JP4178246B2 - 高気孔率発泡焼結体の製造方法 - Google Patents
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Images
Description
特に焼失支持材を混入する方法では稠密充填の限界から気孔率に限界があり80%をこえる気孔率の発泡体を作製することは一般に難しいとされている。焼失支持材としては、スチロール発泡樹脂(特許文献1参照)、微細中空樹脂粉(特許文献2〜4参照)、微細スチロール粉(特許文献5参照)などが提案されているが、気孔率90%を超える発泡焼結体の製造は困難なのが現状であり、またこれらの特許文献中には金属により発泡焼結体の製造を試みる例はみあたらない。
このように、バインダーとして粘性のある高分子水溶液を用いることにより、金属粉末又はセラミックス粉末を含むスラリーが空間支持材である中空樹脂又は発泡樹脂の表面にコーティングされた状態になり、それらが集合して支持材由来の気孔とは別の気孔が形成され、支持材の充填率以上の高気孔率の状態が実現されるようになる。
また、セラミックス粉末としては、例えばシリカ、シリカ‐アルミナ、シリカ‐マグネシア、シリカ‐チタニア、シリカ‐ジルコニア、アルミナ、アルミナ‐マグネシア、アルミナ‐チタニア、アルミナ‐ボリア、アルミナ‐ジルコニア、アルミナ‐ホスファ、チタニア、ジルコニア、ボリア、ケイ石、ケイ砂、カオリン、ベントナイト、マグネサイト、ドロマイト、長石、陶石、ゼオライト、シリコンカーバイド、PZT、磁性セラミックス等が挙げられる。これらは単独で用いてもよいし、また、2種以上を組み合わせて用いてもよい。
金属粉末やセラミックス粉末の粒径については特に制限されないが、通常100μmないしサブミクロンオーダー、好ましくは20〜1μmの範囲で、目標とする気孔径、気孔率等を考慮しつつ選ばれる。
このように、ゲル化可能な水溶性高分子を用いれば、ゲル化させることによって気孔を形成した状態を固定することが可能である。水溶液の粘性は粉末の分散性、混入粒子との濡れ性を考慮し適宜調節するが、通常おおよそ10〜10000cps、好ましくは100〜2000cpsの範囲の粘度とするのが適当である。
この中空又は発泡樹脂の粒径は、20μm〜1mmの範囲で選ばれる。
この中空又は発泡樹脂の材質については特に限定されないが、好ましくは発泡ポリスチレンが用いられる。
また、高気孔率の気孔形成には空間支持材の形状を真球形、あるいはそれに近い形状とすることが望ましい。空間支持材の混入量は目標とする気孔率に合わせて適宜に選択される。
発泡前駆体はそれぞれの金属、セラミックスに応じ適当な温度、雰囲気で焼結される。
このようにして、気孔率85〜98%、好ましくは90〜98%の発泡体が得られる。
本発明方法により得られた発泡焼結体材料の応用範囲は極めて広く、種々の技術分野、例えば、航空宇宙材料、スポーツ用品素材等の軽量かつ高比強度が要求される分野、断熱特性、耐熱性、吸振性の要求される分野、緩衝材料、梱包材料などの衝撃エネルギーの吸収が要求される分野、軽量化の要求される分野、フィルター材料、触媒担体材料、電極材料など広い表面積が要求される分野、生体適合性の要求される分野における素材として利用することが可能である。
本発明方法は、特に安価に供給される鉄系素材やセラミックスについてその発泡化を実現した効果が大きく、様々の分野における発泡軽量材料を供するのに資するものである。
Claims (3)
- 金属粉末又はセラミックス粉末とゲル化可能な水溶性高分子水溶液とのスラリー状混合物に、粒径20μm〜1mmの球状の中空樹脂又は発泡樹脂からなる気孔形成用支持材を混合し、この混合物を成形したのち、凍結ゲル化し、次いで解凍後乾燥し、乾燥した成形体を焼結して、上記気孔形成用支持材を消失させることを特徴とする、気孔率85〜98%の高気孔率発泡焼結体の製造方法。
- 該スラリー状混合物に、さらに界面活性剤を添加する請求項1記載の高気孔率発泡焼結体の製造方法。
- ゲル化可能な水溶性高分子水溶液が、ポリビニルアルコール水溶液である請求項1又は2記載の高気孔率発泡焼結体の製造方法。
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JP5077935B2 (ja) * | 2007-07-18 | 2012-11-21 | 独立行政法人物質・材料研究機構 | 高連通性多孔体の製造方法 |
TWI471424B (zh) | 2009-03-30 | 2015-02-01 | Mitsubishi Materials Corp | 鋁多孔質燒結體的製造方法及鋁多孔質燒結體 |
JP5402380B2 (ja) * | 2009-03-30 | 2014-01-29 | 三菱マテリアル株式会社 | アルミニウム多孔質焼結体の製造方法 |
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