經濟部中央標準局員工消費合作社印製 A7 __________B7___ 五、發明説明（1 ) 發明背景 1 .發明領域 本發明有關製造用於過濾器，蓄電池之電極基質等之 燒結多孔性金屬板之方法及裝置。 2 .相關技藝說明 包括一種立體網狀主幹，而且具有高度多孔性之多孔 性金屬板係充作電池電極，不同的過濾器和觸媒載體。 先前技藝用於製造此種多孔性金屬板之方法包括：一 種方法，其中製板後燃燒一種傳導性聚胺甲酸酯泡沬（曰 本未審查專利4一 2 7 5 9 ); —種方法，其中金屬粉末 黏附於一種塗有黏合劑之胺酯泡沬，並且燃燒之（日本未 審查專利3 - 1 .8 8 2 0 3 );—種方法，其中將一種熔 點低之金屬以壓力注入一個含有細微水溶性晶體粉末之容 器中，於金屬固化之後以水沖法去除該昶溶性晶體粉末 日本未審査專利59 — 165 1)。 但是，日本未審查專利4 一 2 7 5 9中以製板爲基礎 之方法，其金屬組成物受到限制，因此其用途受限。此外 ，第一和第二相關技藝二種方法中，因爲樹脂燃燒，會形 成空心骨架，導致有效之立體容積減少。甚者，日本未審 査專利5 9 — 16 5 1揭示之方法中’鮮少製得孔隙少於 1 0 0 之多孔性結構，因此，形成之多孔性物件比表 面積較小。 本紙張尺度適用中國國家標準（ CNS ) A4規格（210X 297公釐〉_ 4 —n- 1^1 n·^ m nn ^Jm >m * i .—^1· -·(·/ r (請先鬩讀背面之注意事項再V.鳥本頁) ，訂 經濟部中央標準局員工消費合作社印製 A7 B7 五、發明説明（2 ) 發明摘要 本發明之目的係提出一種製造金屬組成物自由度大， 而且比表面積大之燒結多孔性金屬板之方法與裝置。 本發明另一目的係提出製造一種未燒結金屬泡沬作爲 燒結多孔性金屬板中間產物之方法與裝置。 依本發明第一個觀念，製造燒結之多孔性金屬板的方 法包括一個製備含有金屬粉末之泡沬漿體的漿體製置步驟 ;—個將泡沫漿體製成板狀物件之成形步驟；一個使板狀 物件起沬之起泡步驟；一個使該板狀物件起泡後乾燥之乾 燥步驟等步驟。 該泡沫漿體可能包括金屬粉末，一種起泡劑，一種水 溶性樹脂黏合劑和一種表面活性劑。 該方法另外包括一個用於使乾燥步驟後該乾燥之板狀 物件去脂之燃燒步驟更佳。 該燃燒步驟可能包括一個用於燒結板狀物件之步驟。 該泡沫漿體於成型步驟中以一種刮刀法成型較佳。該 刮刀法使用二個以預定空間彼此分離之刮刀。 在漿體製備步驟中，第一種水溶液含有一種起泡劑， 一種表面活性劑和一種水溶性樹脂黏合劑，第二種水溶液 含有金屬粉宋和一種水溶性樹脂黏合劑，這二種水溶液分 別製備較佳’而且第一種水溶液和第二種水溶液於成型步 驟前混合以製備該泡沫漿體。 . 於起泡步驟中，含於該泡沬漿體中之起泡劑於高濕度 時起泡。此種高濕度爲6 5 %或更高較佳。 本紙張尺度適财關家標準（CNS ) A4規格（2淑297公瘦） ' (請先閱讀背面之注意事項再矿4本頁) 裝. •訂 經濟部中央標準局員工消費合作社印製 A7 _______B7 _.__ 五、發明説明（3 ). 該乾燥步驟爲遠紅外線照射乾燥步驟。 該成形步驟於一個載片上進行泡沬板狀物件的成型較 佳。 .. * 成型步驟之前，載體上預先提供可於燃燒步驟燒捧之 脫模膜。更明確地說，該脫模膜包含一種聚胺甲酸酯樹脂 〇 依本發明第二個觀念，一種用於製造燒結之多孔性金 屬板的裝置包括一種用於製備至少含有金屬粉末，起泡劑 和液態介質之泡沫漿體之漿體製備裝置；一個用於使漿體 製備裝置進料之泡沫漿體成爲板狀物件之成型裝置；一種 使該泡沬漿體之板狀物件起泡之起泡裝置；以及一種用於 乾燥該蜂窩狀物件之乾燥裝置；其中這些裝置藉由一種運 輸部分依序整合而成。 該運輸裝置包括一個連續運送片較隹。 在乾燥裝置之後提出一種去脂裝置，以去除該乾燥板 狀物件之油脂較佳。該去脂裝置具有一個運送片更佳。 適當之燒結裝置可以位於去脂裝置之後，以燒結該去 脂板狀物件。 該成型裝置包括一個刮刀裝置較佳。該刮刀裝置包括 二片刮刀。 該漿體製備裝置最好包括一個第一水溶液混合裝置， 其用於混合一種含有該起泡劑’表面活.性劑和水性樹脂黏 合劑之第一水溶液，和一個第二水溶液混合裝置，其用於 混合含有該金屬粉末和第一水溶液混合裝置離析出之水性 本紙ϋ適用中國國家標準（CNS ) A4規格 1 210X297公釐）_ - : —6 一 (請先閲讀背面之注意事項再*'.烏本頁) .裝· ir A7 B7 經濟部中央標準局員工消費合作社印製 五、 發明説明 (4 ) 樹 脂 黏 合 劑 之 第 二 水 溶 液 > 以 及 — 個 第 三 個 混 合 裝 置 9 其 係 於 進 行成 型 步 驟 之 ,.v/« 刖 混 合 第 一 水 溶 液 和 第 二 水 溶 液 以 製 備 該 泡 沬 漿 體 〇2CL 0 - 該 起 泡 裝 置 最 好 包 m — 個 將 大 氣 濕 度 維 持 在 6 5 % 或 以 上 的 裝 置 〇 該 成 型 裝 置 包 括 一 個 漿 體 貯 存 器 > 其 用 於 使 漿 體 製 備 裝 置 進 料 之 泡 沬 漿 體 ns» 停 留 短 暫 時 間 > 以 及 一 個 液 態 介 質 之 噴 霧 裝 置 > 以 避 免 該 泡 沬 漿 體 表 面 乾 燥 〇 該 起 泡 裝 置 包 括 — 個 爐 其 入 □ 和 出 □ 在 該 運 輸 裝 置 的 運 送 途 徑 周 圍 —· 個 位 於 該 爐 中 具 有 恆 溫 器 之 貯 水 器 > —. 個 用 來 加 熱 沿 著 該 爐 運 輸 途 徑 成 形 物 件 之 加 熱 器 和 一 ，個 在 該 爐 內 壁 抗 發 汗 加 熱 器 〇 該 乾 燥 裝 置 包 括 一 個 遠 紅 外 線 照 射 裝 置 〇 在 成 型 裝 置 之 刖 具 有 — 個 脫 模 劑 塗 覆 裝 置 在 該 運 輸 裝 置 表 面 形 成 脫 模 劑 膜 0 該 脫 模 劑 塗 覆 裝 置 包 括 一 個 刮 刀 機 和 脫 模 劑 乾 燥 機 0 適 當 的 燒 結 裝 置 包 括 一 個 隧 道 式 爐 和 一 個 將 去 脂 板 狀 物 自 隧 道 式 爐 的 入 □ 連 續 運 到 出 □ 之 運 送 元 件 該 運 送 元 件 包 括 該 多 運 送 輥 其 於 該 隧 道 式 爐 至 少 —· 部 分 以 運 送 方 向 轉 動 〇 該 運 送 輥 受 到 控 制 9 因 此 其 轉 動 速 率 沿 著 運 送 方. 向 逐 漸 降 低 〇 附 圖 簡 述 由 下 列 與 附 ΓΒ1 圖 有 關 之 說 明 f 本 發 明 之 特 徵 和 優 點 會 更 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐〉 -7 A7 B7 經濟部中央標準局員工消費合作社印製 五、發明説明（5 ) 明顯，其中： 圖1是依本發明第一具體化實例，製造未燒結金屬泡 沬作爲燒結多孔性金屬板中間產物之裝置剖面圖； 圖2是製造第—具體化實例中未燒結泡沬之方法的流 程圖； 圖3是圖1所示具有二片刀片之刮刀主要部分剖面圖 • . » 圖4是圖3所示之刮刀操作剖面圖； 圖5 A至5 E是概略顯示高濕度條件下起泡情形之簡 略剖面圖； 圖6 A至6 E是概略顯示低濕度條件下起泡情形之簡 略剖面圖； 圖7是本發明起泡裝置主要部分之剖面圖； 圖8是本發明乾燥機主要部分之剖面圖； 圖9 A至9 D是概略顯示本發明方法製得之燒結多孔 性金屬的蜂窩狀結構簡略剖面圖； 圖1 0是用於製造本發明第二具體化實例之泡沬漿體 和本發明第四具體化實例組成材料之裝置的剖面圖； 圖1 1是概略圖示本發明第四具體化實例之漿體室結 構的剖面圖； 圖1 2是製造本發明第五具體化實例燒結多孔性金屬 板之方法的流程度；和 圖1 3是用於進行圖1 2所示製造本發明第五貪體4匕 實例燒結多孔性金屬板之方法的裝置。 -8 - (請先閲讀背面之注意事項再'V寫本頁) 裝. 訂 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） 經濟部中央標準局員工消費合作社印製 A7 ___B7_ _ 五、發明説明（6 ) 較佳具體化實例說明 依本發明，製造一種燒結多孔性金屬板，亦製造充作 該燒結多孔性金屬板中間產物之未燒結金屬泡沫。 第一亘體化富例 作爲本發明的第一具體化實例，此處將解釋充作燒結 多孔性金屬板中間產物之未繞結金屬泡沬（或胚板）之製 造。 圖1是用以製造本發明第一具體化實例未燒結金屬泡 沫之裝置，圖2是第一具體化實例中未燒結金屬泡沬製造 方法之流程圖。 如圖1所示，該用尽製造未燒結金屬泡沫之裝置包括 製備脫模劑膜和乾燥部分，泡沬漿體製備部分，起泡部分 ，乾燥部分和裁切部分。該未燒結金屬泡沬以圖2所示之 流程圖方法製造。也就是，該未燒結金屬泡沫經由脫模劑 膜製備步驟，脫模劑乾燥步驟，泡沫漿體製備步驟，成型 步驟，起泡步驟，乾燥步驟和裁切步驟製造。 依圖2所示之方法操作圖1所示之製造未燒結 泡沬用的裝置。該裝置具有第一個輥2 0和第二個輥2 1 ，其間裝有運送板1 0。該運送板在第一個輥2 0和第二 個輥2 1之間移動，作爲一個輸送帶。.由第一個輥2 0至 第二個輥2 1，該裝置具有脫模劑貯存器8 0，脫模劑乾 燥機1 0 0 »漿體貯存器30，起泡用的高溫濕潤劑40 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） ~ (請先閲讀背面之注意事項再V烏本頁) 一訂 經濟部中央標準局員工消費合作社印製 A7 _ B7 五、發明説明（7 ) 以及乾燥機5 0。該脫模劑貯存器8 0是長方形平行六面 I . 體，而且與該運送板接近第一個輥2 0的上層表面連接 °該脫模劑貯存器8 0的右壁具有刮刀9 0。該刮刀如此 安置使得其與運送板1 〇之間的間隙可以調整。以此方式 ’該脫模劑貯存器8 0和該刮刀9 0形成一個刮刀機1 1 〇 圖2所示的方法將參照圖1所示之裝置的每一部分解 釋之。 脫_模劑膜之製備與乾燥 當脫模劑貯存器8 0裝滿一種由胺酯樹脂製備之脫模 塗覆材料u，而且該運送板移動時，該脫模塗覆材料由刮 刀9 0和運'送板1 0之間的間隙擠出，形成設定厚度之塗 覆膜2。該塗覆膜2與運送板1 0移到下一個脫模劑乾燥 機1 0 0以乾燥並固化該塗覆材料。脫模劑膜2之厚度可 以藉由調整刮刀9 0與運送板1 〇之間的間隙而調整之。 該脫模乾燥機1 0 〇乾燥並固化承載板1 0上形成之 脫模劑膜2。該脫模劑乾燥機之較佳實例包括熱空氣乾燥 機和遠紅外線乾燥機。該脫模劑膜2有助於自該運送板除 去該胚板。可以藉由該胚板烺燒步驟中燃燒除去該脫模劑 膜2。此外，該脫模劑膜2可以充作該胚板的運送帶。 乾燥胚板1 C藉由脫模劑膜2之形.成，可以輕易地處 理，如下所述。因此，該胺酯塗覆膜製備步驟和乾燥步驟 對本發明而言並非必要。 先張尺度適用中國國家標準（CNS) A4規格（21〇Χ297公釐）_】 ~ (請先聞讀背面之注意事項Ιφν寫本頁) -裝_ *•11 A7 B7 經濟部中央標準局員工消費合作杜印製 五、 發明説明 (8 ) 泡 沬 漿 髒 製 備 歩 驟 和 成 型 1 驟 在 泡 沫 漿 體 製 備 步 驟 中 » 製 備 一 種 含 有 金 屬 粉 末 9 水 溶 性 樹 脂 黏 合 劑 起 泡 劑 > 表 面 活 性 劑 » 水 等 之 漿 體 〇 該 成 型 步 驟 中 » 將 形 成 之 泡 沫 漿 體 製 成 板 狀 〇 較 佳 之 成 型 方 法 是 刮 刀 法 > 其 將 參 照 圖 3 和 4 於 後 文 說 明 之 〇 雖 然 該 泡 沬 漿 體 製 備 步 驟 和 隨 後 成 型 步 驟 被 視 爲 一 個 —. 貫 的 步 驟 但 是 下 文 將 其 視 爲 彼 此 獨 之 步 驟 解 释 之 〇 A 泡 沬 漿 髎 製 備 歩 驟 漿 體 貯 存 器 3 0 是 長 方 形 的 平 行六 面 體 其 與 該 脫 模 劑 乾 燥 機 1 0 0 <八 刖 方 的 承 載 板 上 層 表 面 接 觸 〇 漿 體 ήχε» 貯 存 器 3 0 上 方 具 有 一 個 用 來 製 備 將 進 料 到 之 泡 沫 漿 體 貯 存 器 3 0 之 泡 沬 漿 體 tlSL S 之 泡 沬 漿 體 混 合 器 1 1 0 〇 該 泡 沫 漿 體 混 合 器 1 1 0 具 有 —. 個 將 加 料 漏 斗 1 1 1 進 料 之 原 料 捏 和 之 捏 和 器 1 1 2 以 及 混 合 一 種 起 泡 劑 之 起 泡 劑 混 合 設 備 1 1 3 〇 該 泡 沬 漿 體 混 合 器 1 1 0 混 合 由 捏 全 器 1 1 2 捏 和 之 原 料 與 在 起 泡 劑 混 合 設 備 1 1 3 中 混 合 後 之 起 泡 劑 > 製 備 — 種 泡 沫 漿 體 ttsz. S 〇 因 爲 該 泡 沫 漿 體 的 組 份 分 成 二 種 液 體 而 且 這 二 種 液 體 在 該 混 合 物 進 料 到 刮 刀 6 0 之 、* -BU- 才 混 合 因 此 可 以 避 免 起 泡 劑 揮 發 〇 在 運 送 器 運 送 方 向 下 游 之 漿 體 貯 存 器 3 0 之 壁 具 有 刮 刀 6 0 〇 彐田 m 整 介 於 刮 刀 與 運 送 板 1 0 之 間 隙 以 製 備 具 有 所 需 厚 度 之 胚 板 1 A 〇 漿 體 flSZ· 貯 存 器 3 0 裝 滿 泡 沫 漿 體 S 並 請 聞 讀 背 之 注 意 事 項 装 訂 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） # -11 經濟部中央標準局員工消費合作社印製 A7 _______B7_._ 五、發明説明（9 ) 且移動該運送板時，該泡沫漿體S由刮刀6 0和運送板 1 0之間的間隙擠出，形成厚度設定之板狀物件。該成型 板狀物件1 A在運送板1 〇上，朝向隨以熱起泡之濕潤器 移動。 該獎體貯存器30最好具有對貯存漿體S表面噴灑一 種液體介質之機制，原因如下。當泡沫漿體供應到該貯存 器時，氣泡B沿著原有漿體表原S s u陷在該漿體內，如 圖4所示® 假如該泡沬漿體之成型板狀物件包括此種氣泡，該多 孔性金屬板上會形成該氣泡所造成意料之外的孔。因爲該 氣泡形成之孔的孔隙大小舆起泡劑形成之孔不同，該多孔 性金屬板的蜂窩狀結構會不均勻。當貯存器中漿體S的表 面乾燥時，氣泡B嚴重陷在其中，這是因爲表面黏度增加 ，因此氣泡幾乎無法脫離之故。相對的，如圖11所示’ 當液體介質酒在該漿體表面時，貯存器內的漿體不是乾燥 的，如此可以避免多孔性金屬板之蜂窩狀結構不均勻。只 要避免該漿體表面乾燥，該液體介質可以連續噴灑或斷續 噴灑。 本發明中用以形成未燒結金屬泡沬的金屬粉末可以視 最終產物的目的適當選擇之。當該金屬泡沫用於電極時’ 金屬粉末之實例包括燒結金屬或合金之粉末，諸如鎳’銅 ，鐵，不銹鋼，鉻，鈷，金和銀。金屬.粉末之平均顆粒大 小最好爲5 0 O em或以下，以〇 · 5至1 0 0 更佳 。平均顆粒大小爲0 · 5 # m或以下時，其孔率太小。另 本紙張尺度適用中國國家標隼（CNS ) A4規格（210X297公釐） (請先閲讀背面之注意事項再V#本頁) ·:装.Printed by the Consumer Cooperatives of the Central Standards Bureau of the Ministry of Economic Affairs A7 __________B7___ V. Description of the Invention (1) Background of the Invention 1. Field of the Invention The present invention relates to a method and device for manufacturing sintered porous metal plates for filters, battery electrode matrices, and the like. 2. Related technical description Including a three-dimensional mesh backbone, and a highly porous porous metal plate used as battery electrodes, different filters and catalyst carriers. A method for manufacturing such a porous metal plate according to the prior art includes: a method in which a conductive polyurethane foam is burned after the plate is made (Japanese Unexamined Patent No. 4 2 7 5 9);-a method , In which metal powder is adhered to an amine ester foam coated with a binder, and burned (Japanese Unexamined Patent 3-1.88 2 0 3); a method in which a metal with a low melting point is injected under pressure In a container containing fine water-soluble crystal powder, the water-soluble crystalline powder is removed by water flushing after the metal is solidified. Japanese Unexamined Patent No. 59-165 1). However, in Japanese Unexamined Patent No. 4 2 759, the method based on plate-making has a limited metal composition, and thus its use is limited. In addition, in the two methods of the first and second related techniques, because the resin burns, a hollow skeleton is formed, resulting in a decrease in effective three-dimensional volume. Furthermore, in the method disclosed in Japanese Unexamined Patent No. 59-161, the porous structure with less than 100 pores is rarely produced, and therefore, the porous object formed has a smaller specific surface area. This paper size applies the Chinese National Standard (CNS) A4 specification (210X 297 mm> _ 4 —n- 1 ^ 1 n · ^ m nn ^ Jm > m * i .— ^ 1 ·-· (· / r ( Please read the precautions on the back before reading this page (V.Bird page), order A7 B7 printed by the Consumer Cooperatives of the Central Bureau of Standards of the Ministry of Economic Affairs 5. Description of the invention (2) Summary of the invention The purpose of the present invention is to propose a freedom to manufacture metal compositions Method and device for sintering porous metal plates with large degree and large specific surface area. Another object of the present invention is to propose a method and device for manufacturing an unsintered metal foam as an intermediate product for sintering porous metal plates. A concept that the method for manufacturing a sintered porous metal plate includes a pulping step for preparing a foamed slurry containing metal powder; a forming step for forming a foamed slurry into a plate-like piece; A foaming step; a drying step for drying the plate-like article after foaming; the foam slurry may include metal powder, a foaming agent, a water-soluble resin binder, and a surfactant. In addition, a burning step for degreasing the dried plate-like article after the drying step is more preferable. The burning step may include a step for sintering the plate-like article. The foam slurry is formed by a doctor blade method in the forming step. The molding is better. The doctor blade method uses two doctor blades separated from each other in a predetermined space. In the slurry preparation step, the first aqueous solution contains a foaming agent, a surfactant and a water-soluble resin binder, and the second The aqueous solution contains metal powder song and a water-soluble resin binder. These two aqueous solutions are preferably prepared separately, and the first aqueous solution and the second aqueous solution are mixed before the molding step to prepare the foam slurry. In the foaming step The foaming agent contained in the foamed pulp is foamed at high humidity. This high humidity is preferably 65% or higher. This paper is suitable for CNS A4 specifications (2 Shu 297 male thin) '(Please read the precautions on the back and then mine 4 pages) installed. • Ordered by the Consumers Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs to print A7 _______B7 _.__ V. Description of the invention (3). The step is a far-infrared irradiation drying step. The forming step is preferably performed on a slide to form a foamed plate-like object .. * Before the forming step, a carrier is provided with a release film which can be burned in the burning step in advance. More specific That is, the release film contains a polyurethane resin. According to the second concept of the present invention, an apparatus for manufacturing a sintered porous metal plate includes a method for preparing at least metal powder, a foaming agent, and A slurry preparation device for a foam slurry of a liquid medium; a molding device for making the foam slurry fed by the slurry preparation device into a plate-like piece; a foaming method for bubbling the plate-like piece of the foamed slurry Device; and a drying device for drying the honeycomb object; wherein the devices are sequentially integrated by a transportation part. The transport device includes a continuous transport piece. It is preferable to propose a degreasing device after the drying device to remove the grease of the drying plate object. It is more preferable that the degreasing device has a transport sheet. A suitable sintering device may be located after the degreasing device to sinter the degreased plate-like object. The forming device preferably includes a doctor blade device. The doctor blade device includes two blades. The slurry preparation device preferably includes a first aqueous solution mixing device for mixing a first aqueous solution containing the foaming agent, a surfactant, and an aqueous resin binder, and a second aqueous solution mixing device. It is used to mix the water-based paper which is separated from the metal powder and the first aqueous solution mixing device. Applicable to China National Standard (CNS) A4 size 1 210X297 mm. _-:-6 I (Please read the precautions on the back first * ' (U.S. page). Equipment · ir A7 B7 Printed by the Consumers' Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs 5. Description of the invention (4) The second aqueous solution of the resin binder > and-a third mixing device 9 In the molding step, .v / «刖 mix the first aqueous solution and the second aqueous solution to prepare the foamed slurry 〇2CL 0-The foaming device preferably includes m-a device that maintains atmospheric humidity at 65% or more 〇The molding device includes a slurry reservoir > Foam slurry for the feed of the slurry preparation device ns »residence time > and a spraying device for a liquid medium > to prevent the surface of the foam slurry from drying out. The foaming device includes-a furnace □ and outlet □ around the transport path of the transport device— · a water reservoir with a thermostat located in the furnace > — a heater for heating the shaped objects along the transport path of the furnace and one in the Furnace inner wall anti-sweat heater. The drying device includes a far-infrared irradiation device. On the side of the molding device, there is a release agent coating device to form a release agent film on the surface of the transport device. The release agent coating device Includes a scraper and mold release dryer. 