JP2019189903A - Production method of foamed metal, production device of foamed metal - Google Patents

Abstract

To provide a production method foamed metal, which can perform a foaming step at a low cost, can produce a foamed metal having a size larger than ever, and can control a shape of the foamed metal.SOLUTION: By using a transportation part 2 that transports a precursor 11 in which a foaming agent is mixed in metal, a mold 5 that transmits light, a light source 4 that illuminates light on the precursor 11, and the precursor 11, molds 5 are arranged to a plurality of the precursors 11, the plurality of the precursors 11 are transported by the transportation part 2, in a state where the precursors 11 are transported, light is irradiated to each of the precursors 11 by transmitting the mold 5 from a light source 4 to heat to make each of the precursors 11 foam to join with the adjacent precursors 11 to prepare a foamed metal 12, and by controlling a shape of the foamed metal 12 by the mold 5 to produce a foamed metal 12.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for producing foam metal and an apparatus for producing foam metal.

  Foamed metal is lightweight because it contains many pores, and has excellent impact energy absorption and silencing properties. It is attracting attention as an ultralight and multifunctional material in various fields such as automobiles, railways, aerospace, and architecture. (For example, see Patent Documents 1 to 3)

As a method for producing a foam metal, conventionally, for example, after producing a precursor in which a foaming agent is mixed with a raw material metal, the precursor is heated in an electric furnace or the like, and is generated by decomposition of the foaming agent. The pores were formed by foaming with gas.
In the step of foaming the precursor, a mold is used for molding the foam metal (for example, see FIG. 1 (e) of Non-Patent Document 1).

  Also, for example, Patent Document 4 proposes a method for heating a precursor disposed in a mold by irradiating radiation from outside the mold as a method for producing a foam such as foam metal. Yes.

JP 2007-61865 A International Patent Publication No. 2010/029864 International Patent Publication No. 2010/106883 JP-T-2006-521467

Totsuo Utsunomiya, Tatsumi Tsukada, Yasuhiko Hanya, “Manufacture of Porous Aluminum Members Using Dies”, Transactions of the Japan Society of Mechanical Engineers, A, 77, p.1017-1020, 2011

  Cost reduction is an issue for the practical use of foam metal, and simplification of the manufacturing process is required.

In conventional atmosphere heating using an electric furnace or the like, the mold is also heated, so that the energy used for heating the precursor is reduced, and the energy utilization efficiency is not good. .
In addition, it took time to raise the temperature to the foaming temperature.
Furthermore, a large electric furnace or the like is indispensable for foaming a large member, and it has been difficult to heat evenly inside the electric furnace.
And since the mold is opaque, the state of foaming inside the mold could not be observed. It was also difficult to observe the inside of the electric furnace.

On the other hand, when foaming is performed without using a mold, the shape is not controlled, and the foam metal is formed in a free shape. Therefore, in order to make the metal foam into a desired shape, it is necessary to perform processing for making the metal into a desired shape after foaming.
However, since the foam metal has pores, it may be deformed by a load applied during processing, and it has been difficult to process into a desired shape.

If the precursor is heated by irradiating with light, only the range irradiated with the light and its surroundings are heated, so that energy utilization efficiency is good and heating can be performed at a lower cost than atmospheric heating.
However, when a metal mold is used for molding the foam metal, the light cannot be transmitted into the metal mold, and thus the precursor cannot be irradiated with light.
In the case of Patent Document 4, since the mold is also heated by radiation, the energy used for heating the precursor is reduced among the heating energy, and the energy utilization efficiency is lowered.
Furthermore, when foaming is performed without using a mold or a mold, as described above, processing is required after foaming in order to obtain a desired shape, but since it has pores, it deforms during processing. It becomes easy and it becomes difficult to process into a desired shape.

  In order to solve the above-described problems, in the present invention, it is possible to perform a foaming process at a low cost, it is possible to foam a member larger than the conventional one, and to control the shape of the foam metal. A foam metal production method and a foam metal production apparatus are provided.

  The foam metal manufacturing method of the present invention uses a precursor in which a foaming agent is mixed with a metal, a mold that transmits light, a light source that irradiates light to the precursor, and a transport unit that transports the precursor. In a state where a mold is arranged with respect to a plurality of precursors, a plurality of the precursors are conveyed by a conveyance unit, and the precursors are conveyed, the mold is transmitted through a light source and light is transmitted to each precursor. The foam metal in a state in which each precursor is foamed and bonded to the adjacent precursor is produced by controlling the shape of the foam metal by the mold.

