by baking a green sheet obtained by thinly forming and drying a slurry containing metal powder.
The slurry is formed by mixing, for example, a metal powder such as SUS316L, an organic binder (for example, methylcellulose or hydroxypropylmethylcellulose), and a solvent (water). In addition to this, a foaming agent (for example, carbon) that is sublimated or vaporized by heat treatment. A water-insoluble hydrocarbon-based organic solvent (e.g., neopentane, hexane, heptane) of 5 to 8 or an antifoaming agent (ethanol) is added as necessary.
In the green sheet manufacturing apparatus, first, slurry is supplied from a hopper in which the slurry is stored onto a carrier sheet conveyed by a roller. Next, the slurry on the carrier sheet is stretched between the moving carrier sheet and the doctor blade and formed into a required thickness.
The formed slurry is further conveyed by a carrier sheet and passes through a heating furnace. And it dries in a heating furnace, and the green sheet of the state in which SUS316L powder was joined by the organic binder is formed.
In addition, when a foaming agent is included in the slurry, the slurry in a state of being extended on the carrier sheet is heat-treated in a high-humidity atmosphere before drying to foam the foaming agent to obtain a foamed slurry, and then dried. Processing is performed to form a green sheet.
This green sheet is removed from the carrier sheet, and then degreased and fired in a vacuum furnace, whereby the organic binder is removed and the porous body 11 is obtained by sintering metal powders.

  In this embodiment, the frame member 12 includes a resin part 14 joined to the side part of the porous body 11 and a seal part joined to the outer peripheral part of the resin part 14 and formed of a rubber-like elastic material. 13. The resin portion 14 is bonded to the entire side in the thickness direction at the side portion of the porous body 11 and over the entire circumference in the direction along the outer peripheral edge of the porous body 11. The seal portion 13 is bonded to the entire outer circumferential surface of the resin portion 14 in the thickness direction and over the entire circumference of the outer circumferential surface of the resin portion 14.

  In the present embodiment, as shown in FIG. 2, the thicknesses of the porous body 11, the seal portion 13, and the resin portion 14 are made equal, and the front and back surfaces of the porous body 11 are substantially the same without any step. Further, the width of the resin portion 14 is set to 0.3 mm or more and 2.0 mm or less as a whole including the penetration depth from the outer peripheral edge of the porous body 11 to the inner side in the surface direction.

Here, as the seal portion 13, a thermosetting resin having rubber-like elasticity such as silicone resin, a thermoplastic resin having rubber-like elasticity such as ethylene / vinyl acetate (EVA) copolymer resin, polybutadiene resin, and thermoplastic polyurethane. Among elastomers and other thermoplastic elastomers (TPE), one kind may be used alone, or two or more kinds may be used in combination. Among these, from the viewpoint of chemical resistance and heat resistance, it is desirable to employ a silicone resin or an olefin-based thermoplastic elastomer. Further, when the composite porous body 10 is used as, for example, a gas diffusion member of a fuel cell, a material that can withstand the usage environment such as temperature, for example, a fluorine-based thermoplastic elastomer or an engineering plastic-based thermoplastic elastomer is adopted. can do.
In place of the above materials, for example, natural rubber, isoprene rubber, butadiene rubber, styrene butadiene rubber, chloroprene rubber, acrylonitrile butadiene rubber or other diene rubber, or butyl rubber, ethylene propylene rubber, urethane rubber, silicone rubber, chlorosulfone Although non-diene rubbers such as fluorinated rubber, chlorinated polyethylene, acrylic rubber, epichlorohydrin rubber, or fluororubber can be employed, when the composite porous body 10 is used, for example, as a gas diffusion member of a fuel cell For example, it is desirable to employ a material that can withstand the use environment such as temperature, for example, fluorine rubber, ethylene propylene rubber, or silicone rubber.