0 Suitable sintering equipment includes a tunnel furnace and a degreasing plate. Conveying elements from the tunnel furnace into □ continuously transported to the exit □ The conveying elements include the multiple conveying rollers which rotate at least in the tunnel furnace in the conveying direction. The conveying roller is controlled 9 so its rotation rate is along Conveyor side. The direction is gradually reduced. The drawings are briefly described by the following descriptions attached to the ΓΒ1 figure. The features and advantages of the present invention will be changed. The paper size applies the Chinese National Standard (CNS) A4 specification (210X297 mm> -7 A7 B7. Printed by the Consumer Cooperatives of the Central Standards Bureau of the Ministry of Economic Affairs 5. The invention description (5) is obvious, of which: Figure 1 is a cross-section of a device for manufacturing unsintered metal foam as an intermediate product of sintered porous metal plates according to the first embodiment of the present invention Figure; Figure 2 is a flowchart of a method for manufacturing an unsintered foam in the first embodiment-Figure 3 is a cross-sectional view of a main part of a scraper having two blades shown in Figure 1.. »Figure 4 is shown in Figure 3 Scraper operation sectional view; Figures 5 A to 5 E is a schematic cross-sectional view showing the foaming situation under high humidity conditions; Figures 6 A to 6 E are schematic cross-sectional views showing the foaming situation under low humidity conditions; Fig. 7 is a cross-sectional view of the main part of the foaming device of the present invention Figure 8 is a sectional view of the main part of the dryer of the present invention; Figures 9 A to 9D are schematic sectional views showing the honeycomb structure of the sintered porous metal obtained by the method of the present invention; Figure 10 is used for manufacturing the present invention A cross-sectional view of the foamed pulp of the second embodiment and the device of the fourth embodiment of the present invention; FIG. 11 is a sectional view schematically showing the structure of the slurry chamber of the fourth embodiment of the present invention; 12 is a flow degree of a method for manufacturing a fifth embodiment of the present invention for sintering a porous metal plate; and FIG. 13 is a diagram for carrying out the fifth embodiment of the present invention for manufacturing a sintered porous metal plate as shown in FIG. 12 Method of device. -8-(Please read the precautions on the back before 'V writing this page') Binding. The size of the paper is applicable to China National Standard (CNS) A4 (210X297 mm) Printed by A7 ___B7_ _ V. Description of the invention (6) A preferred embodiment illustrates that according to the present invention, a sintered porous metal plate is manufactured, and an unsintered metal foam serving as an intermediate product of the sintered porous metal plate is also manufactured. First Carcass Enrichment Example As a first embodiment of the present invention, the production of an unentangled metal foam (or blank) serving as an intermediate product of a sintered porous metal plate will be explained here. Fig. 1 is a device for manufacturing an unsintered metal foam according to a first embodiment of the present invention, and Fig. 2 is a flowchart of a method for manufacturing an unsintered metal foam in the first embodiment. As shown in Fig. 1, the device for exhausting the production of unsintered metal foam includes preparing a release agent film and a drying section, a foam slurry preparing section, a foaming section, a drying section, and a cutting section. This green sintered metal foam was manufactured by the flow chart method shown in FIG. That is, the unsintered metal foam is manufactured through a release agent film preparation step, a release agent drying step, a foam slurry preparation step, a molding step, a foaming step, a drying step, and a cutting step. The apparatus shown in Fig. 1 for manufacturing green sintered foam was operated according to the method shown in Fig. 2. The device has a first roller 20 and a second roller 2 1 with a transport plate 10 therebetween. The transport plate moves between the first roller 20 and the second roller 21 as a conveyor belt. From the first roller 20 to the second roller 21, the device has a release agent reservoir 80, a release agent dryer 1 0 0 »a slurry reservoir 30, a high-temperature wetting agent 40 for foaming This paper size applies to China National Standard (CNS) A4 specification (210X297 mm) ~ (Please read the precautions on the back before printing this page) A book printed by the Consumers Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs A7 _ B7 V. Invention Instructions (7) and dryer 50. The release agent reservoir 80 is a rectangular parallelepiped I. body, and is connected to the upper surface of the conveying plate close to the first roller 20. The right wall of the release agent reservoir 80 has a scraper 90. The scraper is positioned so that the gap between the scraper and the transport plate 10 can be adjusted. In this way, the release agent reservoir 80 and the doctor blade 90 form a doctor blade 1 1 0. The method shown in FIG. 2 will be explained with reference to each part of the apparatus shown in FIG. Preparation and drying of the release agent film When the release agent reservoir 80 is filled with a release coating material u made of an urethane resin, and the conveying plate is moved, the release coating material is formed by a doctor blade 9 0 The gap between the sheet 10 and the sheet 10 is extruded to form a coating film 2 with a set thickness. The coating film 2 and the transport plate 10 are moved to a next release agent dryer 100 to dry and cure the coating material. The thickness of the release agent film 2 can be adjusted by adjusting the gap between the doctor blade 90 and the transport plate 10. The release dryer 100 dries and cures the release agent film 2 formed on the carrier plate 10. Preferred examples of the release agent dryer include a hot air dryer and a far-infrared dryer. The release agent film 2 helps to remove the blank plate from the transport plate. The release agent film 2 can be removed by burning in the sintering step of the blank. In addition, the release agent film 2 can be used as a conveyor belt for the blank. The dried blank 1 C is formed by the release agent film 2 and can be easily processed as described below. Therefore, the amine ester coating film preparation step and drying step are not necessary for the present invention. The pre-stretching scale applies the Chinese National Standard (CNS) A4 specification (21〇 × 297 mm) _] ~ (Please read the note on the back first to write this page)-Equipment _ * • 11 A7 B7 Staff of the Central Bureau of Standards, Ministry of Economic Affairs Consumption cooperation Du printed 5. Description of the invention (8) Preparation steps and molding steps of foaming pulp dirty 1 In the foaming slurry preparation step »Preparation of a metal powder containing 9 water-soluble resin adhesive foaming agent > surfactant »Slurries of water, etc. In this molding step» The formed foam slurry is made into a plate shape. The preferred molding method is a doctor blade method, which will be described later with reference to Figs. 3 and 4. Although the foam slurry The body preparation step and the subsequent forming step are considered to be one-steps. However, the following steps are regarded as mutually exclusive steps. OA foam preparation and the slurry preparation reservoir 30 are rectangular parallelepipeds. Its In contact with the upper surface of the mold release agent dryer 1 0 0 < Hachikata square bearing plate 〇 slurry price ε ε »reservoir 3 0 above there is a bubble for preparing a foam slurry reservoir 3 0 to be fed Slurry slurry mixer TLSL S foam slurry mixer 1 1 0 〇 The foam slurry mixer 1 1 0 has-. A kneader 1 1 2 for kneading the raw materials for the feeding funnel 1 1 1 and mixing A foaming agent mixing device 1 1 3 of the foaming agent The foaming slurry mixer 1 1 0 mixes the raw materials kneaded by the kneader 1 1 2 and mixes them in the foaming agent mixing device 1 1 3 Foaming agent> Preparation — a kind of foam slurry ttsz. S 〇 Because the composition of the foam slurry is divided into two liquids and the two liquids are fed to the scraper 60 in the mixture, * -BU- is mixed so It can avoid the volatilization of the foaming agent. The wall of the reservoir 30 has a scraper blade 6 0 〇 彐 田 m The gap between the scraper blade and the conveying plate 10 is adjusted to prepare a blank plate 1 A with a desired thickness Sl slurry flSZ · The reservoir 30 is filled with foam slurry S Please also read the notes on the back of the book. The size of the paper is applicable to the Chinese National Standard (CNS) A4 specification (210X297 mm) # -11 Printed by A7, Consumer Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs _______ B7 _._ 5. Description of the invention ( 9) When the conveying plate is moved, the foam slurry S is extruded from the gap between the scraper blade 60 and the conveying plate 10 to form a plate-like object with a set thickness. The molded plate-like object 1A is moved on the conveying plate 10 toward a humidifier that is heated by foaming. The prize reservoir 30 preferably has a mechanism for spraying a liquid medium on the surface of the storage slurry S for the following reasons. When the foam slurry is supplied to the reservoir, the bubble B is trapped in the slurry along the original slurry surface, as shown in Figure 4® If the molded plate-like piece of the foam slurry includes such bubbles Unexpected holes caused by the air bubbles will be formed on the porous metal plate. Because the pore size of the pores formed by the bubbles is different from the pores formed by the foaming agent, the honeycomb structure of the porous metal plate may be uneven. When the surface of the slurry S in the reservoir dries, the bubbles B are seriously trapped therein because the surface viscosity increases, so the bubbles can hardly escape. In contrast, as shown in FIG. 11, when the liquid medium wine is on the surface of the slurry, the slurry in the reservoir is not dry, so that the honeycomb structure of the porous metal plate can be prevented from being uneven. As long as the surface of the slurry is prevented from drying, the liquid medium can be sprayed continuously or intermittently. The metal powder used to form the unsintered metal foam in the present invention can be appropriately selected depending on the purpose of the final product. When the metal foam is used for an electrode, examples of the metal powder include powders of sintered metals or alloys such as nickel 'copper, iron, stainless steel, chromium, cobalt, gold, and silver. The average particle size of the metal.powder is preferably 50 O em or less, more preferably from 0.5 to 100. When the average particle size is 0 · 5 # m or less, the porosity is too small. In addition, this paper size is applicable to China National Standard (CNS) A4 (210X297 mm) (Please read the precautions on the back before V # page).