  The apparatus for producing a foam metal according to the present invention includes a transport unit that transports a precursor in which a foaming agent is mixed with a metal, and a light source that irradiates light to the precursor, and uses a mold that transmits light. In the state where a plurality of precursors are conveyed by, and the precursors are conveyed, each precursor is foamed and adjacent by passing through a mold from a light source and irradiating and heating each precursor with light. In this configuration, the foam metal is manufactured in a state where the shape is controlled by the mold while being joined to the precursor.

According to the method for producing a foam metal of the present invention, the precursor is heated by transmitting light from the light source to the precursor and irradiating the precursor with light. Can be heated. Thereby, it can heat at cost lower than atmospheric heating, and can manufacture a foam metal at low cost. And since the type | mold which permeate | transmits light is used, it is possible to observe the foaming state through a type | mold.
Further, by controlling the shape of the foam metal by the mold, it becomes possible to produce a foam metal having a desired shape.
Furthermore, a plurality of precursors are transported by the transport unit, and each precursor is irradiated with light and heated in a state where the precursors are transported, thereby foaming each precursor and joining the adjacent precursors. Since the foamed metal in a state of being made is produced, the foamed metal is formed by joining the adjacent precursors together. Thereby, it becomes possible to manufacture a larger-sized foam metal than before.

According to the apparatus for producing a metal foam of the present invention described above, since the precursor is heated by transmitting the mold from the light source and irradiating the precursor with light, there is little loss of heat due to the mold, and the precursor with high energy utilization efficiency. The body can be heated. Thereby, it can heat at cost lower than atmospheric heating, and can manufacture a foam metal at low cost. And since the type | mold which permeate | transmits light is used, it is possible to observe the state of foaming through a type | mold.
Furthermore, a plurality of precursors are transported by a transport unit, and each precursor is irradiated with light and heated in a state where the precursors are transported, so that each precursor is foamed and joined to an adjacent precursor. At the same time, the metal foam is produced in a state where the shape is controlled by the mold. Thereby, since the foam metal which the precursor which adjoined joined and was formed is formed, it becomes possible to manufacture a larger foam metal than before, and the foam metal of a desired shape is manufactured with a type | mold.

It is a schematic sectional drawing which shows the 1st Embodiment of this invention. It is a top view which shows arrangement | positioning of the precursor in the 1st Embodiment of this invention. It is a schematic sectional drawing which shows the 2nd Embodiment of this invention. It is a top view which shows arrangement | positioning of the precursor in the 3rd Embodiment of this invention. It is a schematic sectional drawing which shows the 4th Embodiment of this invention.

  First, prior to description of specific embodiments of the present invention, an outline of the present invention will be described.

The foam metal manufacturing method of the present invention uses a precursor in which a foaming agent is mixed with a metal, a mold that transmits light, a light source that irradiates light to the precursor, and a transport unit that transports the precursor. The mold is arranged for the plurality of precursors, and the plurality of precursors are conveyed by the conveying unit.
And the manufacturing method of the foam metal of this invention makes each precursor foam by making a type | mold transmit from a light source and irradiating and heating each precursor in the state which is conveying the precursor. While producing the foam metal bonded to the adjacent precursor, the shape of the foam metal is controlled by the mold.

The apparatus for producing a foam metal according to the present invention includes a transport unit that transports a precursor in which a foaming agent is mixed with a metal, and a light source that irradiates the precursor with light.
And the manufacturing apparatus of the metal foam of this invention uses the mold | die which permeate | transmits light, conveys a several precursor with a conveyance part, and permeate | transmits a type | mold from a light source in the state currently conveyed the precursor. Then, each precursor is irradiated with light and heated, whereby each precursor is foamed and joined to an adjacent precursor, and a foam metal is produced in a state where the shape is controlled by a mold.

In the present invention, as the metal constituting the precursor of the foam metal constituting the precursor, a single metal element or an alloy can be used.
For example, aluminum, an aluminum alloy, a magnesium alloy, zinc, a zinc alloy, copper, a copper alloy, iron, an iron alloy, etc. are mentioned.

In the present invention, the foaming agent constituting the precursor and mixed with the metal is conventionally used for foaming of foamed metal, or various foaming agents proposed for foaming of foamed metal. Can be used. Examples thereof include TiH ₂ (titanium hydride) and zirconium hydride.
However, it is desirable to select a foaming agent whose foaming temperature is in an appropriate range so as to match the melting point of the raw material metal.

In the present invention, the method for producing the precursor is not particularly limited as long as a foaming agent is mixed with the metal.
For example, various production methods such as a method of mixing and solidifying a metal powder and a foaming agent powder, and a method of mixing a foaming agent powder on a metal plate with a friction stir tool described in Patent Document 2 and Patent Document 3. Can be applied to make a precursor.