  The resin part 14 includes an ionomer resin, an ethylene / ethyl acrylate copolymer resin, an acrylonitrile / styrene / acrylic rubber copolymer (ASA) resin, an acrylonitrile / chlorinated polyethylene / styrene copolymer (ACS) resin, and an ethylene / vinyl alcohol copolymer. Polymer resin, acrylonitrile / butadiene / styrene copolymer (ABS) resin, fluorine resin, polyamide resin, polyacrylate resin, liquid crystal polymer, polyether ether ketone (PEEK) resin, polyether sulfone (PES) resin, polyethylene terephthalate, polycarbonate Resin, phenylene ether resin, polyphenylene sulfide (PPS) resin, polybutylene terephthalate (PBT), polypropylene resin, polymethylpentene, syndiotactic polices Ren (SPS), polycycloolefin (COP), may be employed a cyclic olefin copolymer (COC) thermoplastic resin such as or epoxy resin, phenol resin, polyimide resin, a thermosetting resin such as melamine resin. Further, when the composite porous body 10 is used as, for example, a gas diffusion member of a fuel cell, a resin material having a deflection temperature under load having an upper limit temperature of 120 ° C. or higher in the fuel cell operating temperature range is selected from the above materials. Among these resin materials, a resin material, more preferably a crystalline resin, excellent in chemical resistance, and low in gas permeability, such as fluororesin, polyamide resin, liquid crystal polymer, polyetheretherketone (PEEK) ) Resin, polyethylene terephthalate, polyphenylene sulfide (PPS) resin, polybutylene terephthalate (PBT), and polypropylene resin can be used, and polyphenylene sulfide (PPS) resin and polypropylene resin are more preferable than these resin materials. be able to.

Next, a method for forming the frame member 12 on the side portion of the porous body 11 will be described.
First, the porous body 11 is disposed as an insert part in the cavity formed between the pair of molds, and the molten resin injected from the runner through the gate is filled into the cavity, so that the side portion of the porous body 11 is filled. Insert molding is performed in which the resin portion 14 is injection-molded over the entire circumference in the thickness direction and along the entire circumference in the direction along the outer peripheral edge of the porous body 11.

And the resin part 14 is joined to the side part of the porous body 11, the intermediate member in which the resin part 14 and the porous body 11 are integrally formed is taken out from the mold, and another mold different from the mold is used. The rubber-like elastic material is press-fitted into the outer peripheral surface side of the resin portion 14 by transfer molding, and the entire circumference of the outer peripheral surface of the outer peripheral surface of the resin portion 14 is entirely pressed. A seal portion 13 joined over the entire area is formed.
As described above, the composite porous body 10 is formed by forming and joining the frame member 12 including the seal portion 13 and the resin portion 14 on the side portion of the porous body 11.

  As described above, according to the composite porous body 10 of the present embodiment, since the frame member 12 includes the resin portion 14 and the seal portion 13, the bonding strength between the porous body 11 and the frame member 12 is sufficient. In addition, a laminated body in which a plurality of the composite porous bodies 10 are laminated and disposed can have good sealing properties.

  That is, since the resin portion 14 is joined to the side portion of the porous body 11 instead of the seal portion 13 formed of a rubber-like elastic material, the side portion of the porous body 11 and the resin portion 14 are joined. The strength can be ensured without greatly reducing the effective use area of the porous body 11, and the outermost peripheral portion of the composite porous body 10 is constituted by the seal portion 13. In the laminated body in which a plurality of layers 10 are arranged, it is possible to bring the seal portions 13 adjacent to each other in the laminating direction into close contact with each other, and a fluid is caused to flow toward the porous body 11 in the laminated body. It is possible to prevent the fluid from leaking from between the composite porous bodies 10 by the close contact of the seal portion 13 when trying to pass in the laminating direction.

  Moreover, according to the manufacturing method of the composite porous body 10 of this embodiment, in addition to being able to form reliably the composite porous body 10 which has the said effect, the resin part 14 is made into a porous body. After the resin part 14 and the porous body 11 are integrally formed by bonding to the side parts of the resin 11, the seal part 13 is formed by transfer molding. It becomes possible to form one, and the seal part 13 can be formed with high accuracy.