<1T 經濟部中央標準局員工消費合作社印製 A7 ______B7_______ 五、發明説明（10) —方面’平均顆粒大小爲5 0 0 或以上時，燒結該未 燒結金屬泡沬製得之燒結多孔性金屬板強度不足。該漿體 中金屬粉末之含量在5至8 0百分比範圍（重量百分比， 下文亦同）30至80百分比更佳。 乾燥步驟之後’該水溶性樹脂黏合劑維持該多孔性物 件的形狀。該水溶性樹脂黏合劑亦可充作—種漿體之黏度 改良劑。該水溶性樹脂黏合劑之實例包括甲纖維素，羥丙 基甲纖維素，羥基乙纖維素，羧基甲纖維素銨，乙纖維素 和聚乙烯基醇。該水溶性樹脂黏合劑之含量最好在〇 . 5 至2 0百分比範圍，以2至1 0百分比更佳。當該含量爲 0 · 5百分比或以下時，該乾燥金屬物件強度大到無法處 理。另一方面，該含量爲2 0百分比或以上時，其黏度太 高無法製得成型物件。 可使用任何釋出氣體形成孔隙之起泡劑，例如在預定 溫度下分解釋出氣體之化合物，以及揮發性有機溶劑。揮 發性有機溶劑之實例包括具有5至8個碳原子的烴有基溶 。這些有機溶劑室溫下爲液態，並於存在有表面活性劑劑 之漿體中形成膠微粒。該有機溶劑於室溫蒸發，並且藉由 加熱於該漿體中形成細小氣泡。具有5至8個碳原子之烴 有機溶劑實例包括戊烷，新戊烷，己烷，異己烷，庚烷， 異庚烷，苯，辛烷和甲苯。起泡劑含量最好在〇 . 0 5至 1 ◦百分比範圍內，以0 5至5百分比更佳。含量少於 0·05百分比無法形成充分的氣泡數達成預定孔率。另 一方面，含量多於5百分比以上導致體積較大之膠微粒生 (請先閱請背面之注意事項号夫寫本頁) -裝_ 訂 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐) ~ 經濟部中央標準局員工消費合作社印製 A7 B7 五、發明説明i η) 成，因此產生較大的氣泡，使得該成型物件和燒結泡沫強 度降低。可以藉由充分混合氣體諸如空氣代替起泡劑製備 該泡沬漿體。 ‘ 該表面活性劑使起泡狀態安定，並且形成該起泡劑的 膠微粒。該表面活性劑的實例包括陰離子表面活性劑，諸 如烷基苯磺酸鹽，α -烯烴磺酸鹽，烷基硫酸酯之鹽類， 烷基醚硫酸酯之鹽類和烷屬烴磺酸鹽；以及非離子表面活 性劑，諸如聚乙烯乙二醇衍生物和多價醇衍生物。該表面 活性劑的含量在0 . 0 5至5百分比範圍內，以0 · 5至 3百分比較佳。數量少於0 .05百分比時，該膠微粒之 生成不穩定，因此在漿體中停留之細小氣泡很少。另一方 面，該含量超過5%並不會加強前述效果。 本發明'之氣泡漿體可能含有一種增塑劑，一種可燃性 物質等與前述必要組份不同者。 加入該增塑劑賦予該未燒結多孔性金屬元件可塑性。 該增塑劑實例包括多價醇，諸如乙烯乙二醇，聚乙烯乙二 醇和縮水甘油；油類，諸如沙丁魚油，油菜籽油和橄欖油 ;醚類，諸如石油醚；和酯類，諸如酞酸二乙酯，酞酸正 丁酯，酞酸二乙基己酯，酞酸二辛酯，單油酸花揪丹酯， 三油酯花揪丹酯，棕櫚酸花揪丹酯以及硬脂酸芯揪丹酯。 該增塑劑之含量在0.1至15百分比範圍較佳，以2至 1 0百分比更佳。含量少於0 . 1百分.比時，無法得到充 分可塑效果，然而含量高於1 5百分比時無痒得到強度令 人滿意之成型物件。較佳之增塑劑、是聚乙烯乙二醇和縮水 本紙張尺度適用中國國家標準（CNS ) Α4規格（210X297公釐） ，』 -14 一 C請先閱讀背面之注意事項再本頁) .裝. 訂 經濟部中央標隼局員工消費合作社印製 A7 _ B7 五、發明説明（：12 ) 甘油。這些增塑劑可以改善該成型物件之多孔性。 該可燃性物質在該乾燥成型物件燃燒步驟中燃燒，可 以促進孔隙形成。‘可以使用任何粉末和纖維可燃性物質》 更詳細地說，使用大約0 . 1至2 0 0 /zm之粉末和長度 200#m以下（3 0至120em較佳）之纖維。可燃 性物質實例包括紙漿，棉花，廢棄纖維，玉米澱粉，羧基 甲纖維素，非水溶性纖維素纖維，聚乙烯基丁醛樹脂，聚 乙烯基樹脂，丙烯酸樹脂和聚乙烯樹脂。 可以混合前述組份製得本發明泡沬漿體。雖然混合順 序沒有限制，但是該起泡劑最後加入較佳，以減少混合步 驟中氣泡生成。該漿體起泡後，該漿體的流動性降低，導 致成型特性差。然而，起泡劑加入之後直到起泡作用開始 的時間可以由起泡劑的種類及數量和骸漿體溫度控制。因 此，使這些參數最適化，該漿體可以在其仍然具有流動性 的時間內形成預定形狀之未燒結多孔性金屬元件。該漿體 黏度在 20，000cps 至 70，OOOcps 較佳， 以 30，OOOcps 至 55 ，OOOcps 更佳。在 20 °C溫度下該黏度低於20，OOOcps時，該蜂窩 狀結構會於燃燒時損壞。另一方面，該黏度高於 70 ，OOOcps時，因爲其黏度高，其成型特性可能 很差。 B .成锄步驟 將上述步驟製備之泡沫漿體製成板狀。適用之成型方 本紙張尺度適用中國國家標準（CNS ) A4規格（210X 297公釐） (請先閣讀背面之注意事項再>4本頁) .裝. *tr -15 - 經濟部中央標準局員工消費合作社印製 A7 _____B7_^___ 五、發明説明（13 ) 法是刮刀法。 圖3和4是本發明具體化實例中，具有二片刀片之刮 刀主要部分剖面圖。 該刮刀單位具有捲動式承載板1 0之第一個輥2 0和 用來捲動該承載板10之第二個輥21(這些輥並未示於 圖3和4)。該刮刀60安置在漿體貯存器30右壁，該 運送板運送方向下游，而且可調整間隙介於刮刀6 0和運 送板1 0之間。該成型物件厚度由介於其間的間隙調整。 當漿體貯存器3 0裝滿泡沬漿體，並且該運送板移動時， 該泡沬漿體S由該間隙擠出形成預定厚度的板狀物件1 a 。將板狀物件移至運送板上下一個起泡區4 〇。 如圖3和4所示，使用二片刀片6 0 A和60 B充作 刮1刀6 0，'大型氣泡由介於6 0 A，6 0 B之間的空隙釋 出。因此’不論泡沬漿體S數量如何，該板狀物件1 A由 第二刀片6 0 B和運送板1 〇之間的間隙推出，不含大型 氣泡，而且該板狀物件1 A之厚度均勻。介於第一刀片 6 0A和運送板1 〇之間隙G 1比介於第二刀片6 0 B和 運送板1 0之間隙G 2大較佳。介於第一刀片6 0 A和第 二刀片6 0 B之距離D最好大約爲5至2 0mm。介於第 二刀片60B和運送板1〇之間隙G2最好爲〇 . 2.至2 mm。 耙泡步驟 該成型物件在乾燥之前充份起泡。該起泡步驟在製造 本紙張尺度適用中國國家標準（CNS )八4規格（210X297公釐） ： -16 - (請先閱讀背面之注意事項再域專本頁) -5 經濟部中央標準局員工消費合作社印製 A7 B7 五、發明説明（14 ) 本發明未燒結金屬泡沬時並非必要。然而，當該成型物件 在成型步驟後立刻乾燥時，該成型物件之表面首先乾燥形 成一層表層，使該成型物件內之起泡作用和水的蒸發作用 受到抑制。因此，該起泡步驟在成型步驟和乾燥步驟之間 進行較佳，以達成均匀起泡作用》 當該成型物件在起泡作用中乾燥時，容易在該成型物 件表面形成裂化。因此，該起泡作用最好在高濕氣氛下進 行，避免成型物件乾燥。例如，當該漿體黏度爲 35，000cps或更高時，該濕度至少爲65百分比 ’至少8 0百分比更佳。當濕度少於6 5百分比時，該成 型物件表面可能會形成裂化。該起泡溫度最好在1 5至 6 5 °C範圍內，以2 8至4 0 °C更隹。當溫度低於1 5 °C 時，起泡作甩所需時間更長，例如2小時。當溫度高於 6 5 °C時，該成型物件會過度起泡，時常導致該成型物件 之破裂。該成型作用通常進行10至45分鐘。 圖5 A至5 E概要圖示高濕度下的起泡狀態。該起泡 漿體形成預定形狀例如成型物件1A之板（圖5A)之後 ，起泡步驟（圖5B和5C)中，該漿體中的起泡劑釋出 氣泡，形成氣泡3。在高濕度起泡步驟中，整個成型物件 1 A之漿體黏度均勻，氣泡會在該成型物件中均勻形成， 因此該成型物件變成具有均勻蜂窩狀結構之蜂巢狀物件1 B (圖5D)。此外，高濕度起泡步驟不會在蜂窩狀物件 1 B表面形成裂化和其它缺點。 圖6 A至6 E概略顯示該泡沫漿體成型後乾燥時或者 本紙張尺度適用中國81^準(CNS ) A4規格（210X297公釐) 一 17 - —J---Ί----批衣-- (請先閱讀背面之注意事項再纟鳥本頁) -r 訂 ί! 經濟部中央標準局員工消費合作社印製 A7 B7 五、發明説明（15 ) 於低濕度起泡時之起泡狀態。此種低濕度起泡作用中，在 泡沫漿體成爲預定形狀，諸如成型物件1A (圖6A)之 後，漿體中的起泡劑釋出氣體，形成起泡步驟中之成型物 件1 A上之氣泡3 (圖6 B和6 C )，其與高濕度起泡步 驟相似。然而，該成型物件1 A表面先乾燥，因爲低濕度 條件之故該成型物件1 A之漿體黏度變得不均勻。因此， 該成型物件中不均勻生成氣泡3 ，造成具有不均勻蜂窩狀 結構之蜂窩狀物件1B(圖6D)。此外，該蜂窩狀物件 1 B表面容易形成裂化和其它缺點（圖6 E )。 起泡作用在具有起泡用之高溫濕潤器之起泡區進行。 圖7是起泡用之高溫濕潤器4 0之具體化實例剖面圖 。用於起泡之高溫濕潤器4 0最好包括一種爐4 6，其在 充作運送裝置之運送板運送途徑周圍，而且具有入口 4 7 和出口 48，一個具有恆溫器之貯水器裝置在該爐中，一 個用於加熱該成型物件之加熱器沿著該爐內之運送途徑安 裝，以及在該爐壁安裝抗汗加熱器4 2。該爐4 6環繞著 該運送板1 0之運送途徑，並且在運送板1 0之上形成空 間4 9 A和4 9 B。運送板10之入口 4 7放置在該爐 4 6之上游壁中段（第一個輥那一側），而山口 4 8放置 在爐4 6下游壁中段（第二個輥那一側）。在該運送板下 方形成之下方空間4 9 A充作一個貯水容器，其中裝著既 定數量的水4 5。在下方空間4 9 A底部裝置一個調節加 熱器，如此該爐中之氣氛可以藉由蒸發水4 5維持既定濕 度。該下方空間4 9 A最好具有一個攪拌器使水的溫度均 表紙張尺度適用中國國家標準（CNS ) A4規格（2丨0X297公釐） ~~ ' ；--1---；--裝--I (請先閱讀背面之注意事項再/',4本頁) if · 言 線， 經濟部中央標準局員工消費合作社印製 A7 B7 五、發明説明（16 ) 勻。板狀加熱器4 2沿著該爐4 6內之運送板1 0之運送 途徑上友空間4 9 B安裝。該板狀加熱器避免水凝結在該 壁上，並且促進調節加熱器操作。沿著運送途徑安裝之板 狀加熱器就在運送板1 0下方，其加熱該運送板1 0上之 成型漿體物件1 A促進起泡作用。該板狀加熱器4 2和 4 4之實例包括碳板加熱器，而該調節加熱器實例包括包 有絕緣體之鎳鉻合金線路加熱器。 乾燥步驟 該蜂窩狀物件1 B由起泡區運送至乾燥區5 0。乾燥 前之氣泡是由水薄膜維持，其中漿體凝聚在氣泡之間的界 面，形成一種骨架結構（蜂窩狀結構）。當水薄膜破壞這 種狀態時，該漿體形成骨架流破壞了該骨架結構。因此， 藉由乾燥可以得到該蜂窩狀結構而不會破壞該骨架結構。 迅速乾燥使該骨.架結構不會破壞的方法之一。遠紅外線乾 燥適用於此種用途。該漿體組成物最好具有水蒸氣極少時 黏度容易增加之特性9 該乾燥步驟中的條件包括，例如1 2 0至1 8 0 °C之 溫度，40至80 °C的大氣溫度，和20至120分鐘乾 燥時間。乾燥之後，製得胚板1 C »該胚板1 C厚度通常 爲圖3所示G 2高度的3至8倍。該胚板向下彎向該運送 板時，藉由運送使其與運送板1 0分離。 該乾燥方法之實例包括熱傳送方法，諸如暖空氣乾燥 法，遠紅外線乾燥法和微波加熱法。其中，微波加熱法乾 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） .n · :~： ~ —I U - … (.請先閱讀背面之注意事項再r寫本頁) :繁. .訂 經濟部中央標準局員工消費合作社印製 A7 B7 五、發明説明（17 ) 燥速度最快，其次是遠紅外線法。因爲該熱傳送方法之乾 燥速度遠低於其它二種方法速度，該蜂窩狀物件表面和內 部不均勻乾燥。因此，遠紅外線法和微波法有利於迅速去 除水分。然而，因爲該泡沬漿體含有金屬粉末，該微波因 爲金屬粉末燃燒之故而無法使用。因此，遠紅外線是最適 用之方法。然而，乾燥機5 0並不限用於遠紅外線乾燥機 。例如，本發明中亦可使用暖氣乾燥機以及遠紅外線加熱 與熱傳送，諸如暖氣乾燥之組合。 圖8是顯示本發明具體化實例之遠紅外線乾燥機結構 剖面圖。該遠紅外線乾燥機5 0圍繞著運送板1 0之運送 途徑，並且具有爐5 1以形成運送板1 0上方之封閉空間 。該爐5 1之上游（第一個輥那一側）壁具有運送板1 0 之·入口 5 6，而爐5 1之卞游（第二個輥那一側）壁具有 出口 5 7。爐5 1之內部沿著運送方向分成三個間隔5 4 A，54B和54C，隔板53A，5 3B與爐51之內 部側壁連接。隔板5 3 A和5 3 B以及運送板1 0之間具 有適當間隙58A，58B，如此運送板10上之蜂窩狀 物件1 B可以通過間隙5 8 A和5 8 B運到下一個間隔。 將遠紅外線加熱器52安置在間隔54八，546，54 C之運送板之運送途徑上方以乾燥在運送板1〇上成型之 蜂窩狀物件1B。排氣鼓風機55A，55B，55C裝 置在間隔5 4 A，5 4 B，5 4 C之上.方壁，排出該間隔 中的濕氣大氣。該間隔54A，54B，54C最好之內 壁最好具有反射特性使遠紅外線有效效地乾燥。本發明中 本紙張尺度適用中國國家標準（CNS ) Α·4規格（210X 297公釐） 77~ _ ~ Zu - ·-'" ^---Ί--.--^-- - '\j.. (請先閲讀背面之注意事項寻i辱本頁) -a< 1T Printed by the Consumer Standards Cooperative of the Central Bureau of Standards of the Ministry of Economic Affairs A7 ______B7_______ V. Description of the Invention (10)-Aspect 'When the average particle size is 500 or more, sintered porous metal made by sintering this unsintered metal foam The board strength is insufficient. The content of the metal powder in the slurry ranges from 5 to 80 percent (weight percent, the same applies hereinafter) from 30 to 80 percent. After the drying step ', the water-soluble resin adhesive maintains the shape of the porous article. The water-soluble resin adhesive can also be used as a viscosity improver for seed slurry. Examples of the water-soluble resin binder include methylcellulose, hydroxypropylmethylcellulose, hydroxyethylcellulose, carboxymethylcellulose ammonium, ethylcellulose and polyvinyl alcohol. The content of the water-soluble resin adhesive is preferably in the range of 0.5 to 20 percent, and more preferably 2 to 10 percent. When the content is 0.5% or less, the strength of the dried metal object is too great to handle. On the other hand, when the content is 20% or more, the viscosity is too high to obtain a molded article. Any foaming agent that releases gas to form pores can be used, such as compounds that explain gas at a predetermined temperature, and volatile organic solvents. Examples of the volatile organic solvent include a hydrocarbon-based solvent having 5 to 8 carbon atoms. These organic solvents are liquid at room temperature and form colloidal particles in a slurry in which a surfactant is present. The organic solvent was evaporated at room temperature, and fine bubbles were formed in the slurry by heating. Examples of hydrocarbons having 5 to 8 carbon atoms include pentane, neopentane, hexane, isohexane, heptane, isoheptane, benzene, octane, and toluene. The foaming agent content is preferably in the range of 0.05 to 1%, and more preferably in the range of 0.5 to 5%. A content of less than 0.05% cannot form a sufficient number of bubbles to achieve a predetermined porosity. On the other hand, the content of more than 5% leads to the generation of larger gel particles (please read the precautions on the back first to write this page)-The size of the paper is applicable to the Chinese National Standard (CNS) A4 specifications ( 210X297 mm) ~ Printed by the Consumer Cooperatives of the Central Standards Bureau of the Ministry of Economic Affairs A7 B7 V. Description of the invention i η), so large bubbles are generated, which reduces the strength of the molded object and sintered foam. The foamed slurry can be prepared by thoroughly mixing a gas such as air instead of the foaming agent. ‘The surfactant stabilizes the foaming state and forms colloidal particles of the foaming agent. Examples of the surfactant include anionic surfactants such as alkylbenzene sulfonates, α-olefin sulfonates, salts of alkyl sulfates, salts of alkyl ether sulfates, and paraffin sulfonates ; And nonionic surfactants such as polyethylene glycol derivatives and polyvalent alcohol derivatives. The content of the surfactant is in the range of 0.05 to 5 percent, and preferably 0.5 to 3 percent. When the amount is less than 0.05%, the formation of the colloidal particles is unstable, so there are few fine bubbles remaining in the slurry. On the other hand, the content above 5% does not enhance the aforementioned effect. The bubble slurry of the present invention may contain a plasticizer, a flammable substance, etc., which is different from the aforementioned essential components. Adding the plasticizer imparts plasticity to the green porous metal element. Examples of the plasticizer include polyvalent alcohols such as ethylene glycol, polyethylene glycol, and glycidol; oils such as sardine oil, rapeseed oil, and olive oil; ethers such as petroleum ether; and esters such as Diethyl phthalate, n-butyl phthalate, diethylhexyl phthalate, dioctyl phthalate, huadandan monooleate, landanyl trioleate, huadandan palmitate, and hard Fatty acid core pandan ester. The content of the plasticizer is preferably in the range of 0.1 to 15 percent, and more preferably 2 to 10 percent. When the content is less than 0.1%, a sufficient plasticizing effect cannot be obtained, but when the content is more than 15%, it is possible to obtain a molded article with satisfactory strength without itching. The preferred plasticizers are polyethylene glycol and shrinkable paper. The size of the paper is applicable to the Chinese National Standard (CNS) A4 specification (210X297 mm), "-14-1C Please read the precautions on the back before loading this page). Order A7 _ B7 printed by the Consumer Cooperatives of the Central Bureau of Standards of the Ministry of Economic Affairs V. Invention Description (: 12) Glycerin. These plasticizers can improve the porosity of the molded article. The flammable substance is burned in the burning step of the dried molded article to promote pore formation. ‘Any powder and fiber flammable substance may be used.’ More specifically, a powder of about 0.1 to 200 / zm and a length of 200 #m or less (preferably 30 to 120 em) are used. Examples of combustible materials include pulp, cotton, waste fiber, corn starch, carboxymethyl cellulose, water-insoluble cellulose fiber, polyvinyl butyral resin, polyvinyl resin, acrylic resin, and polyethylene resin. The foregoing components can be mixed to prepare the foamed syrup of the present invention. Although the order of mixing is not limited, it is preferred that the foaming agent is added last to reduce bubble generation during the mixing step. After the slurry was foamed, the fluidity of the slurry was reduced, resulting in poor molding characteristics. However, the time after the foaming agent is added until the foaming effect starts can be controlled by the type and amount of the foaming agent and the temperature of the skeletal body. Therefore, by optimizing these parameters, the slurry can form an unsintered porous metal element of a predetermined shape within the time that it still has fluidity. The viscosity of the slurry is preferably from 20,000 cps to 70,000 cps, more preferably from 30,000 cps to 55, 000 cps. When the viscosity is lower than 20 at 20 ° C, the honeycomb structure will be damaged during combustion. On the other hand, when the viscosity is higher than 70 cps, its molding properties may be poor due to its high viscosity. B. Forming step The foam slurry prepared in the above steps is made into a plate shape. Applicable molding paper size: Applicable to China National Standard (CNS) A4 specification (210X 297mm) (please read the precautions on the back first> 4 pages). * Tr -15-Central Standard of the Ministry of Economic Affairs A7 printed by the Bureau's Consumer Cooperatives _____ B7 _ ^ ___ V. Description of Invention (13) The method is the scraper method. 