In the present invention, a mold that transmits light is arranged for a plurality of precursors.
For example, in a state where a plurality of precursors are in contact with each other or arranged at equal intervals, a mold that transmits light is disposed so as to surround the plurality of precursors.

  As the mold that transmits light, the mold is composed of a transparent material (hereinafter simply referred to as “transparent material”) having a high transmittance with respect to the light irradiated on the precursor, or a material having an opening. A mold can be used. As the shape of the material having an opening, a mesh shape, a shape in which an opening is formed in a solid, or the like can be considered.

The transparent material used for the mold or the material having an opening can be used as it is when it does not stick to the foamed metal, but it is preferable to use a release agent when it sticks to the foamed metal.
The mold release agent is used by adhering to the mold by spraying, coating, spraying or the like before the mold is used for producing the foam metal.
Examples of the release agent include general-purpose release agents such as silicone, graphite, and boron nitride, and die casting release agents (various types such as oil-based emulsion, aqueous graphite, and aqueous heat-resistant pigment). .
As the mold release agent, an appropriate material is selected in consideration of the mold material and the raw metal so as not to react or interact with the mold and the metal.

  The mold may be produced for each foaming or may be used repeatedly by a plurality of times of foaming. However, in order to reduce the manufacturing cost, it is desirable to use the mold repeatedly.

As a form of use of the mold, it is preferable that a mold having a shape matching a foam metal having a desired shape as in a conventional mold is used.
It is possible to adopt either a form in which the mold is formed only from a material that transmits light, or a form in which a part of the mold is formed from a material that transmits light, and other parts are formed from different materials. In the latter case, the precursor is irradiated with light from the portion of the material through which light passes.
For example, a precursor can be mounted on a heat-resistant substrate and the substrate can be used as a lower mold. In this case, the substrate may not be a material that transmits light as long as light can be irradiated from a part of the mold other than the substrate.

As the transparent material used for the mold, glass, sapphire, quartz glass, crystal, or the like can be used.
Since the transparent material used for the mold is in contact with the foamed metal, it needs to have heat resistance so as not to be decomposed or deformed even in contact with the foamed metal. Therefore, the range of usable transparent materials varies depending on the melting point of the raw material metal.
Since aluminum, magnesium, zinc, and alloys thereof have a relatively low melting point, a wide range of transparent materials such as the glass, sapphire, quartz glass, and quartz described above can be used.

  As a mold made of a material having an opening, it is possible to use a metal net, a punching metal, a net-like ceramic, a ceramic honeycomb, or the like. In consideration of heat resistance and price, it is desirable to use a metal net.

As the metal net (hereinafter referred to as a metal net), it is desirable to use a metal net made of a metal having a melting point higher than that of the starting metal so that the metal net does not deform even when contacted with the foamed metal.
In the case of using aluminum, an aluminum alloy, or the like as a raw material, copper or steel nets can be used.

When using a wire mesh for a mold, the thickness of the metal wire constituting the wire mesh and the interval between the metal wires (corresponding to the size of the opening of the wire mesh) are selected within an appropriate range.
The thicker the metal wire and the narrower the interval between the metal wires, the lower the light transmittance, and the lower the energy utilization efficiency.
Further, the wire mesh is not deformed by foaming of the foam metal, and the strength of the wire mesh is required to some extent in order to control the shape of the foam metal.
Furthermore, since there is surface tension in the soft state during foaming, it is possible to prevent the foam metal from sticking out if the distance between the metal wires is less than a certain degree, but if the spacing between the metal wires is too wide, Foamed metal that is foamed from between will protrude. Therefore, the interval between the metal wires is set within an appropriate range depending on the allowable protrusion amount according to the state of the surface tension of the metal during foaming of the raw material.
If the amount of protrusion is within an allowable range, it is also possible to use the unevenness as a surface modification such as anti-slip between the mold and the foam metal by providing unevenness by the protruding portion.

  When the wire mesh is used as a mold, by further deforming the wire mesh, it becomes possible to form a complex-shaped mold and manufacture a foam metal having a complicated shape.

When using a network-like ceramic or ceramic honeycomb as a mold, the width of the solid (ceramics) portion and the size of the opening are selected within an appropriate range.
Further, a material having a certain strength or more is selected in order to control the shape of the foam metal without being deformed by foaming of the foam metal.

In the present invention, since the precursor is heated by irradiating light, it is possible to select the irradiation range of light and prevent heating except the irradiation range and its surroundings. Thereby, while being able to heat efficiently, the influence by the heat except the range heated can be suppressed.
The light irradiation range is set, for example, by setting the focus of the light source, by setting a mask having an opening to be shielded, and by setting the mold having a portion that transmits light and a portion that does not transmit light. , Etc. are possible.