The various shapes and combinations of the constituent members shown in the above embodiments are merely examples, and various modifications can be made based on design requirements without departing from the spirit of the present invention.
For example, in the above-described embodiment, the resin portion 14 is bonded to the entire area in the thickness direction at the side portion of the porous body 11 and the entire circumference in the direction along the outer peripheral edge of the porous body 11, and the seal portion 13 is bonded. The resin member 14 is bonded to the entire outer circumferential surface of the resin portion 14 in the thickness direction and to the entire outer periphery of the resin portion 14, and the frame member 12 is bonded to the side portion of the porous body 11. The present invention is not limited to the above-described embodiment as long as it is configured to include the seal portion 13 that is joined to the outer peripheral portion of the resin portion 14 and formed of a rubber-like elastic material.

  For example, the resin part 14 is joined to a part of the side part of the porous body 11 or a plurality of positions spaced in the direction along the outer peripheral edge, and the resin part 14 is covered from the outer peripheral part side in the seal part 13. You may make it join the part which continues in a direction along the outer periphery of the porous body 11 to the part to the side part of the porous body 11.

  Specifically, as shown in FIG. 3, a plurality of resin portions 14 are provided on the side portions of the porous body 11 at intervals in the direction along the outer peripheral edge, and the seal portion 13 is provided with the resin portion 14. Covering from the outer peripheral side and filling the space between the resin parts 14, the porous body 11 extends over the entire circumference, and on the side of the porous body 11 between the resin parts 14. You may make it join. Further, as shown in FIG. 3, the resin portion 14 is connected to the edge of the flat plate portion 11b that is continuous with the ridge line from the ridge line formed by the adjacent flat plate portions 11b in the direction along the outer peripheral edge of the porous body 11. You may make it join to the corner | angular part 11a hung on the part.

  Further, instead of the configuration of FIG. 3, as shown in FIG. 4, in the side portion of the porous body 11, each of the pair of flat plate portions 11 b opposed to each other in the surface direction, Separately, the resin part 14 is joined, and the seal part 13 extending over the entire length direction of the flat plate part 11b to which the resin part 14 is joined is covered with the seal part 13 so as to cover the resin part 14 from the outer peripheral side. You may join to the part except the said length direction both ends in the flat plate part 11b.

  Alternatively, in the side portion of the porous body 11, a resin portion 14 is joined to each of the pair of flat plate portions 11b facing each other in the surface direction at the center in the length direction, and these resins The seal portion 13 extending over the entire length direction of the flat plate portion 11b to which the resin portion 14 is bonded so as to cover the portion 14 from the outer peripheral portion side is excluded from the longitudinal direction central portion of the flat plate portion 11b. You may join to the part.

  Furthermore, instead of this, in the side portion of the porous body 11, each of the pair of flat plate portions 11 b facing each other in the plane direction is separately provided in two intermediate portions excluding the central portion in the length direction and both end portions. The resin part 14 is joined, and the sealing part 13 extending over the entire length direction of the flat plate part 11b to which the resin part 14 is joined is covered with the flat plate so as to cover the resin part 14 from the outer peripheral side. You may join to the part except the two said intermediate parts in the part 11b.

  Further, in the above-described embodiment, the frame member 12 is configured to be joined to the side portion of the porous body 11 with almost the same thickness as the porous body 11 without a step, but instead, the seal portion 13 is used. These surfaces may protrude outward in the thickness direction with respect to the surfaces of the porous body 11 and the resin portion 14. For example, as shown in FIG. 5, at least a part of the front and back surfaces of the seal portion 13 is made thicker than the resin portion 14 and the porous body 11, and the front or back surface is the resin portion 14 and the porous body 11. You may employ | adopt the structure which protruded to the thickness direction outward with respect to the surface or back surface.

  In this case, in a laminate in which a plurality of composite porous bodies 10 are laminated and arranged, it is possible to reliably bring the seal portions 13 adjacent in the laminating direction into close contact with each other, and a fluid flows toward the porous body 11, This fluid can be prevented from leaking from between the composite porous bodies 10 when trying to pass this fluid in the stacking direction of the stack.

Moreover, in the said embodiment, although the structure in which only the porous body 11 was provided as the composite porous body 10 was shown, it replaces with this and several porous bodies 11 are spaced apart in the surface direction, and several. In a state where the resin portions 14 are joined to at least a part of the side portions of the respective porous bodies 11, the seal portions 13 are filled between the porous bodies 11, and the resin portions 14 are filled with the seal portions 13. May be covered from the outer peripheral portion side, and the seal portion 13 may be joined to a portion of the side portion where the resin portion 14 is not joined.
Furthermore, in the said embodiment, the planar view rectangular porous body 11 was shown, However For example, a circular shape or a polygon may be sufficient.