3 and 4 are cross-sectional views of main parts of a doctor blade having two blades in an embodiment of the present invention. The scraper unit has a first roller 20 of a rolling type carrier plate 10 and a second roller 21 for rolling the carrier plate 10 (these rollers are not shown in Figs. 3 and 4). The scraper 60 is disposed on the right wall of the slurry reservoir 30, and the conveying plate is downstream in the conveying direction, and the adjustable gap is between the scraper 60 and the conveying plate 10. The thickness of the molded object is adjusted by a gap therebetween. When the pulp reservoir 30 is filled with foamed pulp and the conveying plate is moved, the foamed pulp S is extruded from the gap to form a plate-shaped piece 1 a of a predetermined thickness. Move the plate object to the next blistering area 40 on the transport plate. As shown in Figures 3 and 4, using two blades 60 A and 60 B as a scraper 1 knife 60, the large bubbles are released from the gap between 60 A and 60 B. Therefore, irrespective of the number of foamed pulp S, the plate-like object 1 A is pushed out from the gap between the second blade 60 B and the transport plate 10, and does not contain large bubbles, and the thickness of the plate-like object 1 A is uniform. . The gap G1 between the first blade 60A and the transport plate 10 is larger than the gap G2 between the second blade 60B and the transport plate 10. The distance D between the first blade 60 A and the second blade 60 B is preferably about 5 to 20 mm. The gap G2 between the second blade 60B and the transport plate 10 is preferably 0.2 to 2 mm. Raking step The shaped object is fully foamed before drying. This foaming step applies the Chinese National Standard (CNS) 8-4 specifications (210X297 mm) in the manufacture of this paper: -16-(Please read the precautions on the back first, and then go to the special page) -5 Employees of the Central Standards Bureau of the Ministry of Economic Affairs Printed by the Consumer Cooperative A7 B7 V. Description of the invention (14) The unsintered metal foam of the present invention is not necessary. However, when the molded object is dried immediately after the molding step, the surface of the molded object is first dried to form a surface layer, so that the foaming effect and water evaporation effect in the molded object are suppressed. Therefore, the foaming step is preferably performed between the molding step and the drying step to achieve a uniform foaming effect. When the molded object is dried in the foaming effect, cracks are easily formed on the surface of the molded object. Therefore, the foaming effect is preferably performed in a high-humidity atmosphere to prevent the molded article from drying. For example, when the viscosity of the slurry is 35,000 cps or higher, the humidity is at least 65% 'and more preferably at least 80%. When the humidity is less than 65%, the surface of the shaped object may crack. The foaming temperature is preferably in the range of 15 to 65 ° C, and more preferably in the range of 28 to 40 ° C. When the temperature is lower than 15 ° C, it takes longer to bubbling, such as 2 hours. When the temperature is higher than 65 ° C, the molded article will blister excessively, which often causes the molded article to crack. This molding effect is usually performed for 10 to 45 minutes. 5A to 5E are schematic diagrams showing a foamed state under high humidity. After the foaming slurry is formed into a predetermined shape such as a plate of a molded article 1A (Fig. 5A), in the foaming step (Figs. 5B and 5C), the foaming agent in the slurry releases bubbles to form bubbles 3. In the high-humidity foaming step, the slurry viscosity of the entire molded object 1 A is uniform, and bubbles will be uniformly formed in the molded object, so the molded object becomes a honeycomb-shaped object 1 B having a uniform honeycomb structure (FIG. 5D). In addition, the high-humidity foaming step does not cause cracking and other disadvantages on the surface of the honeycomb article 1B. Figures 6 A to 6 E schematically show that when the foam slurry is dried after molding or the size of this paper is applicable to China 81 ^ Standard (CNS) A4 specification (210X297 mm)-17--J --- Ί ---- batch -(Please read the precautions on the back first, and then click the bird's page) -r Order ί! Printed by the Consumers' Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs A7 B7 V. Description of the invention (15) Foaming state when foaming at low humidity . In this low-humidity foaming effect, after the foam slurry becomes a predetermined shape, such as the molded object 1A (FIG. 6A), the foaming agent in the slurry releases gas to form a shape on the molded object 1A in the foaming step. Bubble 3 (Figures 6B and 6C), which is similar to the high-humidity foaming step. However, the surface of the molded article 1 A was dried first, and the viscosity of the slurry of the molded article 1 A became uneven because of low humidity conditions. Therefore, bubbles 3 are generated unevenly in the molded article, resulting in a honeycomb article 1B having an uneven honeycomb structure (FIG. 6D). In addition, the surface of the honeycomb object 1 B is prone to cracking and other defects (Fig. 6E). Foaming takes place in the foaming area with a high temperature humidifier for foaming. Fig. 7 is a sectional view of a concrete example of a high-temperature humidifier 40 for foaming. The high-temperature humidifier 40 for bubbling preferably includes a furnace 46, which surrounds the conveying path of the conveying plate serving as a conveying device, and has an inlet 47 and an outlet 48, and a water reservoir device having a thermostat is provided thereon. In the furnace, a heater for heating the molded article is installed along the conveying path in the furnace, and an anti-sweat heater 42 is installed on the furnace wall. The furnace 46 surrounds the conveying path of the conveying plate 10 and forms spaces 4 9 A and 4 9 B above the conveying plate 10. The entrance 4 7 of the conveying plate 10 is placed in the middle section of the upstream wall of the furnace 4 6 (on the side of the first roller), and the pass 4 8 is placed in the middle section of the downstream wall of the furnace 4 6 (on the side of the second roller). A lower space 4 9 A formed below the transport plate serves as a water storage container, which contains a predetermined amount of water 4 5. An adjusting heater is installed at the bottom of the space 4 9 A, so that the atmosphere in the furnace can maintain a predetermined humidity by evaporating water 45. The lower space 4 9 A is best equipped with a stirrer so that the temperature of the water is uniformly expressed on the paper. The paper size is applicable to the Chinese National Standard (CNS) A4 specification (2 丨 0X297 mm) ~~ '; --I (Please read the notes on the back before / ', 4 pages) if · Word line, printed by the Consumers' Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs A7 B7 5. The invention description (16) is uniform. The plate heater 42 is installed along the transportation path of the transportation board 10 in the furnace 4 6 through Shangyou Space 4 9 B. The plate heater prevents water from condensing on the wall and facilitates the adjustment of heater operation. A plate-shaped heater installed along the conveying path is just below the conveying plate 10, which heats the molded slurry object 1A on the conveying plate 10 to promote the foaming effect. Examples of the plate-shaped heaters 42 and 44 include carbon plate heaters, and examples of the conditioning heater include nickel-chromium alloy line heaters with insulators. Drying step The honeycomb article 1 B is transported from the foaming zone to the drying zone 50. The air bubbles before drying are maintained by a thin film of water, in which the slurry condenses on the interface between the air bubbles, forming a skeleton structure (honeycomb structure). When the water film destroys this state, the slurry forms a skeleton flow and destroys the skeleton structure. Therefore, the honeycomb structure can be obtained by drying without damaging the skeleton structure. One of the methods to quickly dry the bone frame structure is not damaged. Far-infrared drying is suitable for this purpose. The slurry composition preferably has a property that viscosity increases easily with very little water vapor. 9 Conditions in the drying step include, for example, a temperature of 120 to 180 ° C, an atmospheric temperature of 40 to 80 ° C, and 20 To 120 minutes drying time. After drying, a blank 1 C is obtained. The thickness of the blank 1 C is usually 3 to 8 times the height of G 2 shown in FIG. 3. When the blank plate is bent downward toward the transport plate, it is separated from the transport plate 10 by transport. Examples of the drying method include a heat transfer method such as a warm air drying method, a far-infrared drying method, and a microwave heating method. Among them, the microwave heating method of dry paper is applicable to the Chinese National Standard (CNS) A4 specification (210X297 mm) .n ·: ~: ~ —IU-… (Please read the precautions on the back before writing this page): Fan ... Order A7 B7 printed by the Consumer Cooperatives of the Central Standards Bureau of the Ministry of Economic Affairs 5. Description of the invention (17) The fastest drying speed, followed by the far-infrared method. Because the drying speed of the heat transfer method is much lower than that of the other two methods, the surface and the inside of the honeycomb object are unevenly dried. Therefore, the far-infrared method and the microwave method are advantageous for the rapid removal of moisture. However, because the foam slurry contains metal powder, the microwave cannot be used because the metal powder is burned. Therefore, far infrared is the most suitable method. However, the dryer 50 is not limited to the far-infrared dryer. For example, a heating dryer and a combination of far-infrared heating and heat transfer such as heating drying can also be used in the present invention. Fig. 8 is a sectional view showing the structure of a far-infrared dryer according to a specific embodiment of the present invention. The far-infrared dryer 50 surrounds the conveying path of the conveying plate 10 and has a furnace 51 to form a closed space above the conveying plate 10. The wall upstream of the furnace 51 (on the side of the first roller) has an inlet 5 6 for the transport plate 10, and the wall of the furnace 51 (on the side of the second roller) has an outlet 57. The inside of the furnace 51 is divided into three intervals 5 4 A, 54B, and 54C along the conveyance direction, and the partition plates 53A, 5 3B are connected to the inner side wall of the furnace 51. Appropriate gaps 58A, 58B are provided between the partitions 5 3 A and 5 3 B and the transport plate 10, so that the honeycomb object 1 B on the transport plate 10 can be transported to the next interval through the gaps 5 8 A and 5 8 B. The far-infrared heater 52 was placed above the conveying path of the conveying plates at intervals of 54, 546, 54 C to dry the honeycomb article 1B formed on the conveying plate 10. Exhaust blowers 55A, 55B, and 55C are installed above the partitions 5 4 A, 5 4 B, and 5 4 C. The square walls discharge the atmospheric moisture from the partitions. The inner walls of the intervals 54A, 54B, and 54C preferably have reflection characteristics so that the far infrared rays can be effectively dried. In the present invention, the paper size applies to the Chinese National Standard (CNS) A · 4 specification (210X 297 mm) 77 ~ _ ~ Zu-·-'" ^ --- Ί --.-- ^--' \ j .. (Please read the notes on the back to find this page) -a