In the present invention, for example, a halogen lamp or an infrared lamp can be used as a light source for irradiating the precursor.
And so that the precursor can be heated to give the precursor sufficient energy to make foam metal, and light reflection and absorption by light transmissive materials is minimized. The conditions such as the output of the light source, the wavelength range of the light of the light source, and the irradiation time are selected.

In the present invention, the transport unit transports a plurality of precursors.
In the part where there is no mold or precursor, the transport part is heated by the light irradiation and becomes high temperature because the light from the light source is directly irradiated onto the transport part. A material such as a belt conveyor, a rubber belt, a cloth, or the like used for a general manufacturing apparatus melts or burns when heated, and thus may be damaged or cut. Although it is conceivable that the light source is intermittently turned on and off in accordance with the presence or absence of the precursor, it is difficult to control the light source because it is necessary to reliably link the conveyance state and the light source on and off.
Therefore, it is desirable to use a heat-resistant material that does not melt or burn even when irradiated with light from the light source. For example, a metal and an inorganic material (ceramics etc.) can be considered. However, these materials cannot be bent and stretched freely like a belt conveyor or cloth. Therefore, for example, if a metal or inorganic material is used as a plate-like member, such as a caterpillar, and a large number of plate-like members are connected by connecting members (chains, wires, etc.), it can be bent and stretched at the connecting member. Therefore, the transport unit can be configured.

Although it is conceivable to carry the precursor directly on the conveyance unit, the precursor can be placed on a container such as a tray and the container placed on the conveyance unit in order to prevent adhesion of the produced metal foam and the conveyance unit. Is desirable. In particular, when the transport part is made of metal, if the precursor is placed directly on the transport part, heat escapes from the metal of the transport part, resulting in a large temperature distribution in the foaming precursor and non-uniform foaming. In addition, there is a concern that the foam metal and the metal of the conveying part react and join.
Containers such as trays are preferably made of an inorganic material (ceramics or the like) having a low thermal conductivity in order to prevent reaction with the foam metal and make it difficult for heat to escape. In addition, since the container does not need to be able to bend and stretch like the transport unit, if it is made of a material that has heat resistance and does not react with the foam metal, the portion placed on the transport unit may be flat.

  The container on which the precursor is placed can also be used as a base instead of the mold described above to control the shape of the lower surface of the foam metal.

  Instead of using a container on which the precursor is placed, the mold is provided over the lower side of the precursor, the precursor is placed on the mold, and the lower side of the mold is placed on the transport unit to be transported. It is also possible to do.

The plurality of precursors arranged on the container or the mold are arranged in a direction parallel to the direction of the precursor transport by the transport unit and perpendicular to the direction of the precursor transport by the transport unit. Arrangement in the direction (width direction of the transport unit) is conceivable.
In an arrangement in which a plurality of precursors are arranged in a direction parallel to the direction of conveyance by the conveyance unit, the plurality of precursors are sequentially foamed by a light source.
In an arrangement in which a plurality of precursors are arranged in a direction perpendicular to the direction of conveyance by the conveyance unit, the plurality of precursors are foamed together by a light source.
The arrangement of the plurality of precursors may be other than these arrangements (an arrangement arranged in a direction parallel to the conveyance direction, an arrangement arranged in a direction perpendicular to the conveyance direction). For example, the precursors can be arranged vertically and horizontally in a direction parallel to a direction of conveyance and a direction perpendicular to the direction of conveyance.

  The interval between the plurality of precursors is set to a predetermined interval ranging from a state where there is no interval between adjacent precursors to an interval where the foam metal after foaming is barely joined.

The interval at which the foam metal after foaming joins at the last minute can be determined as follows, for example.
The relationship between the length of the heating time by light and the amount of expansion of the precursor is measured while keeping the output of the light source constant.
Depending on the size of the light spot irradiated from the light source, the number of precursors in which foaming proceeds simultaneously varies. When the number of simultaneously proceeding precursors is one, only one expansion amount is considered. When the number of simultaneously proceeding precursors is two or more, the amount of expansion of the two precursors on both sides of the interval is considered. However, in the arrangement arranged in the direction parallel to the direction of conveyance by the conveyance unit, there is a difference in the heating time to each precursor until the preceding and following precursors are joined, so that there is a certain difference in expansion amount. Yes, and consider that point.
Since the heating time for one precursor is determined from the speed of conveyance by the conveyance unit and the size of the spot of light emitted from the light source, the amount of expansion of the precursor can be known. When the number of precursors that proceed simultaneously is two or more, the expansion amounts of the two precursors on both sides of the interval are summed. The total amount of expansion is the maximum interval for contacting the foam metal after foaming.
Furthermore, a thin oxide film is usually formed on the surface of the precursor, and the oxide film remains unbroken by simply contacting the foam metal, and the foam metal cannot be joined. After the foam metal comes into contact, the expansion due to foaming further proceeds, whereby the oxide film is broken and the foam metal can be joined. Therefore, the amount of expansion required to change the state in which the two foam metals are in contact with each other is also examined and added to the total amount of expansion of the two precursors described above. In this way, it is possible to determine the interval at which the foam metal after foaming joins at the last minute.
And if the speed of conveyance by a conveyance part is made faster, heating time will become short. When the conveyance speed by the conveyance unit is decreased, the heating time becomes longer.