  Furthermore, you may make the resin part 14 of the said embodiment contain 5 to 60 wt% of fibrous inorganic fillers.

  In this case, since the resin portion 14 contains an inorganic filler, the strength of the resin portion 14 itself is increased, thereby increasing the strength of the composite porous body 10 and further improving its handleability. it can.

Further, when the resin portion 14 is formed by insert molding using the porous body 11 as an insert product, molten resin flows into the inside of the porous body 11 from the pores opened in the side portions of the porous body 11. Even when trying to do so, the inorganic filler is entangled in the mesh defining the pores, and the pore opening area on the side of the porous body 11 is reduced. Therefore, at the time of insert molding, it is possible to prevent the molten resin from flowing into the porous body 11 without any limitation, and it is possible to further suppress the decrease in the effective use area of the porous body 11. Furthermore, as described above, since the inorganic filler entangles with the network defining pores opened in the side portion of the porous body 11 during the insert molding, the molten resin is cured in this state, and the molten resin Although the inflow into the porous body 11 is suppressed to the minimum, the resin portion 14 and the porous body 11 can be firmly joined.
Moreover, since it becomes possible to suppress the inflow of the molten resin into the porous body 11, it occurs due to the curing shrinkage of the molten resin when the resin portion 14 is formed on the side portion of the porous body 11 and bonded. Warpage of the porous body 11 can be reduced.

  Further, as shown in FIG. 6, a protrusion 15 extending outward in the surface direction may be provided on the outer peripheral surface of the resin portion 14, and the protrusion 15 may be covered with the seal portion 13. In this case, the bonding strength between the resin portion 14 and the seal portion 13 can be improved.

  Without significantly reducing the effective area of the porous body, the porous body and the frame member are bonded with sufficient bonding strength, and a good seal is provided for a laminated body in which a plurality of composite porous bodies are stacked. To have sex.

It is a top view which shows the composite porous body shown as 1st Embodiment of this invention. It is 1st Embodiment of the AA arrow directional cross-sectional view of the composite porous body shown in FIG. It is a top view which shows the composite porous body shown as 2nd Embodiment of this invention. It is a top view which shows the composite porous body shown as 3rd Embodiment of this invention. It is 2nd Embodiment of the AA arrow directional cross-sectional view of the composite porous body shown in FIG. It is 3rd Embodiment of the AA arrow directional cross-sectional view of the composite porous body shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Composite porous body 11 Porous body 12 Frame member 13 Seal part 14 Resin part 15 Protrusion part

Claims (5)

A composite porous body in which a sheet-like porous body having a three-dimensional network structure and a frame member extending in a plane direction from at least a part of a side portion of the porous body are integrally formed,
The frame member includes a resin portion bonded to a side portion of the porous body, and a composite porous material including a seal portion bonded to the outer peripheral portion of the resin portion and formed of a rubber-like elastic material. body. The composite porous body according to claim 1, wherein
The composite porous body, wherein the resin portion contains a fibrous inorganic filler in an amount of 5 wt% to 60 wt%. In the composite porous body according to claim 1 or 2,
The composite porous body, wherein the seal portion protrudes outward in the thickness direction with respect to the surfaces of the porous body and the resin portion. In the composite porous body according to any one of claims 1 to 3,
A composite porous body characterized in that a projecting portion extending outward in the surface direction is provided on the outer peripheral portion of the resin portion, and the projecting portion is covered with a seal portion. A method for producing a composite porous body in which a sheet-like porous body having a three-dimensional network structure and a frame member extending in a plane direction from at least a part of a side portion of the porous body are integrally formed. ,
After performing the insert molding for injection molding the resin portion joined to the side of the porous body, using the porous body as an insert part,
A composite porous body is formed by forming a frame member having a seal portion and a resin portion by forming a seal portion made of a rubber-like elastic material joined to the outer peripheral portion of the resin portion by transfer molding. A method for producing a composite porous body.

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