經濟部中央標準局員工消費合作社印I A7 ___B7 五、發明説明（IS ) 間隔之數目並無限制。或者該爐並不一定要分成許多間隔 ，其與上述第四具體化實例不同。另外，獨立之遠紅外線 乾燥機可以依序安裝。 該漿體組成物之黏度容易因漿體中少許水蒸發而增加 ，以製得具有所需蜂窩狀結構，而且該骨架結構沒有破損 之胚板。 以遠紅外線乾燥機5 0之乾燥作用係於加器溫度 1 20至1 80 °C，大氣溫度40至80 °C下進行20至 1 2 0分鐘。該乾燥板狀物件或胚板1 C在此步驟中製得 。胚板1C之厚度通常是圖3中G2高度的3至8倍。 裁切步驟 以切刀’7 0將該胚板裁成預定長度》例如，依需要將 經裁切之胚板進料至燃燒步驟。 在圖1所示之本發明具體化實例中，製造燒結多孔性 金屬板之裝置內，當運送板1 0移動時，藉由彎曲使胚板 1 C分離》將胚板1 C以切刀7 0裁切成預定長度，並進 行下一步驟（該圖未顯示）。 上述說明中，成型，起泡和乾燥作用依序進行。或者 ，這些處理可以以其獨立裝置進行。 現在解釋本發明使用製造燒結多孔性金屬板之裝置連 續製造未燒結金屬泡沫之方法。 1 .在運送板10表面形成脫模劑脫2之後，該漿體 貯存器3 0中裝滿泡沫漿體S，並以刮刀60將漿體S製 本紙張尺度適用中國國家標準（CNS_)_ A4規格（210X297公釐） (請先閲讀背面之注意事項再，¾馬本頁) -裝- 訂 -- 經濟部中央標準局員工消費合作社印製 A7 B7 五、發明説明（l9 ) 成板狀。詳細地說，進料到脫模劑貯存器8 0之脫模塗料 u係由刮刀9 0和移動的運送板1 0之間的間隙擠出，形 成既定厚度之塗覆膜2 »以脫模劑乾燥機1 0 0固化運送 板10運送之塗覆膜2。 2 .在形成之脫模劑膜2上使泡沬漿體S形成板狀物 件。運送板1 0充作該板狀物件1 A之輸送帶。進料到漿 體貯存器之漿體S係由介於刮刀6 0和運送板1 0之間隙 擠出，而且製成預定厚度的板狀物件。該板狀物件1 A沿 著運送板10向起泡用之高溫濕潤器移動。 3 .於該起泡甩之高溫濕潤器4 0中，在板狀物件1 A乾燥之前以高濕度大氣使起泡作用徹底完成，避免起泡 作用當中該板狀物件乾燥。 4 .將起泡用之高溫濕潤器內的蜂窩狀物件移到具有 乾燥機5 0之乾燥區，乾燥之後製得胚板1 C » 5 .當運送板10移動時，使該胚板向下彎曲分離之 ，並以切刀7 0裁切成預定長度。將經裁切之綠板送到下 一步驟，例如燃燒步驟（不顯示於圖中）》 實施例1 — 1 參照實施例說明本發明。 以表1所示之配方（重量百分比）爲基礎，化合金屬 粉末，水溶性樹脂黏合劑，起泡劑和表面活性劑製備泡沬 漿體。將每一種泡沬漿體以圖3所示之裝置製成板狀物件 ，其中圖3所示之第一片刀片6 0A之閘門高度爲〇 . 8 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐）_ 22 _ ' ' (請先閲讀背面之注意事項再^一馬本頁) 裝. -訂 經濟部中央橾準局員工消費合作社印製 A7 __B7_ 五、發明説明（2〇 ) mm，而第二片刀片之閘門高度爲0 . 6 m m，運送板 10之移動速度爲20cm/分鐘。 該成型物件l· A在設定爲表2所示溫度和濕度之恆溫 恆濕裝置內進行一定時間之起泡作用。該成型物件1 B以 加熱溫度設定爲1 6 0°C之遠紅外線乾燥機5 0乾燥，製 得胚板1 C。該胚板在一個石墨板上以4 5 0°C空氣去脂 3 0分鐘。該胚板於表2所示之條件下燒結，製得一個燒. 結多孔性金屬板。燒結之後，剪切該多孔性金屬板，其長 度爲胚板之百分之2 0。 將每一片燒結之多孔性金屬板部分以樹脂包埋，並磨 光其截面。將磨光片以影像分析儀測量孔隙大小和孔率， 並以B E T方法測量比表面積》結果示於表2。 依下文製備一種燒結之多孔性金屬板作爲對照實例之 市售賦予導電性之聚胺甲酸酯泡沬內側表面之鎳蒸發成 〇 . 5 // m厚之後，將該泡沬浸入硫酸鎳溶液中；以電流 密度1 A / d m 2對充作負電極之泡沬進行電鍍，在該泡 沫之開放式電池表面形成平均厚度爲7 5 Mm之鎳電鍍層 ;該電鍍泡沬於1 1 0 0 °C氫氣流中停留〇 . 5小時以去 除聚胺甲酸酯泡沫。形成之燒結多孔性金屬板直徑爲5 0 m m ’長度1 〇 〇 m m。該燒結多孔性金屬板之孔隙大小 ’孔率和B E T比表面積以實施例1 一 1相同方.式測定。 結果示於表2。 本紙張尺度適用中國國家標準（CMS ) A4規格（210X297公釐） ---；---Ί--|神衣-- - . (請先聞讀背面之注意事項再技尊本頁) 訂 丨與. β A7 B7 五、發明説明〇/ ) 表 1 成 份 實施例1-1 實施例1-2 金屬 粉末 純鎳(平均顆粒 大小:l〇y m) 60 — 不銹鋼(平均顆 粒大小:12# m) - 60 起泡劑 己烷 1.8 1.8 水溶性 樹脂黏 合劑 HPMC 6.5 6.5 MC 3.5 3.5 表面活 性劑 DBS 2.0 2.0 增塑劑 縮水甘油 2.5 2.5 水 平衡 平衡 (請先閱讀背面之注意事項再.¾寫本頁) .裝· 、11 經濟部中央標準局員工消費合作社印製 HPMC:羥丙基甲纖維素 MC:甲纖維素 D B S :鈉十二基苯磺酸鹽 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） -2^ - A7 B7 經濟部中央標準局員工消費合作社印製 五、發明説明（>〇 表 2 實施例 1-1 實施例 1-2 對照實例 起泡條件 濕度(％) 95 90 - 溫度(°c) 35 30 - 停留時間(分） 15 30 燒結條件 氣氛 N2-5% H2 h2 H2 溫度(°c) 1150 1200 1100 停留時間(小時） 3 1 0.5 燒結物件 厚度(mm) 1.8 2.0 平均孔隙大小 (βτη) 250 300 290 多孔性(％) 95.9 96.5 95 比表面積(cm2/cm3 ) 750 810 41 (請先閱讀背面之注意事項寻考寫本頁) -裝· -訂！Γ 線 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） 經濟部中央標準局員工消費合作社印製 A7 B7 五、發明説明（23 ) 具有立體骨架結構和比表面積大之燒結多孔性金屬板 可以此種方式製備。形成之燒結多孔性金屬板視該漿體製 備，起泡條件，乾燥條件和燃燒條件而定，具有下列如圖 9 A和9 D之不同結構；如圖9 A所示單一蜂窩狀層結構 ，圖9 B所示多層封閉式蜂窩結構，圖9 C所示表面封閉 之骨架結構，以及圖9D所示表面開放之骨架結構。 本發明之燒結多孔性金屬板本身之立體骨架亦爲多孔 性，因爲該骨架係由燒結之金屬粉末製成。因此，該燒結 多孔性金屬板比表面積與BET比表相當，例如300至 1 5 0 0 c m 2/ c m 3。此外，容易形成非常小例如 1 0 0 或以下之氣泡。形成之燒結金屬粉末平均孔隙 大小爲6 0至6 0 0 μ m，而其孔率爲9 0至9 8容積百 分比。 可使用本發明具體化實例製得之未燒結金屬泡沬充作 最終燒結之多孔性金屬板作爲鹼性蓄電池活性材料載體， 水解電極，油加熱器之噴霧單位，磁性屏蔽包裝，使用爆 炸物之空氣緩衝器中之氣體膨脹緩衝物，吸音絕緣材料， 淨水器之水解過濾器，空氣清淨器之靜電過濾器，排氣用 之油霧過濾器，油加熱器之除臭觸媒等，高溫導管之粉塵 過濾器，高壓下孔隙裝填鋁之組成材料基板，以及工業觸 媒和載體。 前沭县體化實例之改良 本發明中，可以達成許多與前述具體化實例不同之改 本紙張尺度適用中國國家橾準（CNS ) A4規格（210X297公釐） ~ 一 ~ -Zb ~ (請先閲讀背面之注意事項再丨，島本頁) 裝· i訂 經濟部中央標準局員工消費合作社印製 A7 B7 五、發明説明（24 ) 良。 例如，可以使用在胚板1 C燃燒步驟時消失，而且不 會影響該燒結金屬泡沬之樹脂膜代替前述具體化實例中之 脫模劑膜2。此種樹脂膜於泡沬漿體起泡步驟和乾燥歩驟 時不會收縮，而且燃燒之後完全消失較隹。此外，該樹脂 膜最好容易與運送板分離。此種樹脂實例包括胺酯樹脂。 環氧樹脂，熱固性聚酯樹脂，耐熱性熱塑型塑膠，丙烯酸 樹脂，聚丙烯樹脂和乙烯一乙酸乙烯基酯樹脂。細節說明 如下。 與刮刀9 0不同之可使用製膜方法實例包括刷塗法， 海綿滾塗法和擠製法。此外，可以使用不須製膜步驟之樹 脂膜。例如，使用一個輥捲動一種樹脂膜，該樹脂膜上形 成之泡沬漿·體或以自該輥脫模。 該乾燥之胚板可以以一種未裁切之長形元件燃燒，與 前述具體化實例中，胚板1 C以切刀裁切之方式不同。本 實例中，因爲乾燥胚板1 C之收縮大，所示容易形成裂化 。因此，胚板收縮造成胚板在運送器上容易移動是必然的 ，如下文所示；將一種潤滑劑塗在運送器表.面，降低胚板 與該運送器之接觸阻力；該運送器係由許多輥組成以減少 胚板與運送器之接觸面積；或者該運送器傾斜使出口.位置 高於入口位置。 如上述，依本具體化實例容易製得·金屬組成自由度高 ，而且比表面積大之未燒結金屬板。 本紙張尺度適用中國國家標準（CNS ) A4規格（210\297公着） ---^---Ί-----裝-- (請先閲讀背面之注意事項号4喬本頁) 訂_ -27 A7 B7 五、發明説明（25) 具體化實例 該泡沬漿體之另一個較佳之具體化實例爲第二具體化 實例。 · 因爲本發明中使用一種含有起泡劑之水性漿體，該起 泡劑有時會在漿體成型前起泡，因此使起泡之金屬特性相 當不穩定。在第二具體化實例中將改善此種問題。 製備該泡沬漿體時，將漿體組份分成二種水溶液，並 在成型之前混合.二種溶液。 圖1 0是連續進行泡沬漿體製備，成型，起泡和乾燥 之裝置示意剖面圖，如圖所示之裝置。該裝置包括一種泡 沫漿體製備裝置1 0 2，運送裝置3 0 0，脫模劑膜製備 裝置1 1，成型裝置5，起泡裝置4 0和乾燥裝置5 0。 該泡沫漿體製備裝置102包括一個用來混合水溶液 (A)之第一混合器，用於混合水溶液（B)之第二混合 器1 1 2，以及第三混合器1 1〇。第三混合器混合由第 一和第二混合器進料之水溶液（A)和（B)，並將混合 後形成之泡沬漿體S送到成型裝置5。第二混合器1 1 2 具有二個自動進料水溶液（B )組份之飼機。 水溶液（A )之成份以預定數量進料到第一混合器 113中混合之，混合之後的水溶液（A)(圖10.以 A q (A)表示）以既定流率經由管1 1 3 a進料到第三 混合器1 1 0。同樣的’水溶液（B ).之組份以預定數是 進料至第二混合器1 1 2中混合，混合後的水溶液（B ) (圖1Ό中以Aq (B)表示）以既定流率經由管1 1 2 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） ：---Ί----^-- (請先閲讀背面之注意事項再^寫本頁) 訂 經濟部中央標準局員工消費合作社印製 經濟部中央標準局員工消費合作社印製 A 7 _ B7 五、發明説明（26 ) a進料到第三混合器1 1 〇。水溶液（A)和（B)在第 三混合器1 1 0中混合製成泡沫漿體S，並經由管1 1 〇 a將泡沫漿體S進料到起泡機5中。 該泡沫漿體含有金屬粉末，水溶性樹脂黏合劑，起泡 劑，表g活性劑和水，與第一具體化實例相同。金屬粉末 聚集在該泡沬漿體細微氣泡周圍的薄液壁上，而且該金屬 粉末以及該水溶性樹脂黏合劑如此固化，以維持氣泡形狀 。燃燒去除該黏合劑，並燒結該金属粉末，製成具有立體 網狀結構之燒結多孔性金屬板。 充作金屬粉末之金屬實例包括所有可以粉末化以及燒 結之金屬。因此，該金屬組成具有高度自由，例如可以使 用該多種金屬和不同種類金屬之許多組合。此外，因爲燒 結金屬之故、該骨架本身具有多孔性結構。因此，燒結之 多孔性金屬具有相當大的比表面積》 本實例中，泡沫漿體之成份分成二種溶液，而且在進 料之成型機之前才混合這種溶液，減少該起泡劑之揮發作 用。 溶液（A )中組份實例包括一種起泡劑，一種表面活 性劑，和一種水溶性樹脂黏合劑。溶液（B )中組份實例 包括金屬粉末和水溶性樹脂黏合劑。 與第一具體化實例相同之起泡劑亦可用於第二具體化 實例。該起泡劑加入水溶液（A )中，其中漿體中該起泡 劑爲0 . 05至1 0重量百分比，以0 . 5至5重量百分 比較佳。如果該含量少於9 0 5重量百分比，形成的氣泡 本紙張尺度適用中國國家標準（CNS ) A4規格.（210X297公釐） (請先閲讀背面之注意事項再本頁) •裝.Printed by the Consumer Standards Cooperative of the Central Bureau of Standards of the Ministry of Economic Affairs I A7 ___B7 5. There is no limit to the number of invention description (IS) intervals. Or the furnace does not have to be divided into many intervals, which is different from the fourth embodiment. In addition, independent far-infrared dryers can be installed sequentially. The viscosity of the slurry composition is easily increased by evaporation of a small amount of water in the slurry to obtain a desired embryonic plate with a desired honeycomb structure, and the skeleton structure is not damaged. The far-infrared dryer 50's drying effect is based on the adder temperature 120 to 180 ° C, and the atmospheric temperature 40 to 80 ° C for 20 to 120 minutes. The dried plate-like article or blank 1 C is obtained in this step. The thickness of the embryonic plate 1C is generally 3 to 8 times the height of G2 in FIG. 3. Cutting step The cutting slab is cut to a predetermined length with a cutter '70. For example, the cutting slab is fed to the combustion step as required. In the embodiment of the present invention shown in FIG. 1, in the apparatus for manufacturing a sintered porous metal plate, when the transport plate 10 moves, the embryonic plate 1 C is separated by bending. The embryonic plate 1 C is cut with a cutter 7 0 is cut to a predetermined length, and the next step is performed (not shown in the figure). In the above description, molding, foaming, and drying are performed sequentially. Alternatively, these processes can be performed in their own independent devices. A method for continuously manufacturing an unsintered metal foam using the apparatus for manufacturing a sintered porous metal plate according to the present invention will now be explained. 1. After the release agent 2 is formed on the surface of the conveying board 10, the slurry reservoir 30 is filled with foam slurry S, and the slurry S is made with a scraper 60. The paper size is in accordance with Chinese national standard (CNS _) _ A4 Specifications (210X297 mm) (Please read the precautions on the back, ¾ page)-Binding-Binding-Printed by the Consumers Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs A7 B7 5. The invention description (l9) is plate-shaped. In detail, the mold release coating material u fed to the mold release agent reservoir 80 is extruded from the gap between the doctor blade 90 and the moving transport plate 10 to form a coating film 2 of a predetermined thickness. The drying agent 100 cures the coating film 2 conveyed by the conveying plate 10. 2. Form the foam slurry S on the formed release agent film 2 into a plate-like member. The transport plate 10 is used as a conveyor belt for the plate-like object 1A. The slurry S fed to the slurry reservoir is extruded from the gap between the scraper 60 and the transport plate 10, and is made into a plate-like member of a predetermined thickness. The plate-like object 1A is moved along the transport plate 10 toward a high-temperature humidifier for foaming. 3. In the high-temperature humidifier 40 that foams and shakes, before the plate-like object 1A is dried, the foaming effect is completely completed in a high-humidity atmosphere, and the plate-like object is prevented from drying during the foaming effect. 4. Move the honeycomb object in the high-temperature humidifier for foaming to a drying area with a dryer 50, and dry the blank plate 1 C »5. When the transport plate 10 moves, make the blank plate downward It is bent and separated, and cut with a cutter 70 to a predetermined length. The cut green board is sent to the next step, such as the burning step (not shown in the figure). Example 1-1 The present invention will be described with reference to examples. Based on the formula (weight percentage) shown in Table 1, compounded metal powder, water-soluble resin binder, foaming agent and surfactant were used to prepare foam paste. Each foam paste was made into a plate-like object by the device shown in FIG. 3, and the gate height of the first blade 60A shown in FIG. 3 was 0.8. This paper size is applicable to the Chinese National Standard (CNS) A4 Specifications (210X297mm) _ 22 _ '(Please read the precautions on the back before ^ this page) Packing.-Order A7 printed by the Staff Consumer Cooperatives of the Central Procurement Bureau of the Ministry of Economic Affairs __B7_ V. Description of the invention (2〇 ) mm, and the gate height of the second blade is 0.6 mm, and the moving speed of the conveying plate 10 is 20 cm / minute. The molded article l · A was foamed for a certain period of time in a constant temperature and humidity device set to the temperature and humidity shown in Table 2. The molded article 1 B was dried in a far-infrared dryer 50 set at a heating temperature of 160 ° C to obtain a blank 1 C. The blank was degreased on a graphite plate with air at 450 ° C for 30 minutes. The blank was sintered under the conditions shown in Table 2 to produce a fired, porous metal plate. After sintering, the porous metal plate was cut to a length of 20% of the blank plate. A part of each sintered porous metal plate was embedded with resin, and its cross section was polished. The polished sheet was measured for pore size and porosity with an image analyzer, and the specific surface area was measured with BET method. The results are shown in Table 2. After preparing a sintered porous metal plate as a comparative example, the nickel on the inner surface of a commercially available polyurethane foam that imparts conductivity was evaporated to a thickness of 0.5 // m, and then the foam was immersed in a nickel sulfate solution. Medium; electroplating was performed on a cell filled with a negative electrode at a current density of 1 A / dm 2 to form a nickel plating layer with an average thickness of 7 5 Mm on the surface of the open cell of the cell; the cell was formed in 1 1 0 0 It was left in a hydrogen flow at ° C for 0.5 hours to remove the polyurethane foam. The formed sintered porous metal plate had a diameter of 50 mm m 'and a length of 100 mm. The pore size 'porosity and B E T specific surface area of this sintered porous metal plate were measured in the same manner as in Example 1-1. The results are shown in Table 2. This paper size applies the Chinese National Standard (CMS) A4 specification (210X297 mm) ---; --- Ί-- | Shenyi ---. (Please read the precautions on the back first and then respect this page) Order丨 and. Β A7 B7 V. Description of the invention 〇 /) Table 1 Composition Example 1-1 Example 1-2 Metal powder pure nickel (average particle size: l0ym) 60 — Stainless steel (average particle size: 12 # m )-60 Foaming agent hexane 1.8 1.8 Water-soluble resin binder HPMC 6.5 6.5 MC 3.5 3.5 Surfactant DBS 2.0 2.0 Plasticizer glycidol 2.5 2.5 Water balance (please read the precautions on the back first. Page) .11, printed by the Consumer Cooperatives of the Central Standards Bureau of the Ministry of Economic Affairs, printed by HPMC: hydroxypropyl methylcellulose MC: methylcellulose DBS: sodium dodecylbenzene sulfonate This paper applies Chinese national standards (CNS) A4 specifications (210X297 mm) -2 ^-A7 B7 Printed by the Consumers' Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs 5. Description of the invention (> 〇 Table 2 Example 1-1 Example 1-2 Comparative Example Foaming Condition Humidity ( %) 95 90-Temperature (° c) 35 30-Dwell time (minutes) 15 30 Burn Conditional atmosphere N2-5% H2 h2 H2 Temperature (° c) 1150 1200 1100 Dwell time (hours) 3 1 0.5 Sintered object thickness (mm) 1.8 2.0 Average pore size (βτη) 250 300 290 Porosity (%) 95.9 96.5 95 Specific surface area (cm2 / cm3) 750 810 41 (Please read the notes on the back to find out and write this page)-Install ·-Order! Γ The size of the paper is applicable to the Chinese National Standard (CNS) A4 (210X297 mm) Economy Printed by A7 B7, Consumer Cooperatives of the Ministry of Standards and Standards of the People's Republic of China 5. Description of Invention (23) A sintered porous metal plate with a three-dimensional skeleton structure and a large specific surface area can be prepared in this way. Depending on the foaming conditions, drying conditions and combustion conditions, it has the following different structures as shown in Figures 9A and 9D; a single honeycomb layer structure as shown in Figure 9A, and a multilayer closed honeycomb structure as shown in Figure 9B. The skeleton structure with a closed surface shown in 9C and the skeleton structure with an open surface shown in Fig. 9D. The three-dimensional skeleton of the sintered porous metal plate of the present invention is also porous, because the skeleton is made of sintered metal. End of the steel. Thus, the sintered porous metal sheet table rather than with a specific surface area BET, for example, 300 to 1 5 0 0 c m 2 / c m 3. In addition, very small bubbles such as 100 or less are easily formed. The sintered metal powder formed has an average pore size of 60 to 600 μm and a porosity of 90 to 98 volume percent. The unsintered metal foam produced by the embodiment of the present invention can be used as the final sintered porous metal plate as a carrier for alkaline battery active materials, hydrolysis electrodes, spray units for oil heaters, magnetic shielding packaging, and Gas expansion buffers in air buffers, sound-absorbing insulation materials, hydrolysis filters for water purifiers, electrostatic filters for air cleaners, oil mist filters for exhaust, deodorizing catalysts for oil heaters, etc., high temperature Dust filters for ducts, substrates made of aluminum filled with pores under high pressure, and industrial catalysts and carriers. Improvements to the previous embodiment of the Qianxian County In the present invention, many modifications different from the previous embodiment can be achieved. The paper size is applicable to the Chinese National Standard (CNS) A4 specification (210X297 mm) ~ 1 ~ -Zb ~ (please first Read the notes on the back again, page on the island.) I. Ordering printed by the Consumer Standards Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs, printed A7 B7 V. Invention Description (24) Good. For example, a resin film which disappears during the burning step of the green sheet 1C and does not affect the sintered metal foam can be used instead of the release agent film 2 in the aforementioned embodiment. This resin film does not shrink during the foaming step of the foaming paste and the drying step, and completely disappears after burning. In addition, the resin film is preferably easily separated from the transport plate. Examples of such resins include amine ester resins. Epoxy resin, thermosetting polyester resin, heat resistant thermoplastic, acrylic resin, polypropylene resin and ethylene vinyl acetate resin. Details are explained below. Examples of usable film forming methods other than the doctor blade 90 include a brush coating method, a sponge roll coating method, and an extrusion method. In addition, a resin film that does not require a film forming step can be used. For example, a roller is used to roll a resin film, and a foam slurry or body formed on the resin film is used to release the film from the roller. The dried slab can be burned with an uncut long element, which is different from the way in which the slab 1 C is cut with a cutter in the previous embodiment. In this example, since the shrinkage of the dried blank 1 C is large, cracking is easily formed as shown. Therefore, it is inevitable that the blank plate shrinks and causes the blank plate to move easily on the conveyor, as shown below; apply a lubricant to the surface of the conveyor to reduce the contact resistance between the blank plate and the conveyor; the conveyor system It is composed of many rollers to reduce the contact area between the blank and the conveyor; or the conveyor is inclined so that the exit position is higher than the entrance position. As described above, according to this embodiment, an unsintered metal plate having a high degree of freedom in metal composition and a large specific surface area can be easily produced. This paper size is applicable to Chinese National Standard (CNS) A4 specification (210 \ 297) --- ^ --- Ί ----- pack-(Please read the note on the back first page 4 of this page) Order _ -27 A7 B7 V. Description of the Invention (25) Specific Example Another preferred specific example of the foamed pulp is the second specific example. · Because an aqueous slurry containing a foaming agent is used in the present invention, the foaming agent may foam before the slurry is formed, thereby making the foamed metal characteristics relatively unstable. This problem will be improved in the second embodiment. When preparing the foamed soy slurry, the slurry components are divided into two aqueous solutions, and the two solutions are mixed before forming. Fig. 10 is a schematic cross-sectional view of an apparatus for continuously preparing, molding, foaming and drying foam paste, as shown in the apparatus shown in the figure. The device includes a foam slurry preparation device 102, a conveying device 300, a release agent film preparation device 11, a molding device 5, a foaming device 40, and a drying device 50. The foam slurry preparing apparatus 102 includes a first mixer for mixing the aqueous solution (A), a second mixer 1 12 for mixing the aqueous solution (B), and a third mixer 1 110. The third mixer mixes the aqueous solutions (A) and (B) fed from the first and second mixers, and sends the foamed slurry S formed after the mixing to the molding device 5. The second mixer 1 1 2 has two feeders for automatically feeding the aqueous solution (B) component. The components of the aqueous solution (A) are fed into the first mixer 113 in a predetermined amount and mixed, and the mixed aqueous solution (A) (shown as Aq (A) in FIG. 10) passes through the tube 1 1 3 a at a predetermined flow rate. Feed to the third mixer 1 1 0. The same 'aqueous solution (B)' component is fed into the second mixer 1 12 at a predetermined number and mixed, and the mixed aqueous solution (B) (indicated by Aq (B) in Fig. 1) is at a predetermined flow rate Via tube 1 1 2 This paper size applies Chinese National Standard (CNS) A4 specification (210X297 mm): --- Ί ---- ^-(Please read the precautions on the back before writing this page) Printed by the Consumer Standards Cooperative of the Ministry of Standards and the Ministry of Economic Affairs Printed by the Consumer Standards Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs A 7 _ B7 V. Invention Description (26) a is fed to the third mixer 1 110. The aqueous solutions (A) and (B) are mixed in a third mixer 110 to prepare a foam slurry S, and the foam slurry S is fed into the foaming machine 5 via a tube 110a. This foam slurry contains metal powder, a water-soluble resin binder, a foaming agent, an active agent and water, and is the same as the first embodiment. The metal powder is gathered on the thin liquid wall around the fine bubbles of the foamed slurry, and the metal powder and the water-soluble resin binder are so cured to maintain the shape of the bubbles. The binder is removed by combustion, and the metal powder is sintered to form a sintered porous metal plate having a three-dimensional network structure. Examples of the metal used as the metal powder include all metals which can be powdered and sintered. Therefore, the metal composition has a high degree of freedom, and for example, many combinations of the plurality of metals and different kinds of metals can be used. In addition, because the metal is sintered, the skeleton itself has a porous structure. Therefore, the sintered porous metal has a relatively large specific surface area. In this example, the components of the foam slurry are divided into two solutions, and this solution is mixed before the feeding molding machine to reduce the volatilization of the foaming agent. . Examples of the components in the solution (A) include a foaming agent, a surfactant, and a water-soluble resin binder. Examples of the components in the solution (B) include metal powder and a water-soluble resin binder. The same foaming agent as in the first embodiment can also be used in the second embodiment. The foaming agent is added to the aqueous solution (A), wherein the foaming agent in the slurry is 0.05 to 10 weight percent, and 0.5 to 5 weight percent is better. If the content is less than 95% by weight, the air bubbles formed The paper size applies the Chinese National Standard (CNS) A4 specification. (210X297 mm) (Please read the precautions on the back before this page) • Packing.
、-IT -29 ' 經濟部中央標準局員工消費合作社印裝 A7 B7 五、發明説明（27) 不足，或者孔率降低。另一方面，含量高過內重量百分比 時，會形成較大之膠微粒。因此，形之胚板和燒結物件可 能會因較大型氣泡生成而降低其強度。 第一具體化實例中使用之相同表面活性劑亦可用於第 二具體化實例，使起泡狀態穩定，並且促進膠微粒生成。 該表面活性劑加入水溶液（A)中，漿體中之表面活性劑 含量爲0· 0 5至5重量百分比，最好是0 . 5至3重量 百分比。當含量低於0.05重量百分比時，膠微粒生成 不穩定，而且無法使細小氣泡保留在漿體中。另一方面， 該含量高於5重量百分比時，效果不會再改善。該表面活 性劑可以同時加入水溶液（A )和（B )中。 該水溶性樹脂黏合劑在漿體乾燥作用中加入，維持蜂 窩狀物件之形狀，並調整該漿體濃度。與第一具體化實例 中相同之水溶性樹脂黏合劑亦可用於第二具體化實例。調 整水溶液（A )之水溶性樹脂黏合劑數量，使其與水溶液 (B)混合後，在泡沫漿體中之濃度爲〇·5至20重量 百分比較佳，2至10重量百分比更佳》用量少於〇 . 5 重量百分比會導致強度過低，無法符合處理需求。另一方 面，用量高於2 0重量百分比會導致黏度增加過多使得成 型特性差。 溶液（A )每一種組份含量如下： 起泡劑：0 . 0 5至1 0重量百分比，特別是0 . 5 ，至5重量百分比 表面活性劑：0 · 0 5至5重量百分比，特別是 本紙張尺度適用中國國家標準（CNS ) A4規格（210.X 297公釐） (請先閱讀背面之注意事項再"寫本頁) 裝·、 -IT -29 'Printed by the Consumer Cooperatives of the Central Bureau of Standards of the Ministry of Economic Affairs A7 B7 V. Explanation of the invention (27) is insufficient, or the porosity is reduced. On the other hand, when the content is higher than the internal weight percentage, larger colloidal particles are formed. As a result, shaped blanks and sintered objects may have reduced strength due to the formation of larger bubbles. The same surfactant used in the first embodiment can also be used in the second embodiment to stabilize the foaming state and promote the generation of colloidal particles. The surfactant is added to the aqueous solution (A), and the content of the surfactant in the slurry is from 0.5 to 5 weight percent, preferably from 0.5 to 3 weight percent. When the content is less than 0.05% by weight, the generation of colloidal particles is unstable, and it is impossible to keep fine bubbles in the slurry. On the other hand, if the content is more than 5 weight percent, the effect will not be improved any more. The surfactant can be added to the aqueous solutions (A) and (B) simultaneously. The water-soluble resin adhesive is added during the drying of the slurry to maintain the shape of the honeycomb object and adjust the concentration of the slurry. The same water-soluble resin adhesive as in the first embodiment can also be used in the second embodiment. After adjusting the amount of water-soluble resin adhesive in the aqueous solution (A) to make it mixed with the aqueous solution (B), the concentration in the foam slurry is preferably 0.5 to 20% by weight, and more preferably 2 to 10% by weight An amount of less than 0.5 weight percent will cause the strength to be too low to meet processing requirements. On the other hand, an amount higher than 20% by weight will result in excessive viscosity increase and poor molding characteristics. The content of each component of the solution (A) is as follows: Foaming agent: 0.5 to 10 weight percent, especially 0.5 to 5 weight percent surfactant: 0. 0 5 to 5 weight percent, especially This paper size applies to China National Standard (CNS) A4 specification (210.X 297 mm) (Please read the precautions on the back before writing this page)