  Moreover, the heating time required in order to join the precursor of a specific space | interval can be calculated | required using what was described above. If the heating time is known, the speed of conveyance by the conveyance unit may be selected so that the heating time is reached.

In the present invention, since the precursor is transported by the transport unit and heated and foamed by light irradiation, a predetermined number of precursors are sequentially supplied to the transport unit, and the foam metal is sequentially recovered from the transport unit.
The mold can be configured to supply the mold sequentially to the transport section and collect the mold sequentially from the transport section, to use the mold without fixing and transport it, to move the transport section and the mold independently, etc. is there.
When a container such as a tray is used, a predetermined number of precursors and molds are supplied together with the container, and the produced foam metal and mold are collected together with the container.

In the present invention, it is possible to configure a reaction chamber including a transport section and a space through which the precursor, foam metal, mold, and container are transported by the transport section.
Note that the light source can be configured to be disposed in the reaction chamber or to be irradiated with light from the outside of the reaction chamber through a transparent window. For efficient heating, it is desirable to arrange a light source in the reaction chamber.

The pressure in the reaction chamber may be atmospheric pressure or vacuum. When a light source is provided in the reaction chamber and the reaction chamber is used in a vacuum, the light source is configured to be usable in a vacuum (for example, a vacuum lamp).
The atmosphere in the reaction chamber can be air, nitrogen, or an inert gas atmosphere.

In the present invention, since a mold that transmits light is used, the state of foaming can be observed through the mold.
In the case of a conventional electric furnace, it was difficult to see inside the electric furnace. In contrast, in the present invention, if the reaction chamber is at atmospheric pressure, the foaming state can be easily observed.
Furthermore, for example, a camera monitor can be provided inside the reaction chamber, and the state of foaming can be monitored with the camera monitor. Accordingly, it is possible to increase or decrease the conveyance speed of the conveyance unit corresponding to the state of foaming using manual control or control by a computer program.
For example, if foaming is inadequate, the conveying speed is slowed so that the precursor is heated for a longer time.
For example, when the temperature is too high, the conveyance speed is increased to shorten the time during which the precursor is heated.

For the light source for heating and foaming the precursor, it is also possible to provide a preheating unit that preheats the precursor in front of the light source.
The preheating unit may have a configuration (lamp or the like) that emits light similar to the configuration of the light source. However, in the preheating section, the configuration for irradiating light (such as a lamp) and the irradiation conditions are selected so that the precursor is in a temperature zone that is somewhat lower than the foaming temperature.

  It is also possible to provide a cooling unit for cooling the foam metal after the light source.

Next, specific embodiments of the present invention will be described with reference to the drawings.
In addition, this invention can take arbitrary structures within the range prescribed | regulated to the claim, and is not limited to the structure of the following embodiment or an Example.

(First embodiment)
A first embodiment of the present invention is shown in the schematic cross-sectional view of FIG.
In the present embodiment, a plurality of precursors are arranged in a direction parallel to the direction of conveyance by the conveyance unit.

  As shown in FIG. 1, a transport apparatus 2 and a light source section 3 are provided in a reaction chamber 1 to constitute a manufacturing apparatus 100. Then, a plurality of precursors 11 and a mold 5 that transmits light are placed on a container (tray or the like) 6, and are transported together with the container 6 by the transport unit 2.

The reaction chamber 1 is configured to be sealed to make the inside uniform.
For example, the inside of the reaction chamber 1 can be evacuated to a vacuum (for example, a pressure of less than 100 Pa), or the inside of the reaction chamber 1 can be set to a predetermined atmosphere.

  The conveyance part 2 is comprised with the material (metal, inorganic substance) which has heat resistance so that it can endure the heating by irradiation of light. Further, for example, a flat plate member is connected by a connecting member so as to be bent and stretched to form a caterpillar shape. Preferably, the flat plate member made of metal is connected by a connecting member such as a chain or a wire to form the caterpillar-shaped transport unit 2.