、1T A7 B7 五、發明説明(：28 ) 0 . 5至3百分比 水溶性樹脂黏合劑：0 . 5至2 0重量百分比，.特.別 是2至10百分比 水溶液（A)之黏度於室溫下以50〇〇至 80000cps 較佳，10000 至 4〇〇〇〇cps 更佳。 水溶液（A)係以第一混合器1 1 3將上述組份混合 製得。可以使用諸如葉片混合器和固定混合器之混合器充 作第一混合器1 1 3。 經濟部中央標準局員工消費合作社印製 (請先閲讀背面之注意事項再ir寫本頁) 另一種水溶液（B )包括金屬粉末’水溶性樹脂黏合 劑等’其如前文所述。可使用之金屬不受限制，而且可以 包括所有燒結金屬和鎳，銅，鐵，不銹鋼，鉻，銘，金， 銀等之合金’金屬粉末之平均顆粒大小爲5 〇 〇 vm或以 下’以0 · 5至100 ym更佳。平均顆粒大小小於 0 . 5em時，無法達成預期的孔率。另一方面，平均顆 粒大小超過5 0 0 e m時，燒結多孔性金屬板強度太低。 將該金屬粉末加入溶液（B)中，，其與溶液（a)混合後 ’於泡沬漿體中之含量爲5至8 0重量百分比，以30至 80重量百分比較佳。 可以使用前述任一種水溶性樹脂黏合劑。將水溶性樹 脂黏合劑加入，使水溶液（B )於室溫之黏度爲 20000 至 2000 0 Ocps，以.25000 至 50000cp s較佳。水溶液（B)中每一種組份含量 如下： 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） -31 - 經濟部中央標準局員工消費合作社印製 A7 B7 五、發明説明（29 ) 金屬粉末：5至80重量百分比’特別是5 0至7 0 重量百分比 ‘ 水溶性樹脂黏合劑：0 . 5至2〇重量百分比’特別 是2至1 〇重量百分比 因爲水溶液（B )之黏度高，可以使用—般葉片混合 器和捏和器充作第二混合器1 1 2。 第二具體化實例中之泡沬漿體包括一種增塑劑，—種 促進孔隙生成之可燃性材料，其與前述必要組份不同。雖 然這些添加劑可以加入水溶液（A)或（B )任一者，但 是加入水溶液（B)較佳。 該增塑劑賦予該成型物件可塑性，而且第二具體化實 例中可以使用與第一具體化實例相同之增塑劑。該增塑劑 加入水溶液（A )或（B )，使其於泡沫漿體中之濃度爲 0 . 1至1 5重量百分比，以2至1 0重量百分比更佳。 如果其於泡沬漿體中之含量少於0.1重量百分比，其可 塑性不足。另一方面，其含量高於15重量百分比時該成 型物件之強度不足。 促進孔隙生成之可燃性材料在乾燥成型物件燃燒步驟 中消失，促進孔隙生成。可以使用任何具有形狀，諸如粉 末和纖維，並且可以在燃燒步驟消失之材料。此種材料實 例包括0 . 1至200βιη之粉末和長度爲2〇 Oem以 下，最好是30至120 /zm之纖維。. 混合水溶液（A )和（B )可以製備第二具體化實例 之泡沬漿體。水溶液（A )對水溶液（B )之重量比率（ 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐〉 (請先閲讀背面之注意事項再¥良本頁) 訂 -32 - 經濟部中央標準局員工消費合作社印製 A7 _B7__ 五、發明説明（30 ) A)/(B)在0 . 5/9，5至3/7範圍內，以 0.9/8 至 1.8/7. 5 較佳》 第三混合器l·10之實例包括旋轉螺旋或Z型葉片之 混合器和內部混合器。形成之泡沬漿體在2 0°C時黏度爲 20000 至 700 0 0 cps ，3000 0 至 55000cps較佳。當黏度低於2000cos時， 該蜂窩狀結構會於乾燥步驟中破損。另一方面，黏度超過 70000cps時，該漿體幾乎無法成型。 第二具體化實例所述之裝置中，將第三混合器混合製 得之泡沫漿體進料到起泡機5。因此，可以大幅縮短起泡 劑混入泡沬漿體至漿體進入起泡步驟的時間。 第三具體化'實例 將泡沬漿體之乾燥成型板狀物件進行燒結步驟，形成 一燒結多孔性金屬板。該充作中間產物之乾燥板狀物件易 碎，因此難以運送或貯存。 第三具體化實例中，其目的係提出一種組成材料充作 中間產物，使該乾燥板狀物件易於處理，提出一種製造該 組成材料之方法，和使用該組成材枓製造燒結多孔性金屬 板之方法。 圖10亦爲一種製造第三具體化實例之組成材料。參 照圖1 0將說明其用於製備泡沫漿體部.分以外之零件及其 操作。該組成材料製法以外之方法與第一具體化實例相同 〇 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） ~ ♦ - 00 ^ (請先閱讀背面之注意事項再ifl本頁) •裝· 訂 經濟部中央標隼局員工消費合作社印裝 A7 B7 五、發明説明（3l ) 第三具體化實例中，藉著像輸送帶般移動組成材料運 續製造由胚板和樹脂膜組成之組成材料。 該運送裝置3‘0 0依箭頭方向以輥3 3 2 ’ 3 3 3驅 動（其係由驅動能源驅動，該圖未顯示），像輸送帶一般 移動運送板3 3 1。由該運送板33 1之頭端到終端，該 材料進行3脫模劑製膜步驟，成型步驟’起泡步驟，乾燥 步驟和裁切步驟，其與第一具體化實例相同。 該泡沬漿體由介於刀片6 0與樹脂膜R之間隙擠出’ 形成預定厚度之板》 在脫模劑製模步驟中，如圖1 0中沿著線4 A之剖面 圖（A)所示，在運送板3 3 1上形成樹脂膜R。在樹脂 膜R上形成泡沬漿體。使用刮刀9 0充作脫模劑製膜機1 1。在運送板上，例如，以刮刀90塗上厚度爲0 · 05 至0 . 2 m m之未熟化聚胺甲酸酯，而且在乾燥機1 ◦ 0 中熟化，在運送板3 3 1上形成脫模膜R。可以在脫模樹 脂膜製成之輥上使泡沬漿體成型，代替脫模劑製膜步驟。 在成型步驟中，在樹脂膜R上，以具有二片刀片之刮 刀6 0將泡沬漿體製成厚度爲0 . 1至1 5mm之薄膜， 以0.2至2mm較佳。 運送板3 3 1上之泡沬漿體進入起泡機4 0中，使該 泡沬漿體完全起泡。雖然起泡機4 0可能爲圖7所示之濕 潤器與加熱器型，但是不使用濕潤器與.加熱器型機器亦可 達成高濕、高溫條件。該泡沫漿體於起泡機4 0中起泡 1 0至4 5分鐘。 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） ~ ~ (請先閲讀背面之注意事項再铲1SC、本頁) 訂 經濟部中央標準局員工消費合作社印製 A7 ____B7 _ 五、發明説明（32 ) 該起泡之漿體於圖8所示之乾燥機5 0中乾燥，製得 一種由乾燥板狀物件或胚板G及樹脂膜R組成之組合材料 。適用之乾燥機是一種遠紅外線乾燥機，而且其乾燥條件 與第一或第二具體化實例相同，例如，加熱器溫度爲 1 20至1 80°C，大氣溫度爲40至80°C，乾燥時間 爲2 0至1 2 0分鐘。以此種方式，製備前述圖1〇 (b )壓層在樹脂模R上之乾燥板狀胚板G。該胚板G之厚度 通常是成型後厚度的3至8倍。在運送板上形成圖1 0中 沿著B - B線剖面圖所示，包括該乾燥胚板G與樹脂膜R 之組成材料。 其次，將組成材料1從運送板上分離。最後，以切刀 70裁切成既定長度之組成材料1。 易碎胚孩G2處理可以由具有樹脂R之組成物1改良 。可使用之樹脂膜是會在該乾燥蜂窩狀物件G燒結步驟中 消失，並且不會影響該燒結多孔性金屬板特性者。該樹脂 在起泡作用和泡沬漿乾燥步驟中不會收縮，而且在燒結步 驟中完全消失者較佳。此外，該樹脂最好容易與運送板 3 3 1分離較佳。該樹脂之較佳實例是胺酯樹脂》其它可 使用之樹脂實例包括環氧樹脂，熱固性聚酯，耐熱性熱塑 性樹脂，諸如聚乙烯基樹脂，丁醛樹脂和丙烯酸樹脂。 圖1 0所示之裝置中，該樹脂膜係藉著運送板3 3 1 向輥3 3 2捲動時，與運送板3 3 1分離。將包括乾燥胚 板G與樹脂膜R之組成材料1切刀7 0裁切成預定長度。 並堆起如圖所示。 本紙張尺度適用中國國家標準（CNS)A4規格（ 210X297公釐）_ —00 一 (請先閱讀背面之注意事項再*/4本頁) -裝- 訂 經濟部中央標準局員工消費合作社印製 A7 ___._B7_ 五、發明説明（33 ) 該泡沫漿體可以直接在運送板3 31上直接成型，代 替樹脂膜之用途。 經由第二具體化實例之燒結步驟，使組成材料1轉換 成燒結之多孔性金屬板。 該樹脂膜在去脂步驟中消失。因爲去脂和燒結中，體 積減少大約百分之2 0，因此在一種可滑動板，諸如石墨 板上進行去脂和燒結。該厚度可以藉由燒結步驟後之表層 途徑滾動等控制之。 如上所述，第三具體化實例之組成材料係在樹脂膜上 成型並乾燥該含有金屬粉末之泡沫漿體製得。該組成材料 使該易碎胚板容易處理，運送並貯存。燒結之後，藉由燃 燒該樹脂膜可以製得燒結之多孔性金屬板。可以使用事先 製備之樹脂'膜》或者，在泡沫漿體成型步驟之前才以製膜 步驟形成之樹脂膜上使泡沬漿體成型。較佳之樹脂膜材料 是一種聚胺甲酸酯樹脂，其於泡沫漿體乾燥步驟中縮小得 較少，具有良好之固形性，並且會在燒結過程中消失》 如第三具體化說明，易處理之胚板組成材料可以如前 述方法製作。因此，最後可製得高產率之燒結多孔性金屬 板。 實施例1 — 2 —種包括乾·燥胚板G和樹脂膜R之.組成材料係以與實 施例1 - 1相似方式製備，但是加上樹脂膜製造步驟。 在樹脂膜製造步驟中，在運送板3 3 1上形成樹脂膜 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐）_ 36 _ (請先鬩讀背面之注意事項再本頁) -裝_ -^訂 經濟部中央標準局員工消費合作社印製 A7 _____B7___ 五、發明説明（34 ) R，如圖1 0沿著A_A線之剖面圖（A)。將一種未熟 化聚胺甲酸酯溶液U，例如，以刮刀9 0充作脫模劑製膜 機1 1，在運送板上塗覆例如0 . 05至0 . 3#m厚， 並且於乾燥機1 0 0.中熟化形成運送板3 3 1上之脫模膜 R。 隨後之成型，起泡，乾燥和裁切步驟與實施例1 一 1 相同。 第四息體化眘例 當泡沫漿體同時起泡並乾燥時，該胚板表面先行乾燥 ，因此可能發生起泡不均勻，或者胚板表面產生裂化。 在第四具體化實例中，目的之一係提出一種使泡沬漿 體內部均勻起泡之方法和裝置。 當漿體貯存器放置在地上時，將一種液體介質噴灑在 開放室泡沫漿體表面。雖然該開放室有利於使陷在泡沬漿 體中之氣泡釋放到大氣中，但是開放室中之泡沬漿體表面 同時乾燥。因此，當泡沫漿體供應至開放室時，氣泡會沿 著原有漿體的界面S s U陷在泡沫漿體中。假如該泡沬漿 體之成型板狀物件包括此種氣泡，該多孔性金屬板上會形 成許多因空氣氣泡而產生之意料外的孔隙。因此空氣氣泡 造成之孔隙之孔隙大小與起泡劑形成之孔隙不同，該多孔 性金屬板具有不均匀蜂嵩狀結構。當該.液體介質噴灑在漿 體表面時，漿體表面不會乾屬，因此可以、避免多孔性金屬 板產生不均勻蜂窩狀結構。 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） ~~~ ： • · - 37 - (請先閱讀背面之注意事項再穿1^'頁) •裝. -訂 .經濟部中央標準局員工消費合作社印製 A7 __________ 五、發明説明（35 ) 第四具體化實例之特性係其於泡沫漿體表面噴灑液體 介質。 第四里體化眚例之改良 在第四具體化實例中，該漿體貯存器或開放式3 0具 有濕潤器6 9，用來對漿體S表面噴灑液體介質。由該濕 潤器對漿體表面噴灑液體介質可以避免該漿體貯存器3 0 中之漿體S表面S s u乾燥。此外，氣泡不會陷在該漿體 內部。該噴霧操作可以連續或間斷式進行。 使甩圖3和4所示之二片刀片6 0A，6 Ob充作體 B本具體化實例之刮刀6 0。 實施例2 ' 將一種充作膜模劑（R )之氟碳樹脂分散劑塗在圖1 和10所示之裝置的鋼板中》 在漿體混合機1 0 2之混合器1 1 0中混合水溶液（ A )和水溶液（B )製備泡沫漿體（S )，其中水溶液（ A)含有1 . 5重量百分比之羥丙基甲纖維素，3 0 . 8 重量百分比之縮水甘油，30 · 8重量百分比之己烷，4 重量百分比之十二基苯礎酸鈉，以及均衡水，水溶液（B )含有6 2 · 〇重量百分比平均顆粒大小爲1 〇 vm之純 鎳粉末，2 . 4重量百分比之羥丙基甲.纖維素和均衡的水 。蜂窩狀物件1至9每一者係由下列程序製備；將該泡沫 漿體（S )以表3所示高度之刮刀6 0塗在鋼帶上；泡沫 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） ~ (請先閱讀背面之注意事項再埗1¾本頁) -裝· 訂 經濟部中央標率局員工消費合作杜印製 A7 _ B7 五、發明説明（36) 漿體於表3所示之條件下，調整具有加熱器之濕潤器中加 熱器42，43，44溫度而起泡之；然後該泡沬漿體於 表3所示條件下，·以遠紅外線乾燥機5 0乾燥之。 漿體在濕潤器4 0中之停留時間藉由改變經鋼帶移動 速度調整之。將形成之蜂窩狀物件去脂，並且於5%含氮 氫氣中，以8 5 0 °C預浸燒結3 0分鐘，並於1 2 5 0 °C 下燒結3 0分鐘製得金屬泡沫1至9號》由重量和體積計 算每一種形成金屬泡之孔率。孔隙大小係由光學照相顯微 鏡測量，其以1 0倍放大於1 0僻點上進行。結果如表4 摘要》 爲了比較，以相同之成型和燒結條件製備表4所示之 金屬泡沫1 1至1 4，但是起泡作用於2 0 °C室溫和5 5 %濕度下，'不操高溫濕潤器進行。以相同方法測量孔率和 孔隙大小。 表3和表4明顯地顯示使用高溫濕潤器在預定條件， 例如，本具體化實例中3 5至6 5 °C溫度，7 0 %或以上 濕度下，容易在短時間內成型製造高孔率9 7 %以上之泡 沫金屬。 依本具體化實例該乾燥胚板內部具有均勻蜂窩狀結構 。因此，容易並且一定可以製造金屬組成自由度高以及比 表面積大之燒結多孔性金屬板。 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐）. (請先閱讀背面之注意事項再f本頁)、 1T A7 B7 V. Description of the invention (: 28) 0.5 to 3 percent water-soluble resin adhesive: 0.5 to 20 weight percent, especially. 2 to 10 percent aqueous solution (A) viscosity in the chamber The temperature is preferably 50,000 to 80,000 cps, and more preferably 10,000 to 40,000 cps. The aqueous solution (A) was prepared by mixing the above components with a first mixer 1 1 3. As the first mixer 1 1 3, a mixer such as a blade mixer and a fixed mixer can be used. Printed by the Consumer Cooperatives of the Central Bureau of Standards of the Ministry of Economic Affairs (please read the precautions on the back before writing this page) Another aqueous solution (B) includes metal powder ‘water-soluble resin adhesives’ etc. as described above. The metals that can be used are not limited, and can include all sintered metals and alloys of nickel, copper, iron, stainless steel, chromium, metal, gold, silver, etc. 'The average particle size of the metal powder is 500 vm or less' 5 to 100 ym is better. When the average particle size is less than 0.5em, the expected porosity cannot be achieved. On the other hand, when the average particle size exceeds 500 e m, the strength of the sintered porous metal plate is too low. The metal powder is added to the solution (B), and after mixing with the solution (a), the content of the metal powder in the foam paste is 5 to 80% by weight, and preferably 30 to 80% by weight. Any of the aforementioned water-soluble resin adhesives can be used. The water-soluble resin binder is added so that the viscosity of the aqueous solution (B) at room temperature is 20000 to 20000 Ocps, preferably .25000 to 50000cp s. The content of each component in the aqueous solution (B) is as follows: This paper size applies the Chinese National Standard (CNS) A4 specification (210X297 mm) -31-Printed by the Consumers Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs A7 B7 V. Description of the invention (29 ) Metal powder: 5 to 80% by weight 'especially 50 to 70% by weight' Water-soluble resin binder: 0.5 to 20% by weight 'especially 2 to 10% by weight because of the viscosity of the aqueous solution (B) High, you can use the general blade mixer and kneader as the second mixer 1 1 2. The foam paste in the second embodiment includes a plasticizer, a flammable material that promotes pore formation, which is different from the aforementioned essential components. Although these additives may be added to either the aqueous solution (A) or (B), it is preferable to add the aqueous solution (B). The plasticizer imparts plasticity to the molded article, and the same plasticizer as in the first embodiment can be used in the second embodiment. The plasticizer is added with an aqueous solution (A) or (B) so that its concentration in the foam slurry is 0.1 to 15 weight percent, and more preferably 2 to 10 weight percent. If its content in the foam paste is less than 0.1% by weight, its plasticity is insufficient. On the other hand, when the content is more than 15% by weight, the strength of the molded article is insufficient. The flammable material that promotes void generation disappears during the combustion step of the dried molded object, and promotes void generation. Any material having a shape such as powder and fiber, and which can disappear during the burning step can be used. Examples of such materials include powders of 0.1 to 200 βm and fibers having a length of 20 Oem or less, preferably 30 to 120 / zm. Mixing the aqueous solutions (A) and (B) can prepare the foamed paste of the second embodiment. The weight ratio of aqueous solution (A) to aqueous solution (B) (This paper size applies Chinese National Standard (CNS) A4 specification (210X297 mm) (Please read the precautions on the back before ¥ good page)) Order -32-Ministry of Economy Printed by the Consumer Standards Cooperative of the Central Bureau of Standards A7 _B7__ V. Description of the invention (30) A) / (B) is in the range of 0.5 / 9, 5 to 3/7, and 0.9 / 8 to 1.8 / 7.5 is better 》 Examples of the third mixer l · 10 include a rotating spiral or Z-blade mixer and an internal mixer. The formed foam paste has a viscosity of 20,000 to 70,000 cps at 20 ° C, and 3000 to 55,000 cps. Better. When the viscosity is lower than 2000cos, the honeycomb structure will be damaged during the drying step. On the other hand, when the viscosity exceeds 70,000 cps, the slurry can hardly be formed. In the device described in the second embodiment, the first The foamed slurry prepared by the three mixers is fed to the foaming machine 5. Therefore, the time taken for the foaming agent to be mixed into the foaming slurry to the time when the slurry enters the foaming step can be greatly shortened. The dried and shaped plate-like part of the slurry is subjected to a sintering step to form a sintered porous Metal plate. The dried plate-like object used as the intermediate product is fragile, so it is difficult to transport or store. In the third embodiment, the purpose is to propose a composition material as the intermediate product to make the dried plate-like object easy to handle A method for manufacturing the constituent material and a method for manufacturing a sintered porous metal plate using the constituent material are proposed. FIG. 10 is also a constituent material for manufacturing a third embodiment. Referring to FIG. Parts and operations other than the pulp part. The method other than the method of making the constituent materials is the same as the first embodiment. This paper size applies the Chinese National Standard (CNS) A4 specification (210X297 mm) ~ ♦-00 ^ ( Please read the precautions on the back first, and then ifl this page) • Binding and ordering printed by the Central Bureau of Standards of the Ministry of Economic Affairs and Consumer Cooperatives printed A7 B7 V. Description of the invention (3l) In the third embodiment, it is moved like a conveyor belt Constituent materials continue to manufacture the constituent materials composed of the blank and the resin film. The conveying device 3'0 0 is driven by the roller 3 3 2 '3 3 3 in the direction of the arrow (which is driven by the driving energy Source driven, the figure is not shown), moving the conveying plate 3 3 1 like a conveyor belt. From the end of the conveying plate 33 1 to the terminal, the material is subjected to 3 release agent film forming steps, the forming step 'foaming step, The drying step and the cutting step are the same as the first embodiment. The foam paste is extruded from the gap between the