The light source unit 3 is provided above the position where the precursor 11 and the mold 5 pass, and is composed of several lamps 4.
The precursor 11 can be heated and foamed by irradiating the precursor 11 with the light L from the lamp 4 of the light source unit 3 through the mold 5.
When the inside of the reaction chamber 1 is evacuated and used, it is desirable that the lamp 4 be a vacuum lamp.

  The precursor 11 has a configuration in which a foaming agent is mixed with a metal. As the metal and the foaming agent, various materials described above can be used.

  The mold 5 is configured to transmit light, and is a mold configured with a transparent material that is transparent to light irradiated to the precursor and has a high transmittance, or a mold configured with a material having an opening. Can be used. Examples of the shape of the material having an opening include a mesh shape, a shape in which an opening is formed in a solid, and the like.

  The container 6 is made of a heat resistant material. Preferably, in addition to heat resistance, a material with low thermal conductivity (ceramics or the like) is used to prevent heat from escaping from the precursor 11 being heated to the transport unit 2 through the container 6.

  In the present embodiment, as shown in FIG. 1, three precursors 11 are placed on the container 6, and the mold 5 is disposed so as to surround the upper side and the side of the precursor 11. And it has the structure which conveys these precursor 11, the container 6, and the type | mold 5 to the right direction in the figure by the conveyance part 2. FIG.

In the present embodiment, the three precursors 11 are arranged in a direction (left and right direction in FIG. 1) parallel to the direction (right direction) of conveyance by the conveyance unit 2.
Here, the arrangement of the precursor 11 in the present embodiment is shown in the plan view of FIG. In FIG. 2, the illustration of the mold 5 in FIG. 1 is omitted.
As shown in FIG. 2, three precursors 11 having a rectangular planar shape are arranged at equal intervals in the horizontal direction in the drawing, which is a direction parallel to the direction of conveyance by the conveyance unit 2, and placed on the container 6. Yes.
When the precursor 11 is foamed in the mold 5 by irradiation with the light L from the light source unit 3, as shown on the right side in FIG. 2, the foam metal 12 that is long in the left-right direction parallel to the direction of conveyance by the conveyance unit 2 can get.

  The interval between the precursors 1 adjacent to each other is selected in consideration of the degree of foaming so as to be joined after foaming.

In FIG. 2, three precursors 11 are arranged on the container 6, but the number of the precursors 11 arranged on the container 6 is not particularly limited.
Moreover, the dimension of the precursor 11, the space | interval of the precursor 11, etc. are not specifically limited to the structure of this FIG.

In addition, even if it arrange | positions so that several precursors may adjoin (no space | interval), the joined metal foam can be produced similarly.
However, if the distance between the precursors is increased, foaming can be performed freely until joining, so that foaming can be performed quickly, and the outer peripheral portion and the interior can be more uniformly foamed.

  In FIG. 1, the upper surface of the precursor 11 is not in contact with the mold 5, but the mold 5 can be disposed in contact with the upper surface of the precursor 11. However, since the direction in which the upper surface of the precursor 11 is not in contact with the mold 5 can be foamed more freely, the difference in the degree of foaming between the upper side and the side can be reduced.

(Second Embodiment)
A second embodiment of the present invention is shown in the schematic cross-sectional view of FIG.
This embodiment is a case where a preheating unit and a cooling unit are added to the manufacturing apparatus 100 of the first embodiment.

  As shown in FIG. 3, in addition to the configuration of the manufacturing apparatus 100 of the first embodiment, the manufacturing apparatus 110 of the present embodiment includes a preheating unit including several lamps 8 at the front stage of the light source unit 3. 7 is provided. In addition, a cooling roller 9 is provided as a cooling unit after the light source unit 3.

The precursor 11 can be preheated by irradiating the precursor 11 with the light L2 through the mold 5 from the lamp 8 of the preheating unit 7.
The heating temperature by the preheating unit 7 is set to a low temperature to some extent.

  The cooling roller 9 of the cooling unit cools the mold 5 and the metal foam 12 by contacting the mold 5.

(Third embodiment)
Subsequently, a third embodiment of the present invention will be described.
In the present embodiment, a plurality of precursors are arranged in a direction perpendicular to the transport direction by the transport unit.

The arrangement of the precursor 11 in the present embodiment is shown in the plan view of FIG. In FIG. 4, illustration of the mold is omitted as in FIG. 2 of the first embodiment.
As shown in FIG. 4, the three precursors 11 are placed on the container 6 in the same manner as in FIG. 2 of the first embodiment. 2 are arranged at equal intervals in a direction perpendicular to the conveyance direction (right direction in the figure) (width direction of the conveyance unit 2).

Also in the case of the third embodiment, similarly to the first and second embodiments, the plurality of precursors 11 are caused to foam by irradiating the plurality of precursors 11 with light. The foam metal 12 can be manufactured by bonding with the adjacent precursor 11.
When the precursor 11 is foamed in the mold by irradiation with light L from the light source unit 3, a foam metal 12 that is long in a direction perpendicular to the direction of conveyance by the conveyance unit 2 is obtained as shown on the right side in FIG. .

  By arranging the plurality of precursors 11 side by side in a direction perpendicular to the conveyance direction by the conveyance unit 2, the plurality of precursors 11 are heated and foamed almost simultaneously by irradiation with light from a light source. It is possible.

In FIG. 4, three precursors 11 are disposed on the container 6, but the number of precursors 11 disposed on the container 6 is not particularly limited.
Further, the dimensions of the container 6, the dimensions of the precursor 11, and the arrangement of the precursor 11 in the container 6 (position and spacing between adjacent precursors 11) are the same as in FIG. 2 of the first embodiment. However, the dimensions of the precursor 11 and the spacing between the precursors 11 are not particularly limited to the configuration of FIG.

Although not shown in the present embodiment, the precursor 11 is transported by the transport unit 2 as in FIG. 1 of the first embodiment and FIG. 3 of the second embodiment, and the light source The foamed metal 12 is produced by foaming the precursor 11 by irradiating light from a part of the lamp.
In the present embodiment, since the three precursors 11 are arranged in a direction perpendicular to the transport direction of the transport unit 2, the length of the foam metal 12 in the direction parallel to the transport direction of the transport unit 2 is long. However, it becomes shorter than 1st and 2nd embodiment. Therefore, the length of the light source unit in the direction parallel to the transport direction of the transport unit 2 may be shorter than that of the first and second embodiments.

(Modification)
In each of the above-described embodiments, as described above, a camera monitor can be provided inside the reaction chamber 1 and the foaming state can be monitored with the camera monitor. Thereby, it is possible to increase / decrease the conveyance speed of the conveyance part 2 according to a foaming state using manual control or control by a computer program.
For example, when foaming is insufficient, the conveyance speed is decreased so that the precursor 11 is heated for a longer time.
For example, when the temperature of the precursor 11 is too high, the conveyance speed is increased to shorten the time during which the precursor 11 is heated.

In each of the first and second embodiments described above, the plurality of precursors 11 are arranged in parallel to the direction of conveyance by the conveyance unit 2.
In this way, when a plurality of precursors 11 are arranged in parallel to the direction of conveyance by the conveyance unit 2, if the precursor 11 is continuously supplied, a longer foam metal 12 can be continuously produced. It becomes possible.

However, when the precursor 11 is continuously supplied and the long foam metal 12 is continuously prepared, the precursor 11 is individually provided for each of the several precursors 11 as shown in FIGS. Container 6 and mold 5 cannot be used.
For this reason, when supplying the precursor 11 continuously, it is possible to employ | adopt the structure as follows, for example.
The precursor 11 is directly placed on the transport unit 2 and transported. Alternatively, instead of the container 6, a plate-like member made of a heat-resistant material similar to that of the container 6 is used, and a plate-like member is arranged during conveyance, and the precursor 11 is placed on the plate-like member by the conveyance unit 2. The members are transported. The plate-like member is added on the transport unit 2 at the entrance of the transport unit 2 and collected at the exit of the transport unit 2. The plate-like members are arranged without a gap or are arranged at a narrow interval such that the foam metal 12 does not protrude.
A configuration for supplying the precursor 11 (for example, a feeder or a robot arm) is provided.
A configuration for separating the collected metal foam 12 from the transport unit 2 and collecting it is provided. For example, a member that supports the conveyed foam metal 12 and enables further movement of the foam metal 12 is provided at a location where the transport unit 2 descends in FIGS. 1 and 2.
A configuration (for example, a storage room separate from the foaming room) for temporarily storing and storing the produced metal foam 12 is provided.
-With the mold entrance and exit as openings, the mold 5 is fixed and the mold 5 is not conveyed, and the precursor 11 and the foam metal 12 move inside the mold 5. The mold 5 is held and fixed at a portion that is not exposed to heating light (L, L2). The supplied new precursor 11 enters the mold 5 at the entrance of the mold 5, and the produced foam metal 12 exits the mold 5 at the exit of the mold 5. At this time, the mold 5 and the conveying unit 2 or the plate-like member are provided with a slight gap so that the foam metal 12 does not protrude so that friction resistance does not occur in the mold 5.

(Fourth embodiment)
A fourth embodiment of the present invention is shown in the schematic cross-sectional view of FIG.
This embodiment is one of the cases in which the long foam metal 12 described above is continuously produced.

  The precursor 11 and the foam metal 12 are directly placed on the transport unit 2 and transported in the right direction in the figure.

In the present embodiment, a wire netting mold 21 is used as a mold that transmits light.
The metal mesh mold 21 has a sufficiently large opening (not shown), and can irradiate the precursor 11 and the foam metal 12 with light transmitted through the opening.
Then, the metal mesh mold 21 is configured to have a continuous shape, and the metal mesh mold 21 is circulated by the rotation of the two pulleys 22.

That is, in the present embodiment, the transport unit 2 and the wire netting mold 21 are moved independently.
The speed of transporting the precursor 11 and the foam metal 12 by the transport unit 2 and the speed of movement of the metal mesh mold 21 are preferably substantially the same, but even if there is some difference in these speeds, The foam metal 12 can be produced without any problem.

A cooling roller 23 is provided inside the right side of the metal mold 21.
The cooling roller 23 cools the foam metal 12 as a configuration in which the cooling water is passed inside.
The cooling roller 23 presses against the metal mold 21 to form the foam metal 12 together with the metal mold 21.

  Then, the light L is irradiated from above the wire netting mold 21. The light L is applied to the precursor 11 and the foam metal 21 through the opening of the metal mesh mold 21.

  In the figure, 31 indicates a foaming process by light heating, and 32 indicates a molding process by the cooling roller 23.

By the light heating, the precursor 11 is gradually foamed to become the foam metal 12.
Then, by cooling and molding the foam metal 12 with the cooling roller 23, the molded continuous foam metal 12 can be produced.

In addition, on the front side and the back side (not shown) of the foam metal 12, molding members that are separate from the transport unit 2 and the metal mold 21 are arranged on the front side and the back side, respectively. Can be molded.
For example, the molding member is disposed at a fixed position with respect to the conveyance unit 2 or the metal mold 21 so as to provide a slight gap so that the foam metal 12 does not protrude.
Since the light L is irradiated from above, the molding member may be a material that does not transmit the light L.
Although it is sufficient if the molding member is provided over the entire steps 31 to 32, the molding member may be provided in the middle of the foaming step 31.
Further, the molding member can be formed by one member or by arranging several members side by side.

According to the structure of this Embodiment, the continuous foam metal 12 can be manufactured easily.
Then, the continuous foam metal 12 can be formed into a desired shape by the transport unit 2, a molding member (not shown), a metal net mold 21, and a cooling roller 23.
Further, by circulating the metal mesh mold 21, the foam metal 12 and the metal mesh mold 21 can be easily separated at the right end, and foaming is performed on the precursor 11 continuously supplied. Later molding can be performed.

1 reaction chamber, 2 transport section, 3 light source section, 4,8 lamp, 5 mold, 6 container, 7 preheating section, 9,23 cooling roller, 11 precursor, 12 foam metal, 21 wire mesh mold, 22 Pulley, 100, 110 Manufacturing equipment, L, L2 light

Claims (5)

Using a precursor in which a foaming agent is mixed with a metal, a mold that transmits light, a light source that irradiates light to the precursor, and a transport unit that transports the precursor,
Arranging the mold for a plurality of the precursors,
A plurality of the precursors are transported by the transport unit;
In the state where the precursor is conveyed, the precursor is transmitted through the mold and irradiated with light to heat each precursor, thereby foaming each precursor and joining the adjacent precursors. A method for producing a foam metal, comprising producing a foam metal in a state of being made, and controlling the shape of the foam metal by the mold.   The foam metal according to claim 1, wherein a plurality of the precursors are arranged in a direction parallel to a direction of transport of the precursors by the transport unit, and the plurality of precursors are sequentially foamed by the light source. Manufacturing method.   The foam according to claim 1, wherein a plurality of the precursors are arranged in a direction perpendicular to a direction in which the precursor is transported by the transport unit, and the plurality of the precursors are foamed together by the light source. Metal manufacturing method.   The method for producing a foam metal according to any one of claims 1 to 3, wherein a metal net is used as the mold. A transport unit for transporting a precursor in which a foaming agent is mixed with a metal;
A light source for irradiating the precursor with light;
A mold that transmits light is disposed for a plurality of the precursors, a plurality of the precursors are conveyed by the conveying unit, and the molds are transferred from the light source in a state where the precursors are conveyed. By passing through and irradiating each precursor with light and heating, each precursor is foamed and joined to the adjacent precursor, and a foam metal is produced in a state in which the shape is controlled by the mold. Manufacturing equipment for foam metal.

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