blade 60 and the resin film R to form a plate of a predetermined thickness. In the mold release step, such as As shown in the cross-sectional view (A) along the line 4A in FIG. 10, a resin film R is formed on the transport plate 3 31. A foamed slurry was formed on the resin film R. Using a doctor blade 90 as a mold release agent film making machine 1 1. On the conveying plate, for example, an uncured polyurethane having a thickness of 0.05 to 0.2 mm is coated with a doctor blade 90 and cured in a dryer 1 ◦ 0 to form a peel on the conveying plate 3 3 1 Die film R. Instead of the release agent film-forming step, the foam slurry can be formed on a roll made of a release resin film. In the forming step, on the resin film R, the foamed slurry is made into a film having a thickness of 0.1 to 15 mm, preferably 0.2 to 2 mm, using a doctor blade 60 having two blades. The foaming paste on the conveying plate 3 3 1 enters the foaming machine 40, so that the foaming paste is completely foamed. Although the bubbler 40 may be a humidifier and heater type as shown in FIG. 7, high humidity and high temperature conditions can be achieved without using a humidifier and a heater type machine. The foam slurry was foamed in a foaming machine 40 for 10 to 45 minutes. This paper size applies Chinese National Standard (CNS) A4 specification (210X297 mm) ~ ~ (Please read the precautions on the back before shoveling 1SC, this page) Order printed by the Consumer Standards Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs ____B7 _ 5. Description of the invention (32) The foamed slurry is dried in a dryer 50 shown in FIG. 8 to obtain a composite material composed of a dried plate-like member or blank plate G and a resin film R. The applicable dryer is a far-infrared dryer, and its drying conditions are the same as those of the first or second embodiment. For example, the heater temperature is 120 to 180 ° C, and the atmospheric temperature is 40 to 80 ° C. The time is from 20 to 120 minutes. In this way, the dried plate-shaped blank G laminated on the resin mold R shown in FIG. 10 (b) described above was prepared. The thickness of the blank G is usually 3 to 8 times the thickness after molding. On the conveying plate, a cross-sectional view taken along line B-B in FIG. 10 is formed, including the dry blank G and the resin film R. Next, the constituent material 1 is separated from the transport plate. Finally, the cutter 70 is used to cut the component material 1 of a predetermined length. Fragile embryo G2 treatment can be improved from composition 1 with resin R. A usable resin film disappears during the sintering step of the dried honeycomb article G and does not affect the characteristics of the sintered porous metal plate. It is preferred that the resin does not shrink during the foaming and foam drying steps, and completely disappears during the sintering step. In addition, it is preferable that the resin is easily separated from the transport plate 3 3 1. Preferable examples of the resin are amine ester resins. Other examples of resins that can be used include epoxy resins, thermosetting polyesters, heat-resistant thermoplastic resins such as polyethylene-based resins, butyraldehyde resins, and acrylic resins. In the apparatus shown in FIG. 10, the resin film is separated from the conveying plate 3 31 when the resin film is rolled toward the roller 3 3 2 by the conveying plate 3 3 1. A component material 1 including a dry blank G and a resin film R is cut to a predetermined length. And pile up as shown. This paper size applies to China National Standard (CNS) A4 specification (210X297 mm) _ —00 1 (Please read the precautions on the back before printing on this page * / 4 page) A7 ___._ B7_ 5. Description of the invention (33) The foam slurry can be directly molded on the conveying plate 3 31 instead of the use of resin film. Through the sintering step of the second embodiment, the constituent material 1 is converted into a sintered porous metal plate. The resin film disappeared during the degreasing step. Because the volume is reduced by about 20% during degreasing and sintering, degreasing and sintering are performed on a slidable plate such as a graphite plate. This thickness can be controlled by surface rolling or the like after the sintering step. As described above, the constituent material of the third embodiment is obtained by molding and drying the foam slurry containing metal powder on a resin film. This constituent material makes the fragile blank plate easy to handle, transport and store. After sintering, the sintered porous metal plate can be obtained by burning the resin film. The resin 'film' prepared in advance can be used, or the foamed slurry can be formed on the resin film formed by the film forming step before the foam slurry forming step. The preferred resin film material is a polyurethane resin, which shrinks less during the drying step of the foam slurry, has good solidity, and will disappear during the sintering process. As described in the third embodiment, it is easy to handle The blank material can be made as described above. Therefore, a sintered porous metal plate having a high yield can be finally produced. Example 1-2-A kind including dry and dried blank G and resin film R. The constituent materials were prepared in a manner similar to that in Example 1-1, except that the resin film manufacturing step was added. In the resin film manufacturing step, a resin film is formed on the conveying plate 3 3 1 The paper size applies the Chinese National Standard (CNS) A4 specification (210X297 mm) _ 36 _ (Please read the precautions on the back before this page) -Equipment _-^ Order printed by the Consumer Standards Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs A7 _____B7___ V. Description of the invention (34) R, as shown in Fig. 10 A (A) cross-sectional view along line A_A. An uncured polyurethane solution U, for example, a doctor blade 90 is used as a mold release film forming machine 11, and the conveying plate is coated with a thickness of, for example, 0.05 to 0.3 #m, and applied to a dryer. 1 0 0. Middle-aged to form a release film R on the conveying plate 3 3 1. The subsequent forming, foaming, drying and cutting steps are the same as those in Example 1-11. Fourth case of cautious formation When the foam slurry foams and dries at the same time, the surface of the slab is dried first, so uneven foaming may occur, or the surface of the slab may crack. In the fourth embodiment, one of the objectives is to propose a method and a device for uniformly foaming the inside of the foam paste. When the slurry reservoir is placed on the ground, a liquid medium is sprayed onto the surface of the open-cell foam slurry. Although the open chamber facilitates the release of bubbles trapped in the foamed pulp to the atmosphere, the surface of the foamed pulp in the open chamber is simultaneously dried. Therefore, when the foam slurry is supplied to the open chamber, bubbles will be trapped in the foam slurry along the interface S s U of the original slurry. If the shaped plate-like member of the foamed slurry includes such bubbles, the porous metal plate will form many unexpected pores due to air bubbles. Therefore, the pore size of the pores caused by air bubbles is different from the pores formed by the foaming agent, and the porous metal plate has an uneven bee-like structure. When the liquid medium is sprayed on the surface of the slurry, the surface of the slurry will not dry out, so it is possible to avoid the non-uniform honeycomb structure of the porous metal plate. This paper size applies Chinese National Standard (CNS) A4 specification (210X297 mm) ~~~: • ·-37-(Please read the precautions on the back before wearing 1 ^ 'pages) • Packing.-Order. Central Ministry of Economic Affairs Printed by the Consumer Bureau of Standards Bureau A7 __________ V. Description of Invention (35) The fourth embodiment is characterized in that it sprays liquid medium on the surface of foam slurry. Improvement of the fourth example of the internalization of the slurry In the fourth embodiment, the slurry reservoir or open 30 has a humidifier 69, which is used to spray the surface of the slurry S with a liquid medium. Spraying a liquid medium on the surface of the slurry by the humidifier can prevent the surface S s u of the slurry S in the slurry reservoir 30 from drying out. In addition, air bubbles will not be trapped inside the slurry. This spraying operation can be performed continuously or intermittently. The two blades 60 0A and 6 Ob shown in Figs. 3 and 4 are made to act as the body B of the scraper 60 of the embodiment. Example 2 ′ A fluorocarbon resin dispersant used as a film mold agent (R) was applied to a steel plate of the apparatus shown in FIGS. 1 and 10》 mixed in a mixer 1 10 of a slurry mixer 10 2 An aqueous solution (A) and an aqueous solution (B) are used to prepare a foam slurry (S), wherein the aqueous solution (A) contains 1.5% by weight of hydroxypropyl methylcellulose, 30.8% by weight of glycidol, 30.8% by weight Percent hexane, 4 weight percent sodium dodecyl benzoate, and balanced water. The aqueous solution (B) contains 6 2. 0 weight percent pure nickel powder with an average particle size of 1 0 vm, 2.4 weight percent Hydroxypropyl methylcellulose and balanced water. Each of the honeycomb objects 1 to 9 was prepared by the following procedure; the foam slurry (S) was coated on a steel strip with a doctor blade 60 of the height shown in Table 3; the paper size of the foam was applicable to the Chinese National Standard (CNS) A4 specifications (210X297 mm) ~ (Please read the precautions on the back before going to 1¾ of this page)-Binding and ordering. Staff consumption cooperation of the Central Standards Bureau of the Ministry of Economic Affairs. Printing A7 _ B7 V. Description of the invention (36) Paste Under the conditions shown in Table 3, adjust the temperature of the heaters 42, 43, 44 in the humidifier with a heater to foam; then, the foam paste is under the conditions shown in Table 3, and the far-infrared dryer 5 0 dry it. The residence time of the slurry in the humidifier 40 was adjusted by changing the speed of movement through the steel belt. The formed honeycomb pieces were degreased and pre-soaked and sintered at 850 ° C for 30 minutes in 5% nitrogen-containing hydrogen, and sintered at 1250 ° C for 30 minutes to obtain metal foams 1 to No. 9 "calculates the porosity of each metal bubble formation by weight and volume. The pore size was measured by an optical photomicroscope, which was performed at 10 outliers at 10x magnification. The results are summarized in Table 4. For comparison, the metal foams 1 to 14 shown in Table 4 were prepared under the same molding and sintering conditions, but the foaming effect was at 20 ° C room temperature and 55% humidity. High-temperature humidifier. The porosity and pore size were measured in the same way. Tables 3 and 4 clearly show that using a high-temperature humidifier under predetermined conditions, for example, in this embodiment, at a temperature of 35 to 65 ° C and a humidity of 70% or more, it is easy to mold and produce high porosity in a short time. More than 97% of metal foam. According to this embodiment, the dried embryonic plate has a uniform honeycomb structure inside. Therefore, a sintered porous metal plate having a high degree of freedom in metal composition and a large specific surface area can be easily and certainly manufactured. This paper size is applicable to China National Standard (CNS) A4 specification (210X297 mm). (Please read the precautions on the back before f this page)
、tT 線 一 _ A7 B7 經濟部中央標準局員工消費合作社印製 五、發明説明（37) 表 3 樣品 起 泡 條 件 刮刀 高度 mm 高溫濕潤器(起海條件） 遠紅外線乾燥機 溫度 °c 濕度 Y% 停留時間 分 加熱器 濃度°C 氣氛溫度 °c 使用本 發明高 溫濕潤器 1 0.10 35 95 15 140 40 2 0.10 50 75 15 140 40 3 0.30 65 80 5 160 45 4 0.30 40 95 20 140 40 5 0.50 35 90 30 140 40 6 0.50 50 70 15 160 45 7 0.10 25 65 10 140 40 8 0.30 30 60 20 140 40 9 0.50 30 65 15 160 45 不使用 1 1 0.10 20 55 5 140 40 1 2 0.30 20 55 15 140 40 1 3 0.30 20 55 30 160 45 1 4 0.50 20 55 60 160 45 •--(請先閱讀背面之注意事項再fl本頁) 裝· 泉 本紙張尺度適用中國國家標準（CNS ) A4規格（210'〆297公釐）·And tT line 1_ A7 B7 Printed by the Consumer Cooperatives of the Central Standards Bureau of the Ministry of Economic Affairs 5. Description of the invention (37) Table 3 Sample foaming conditions Blade height mm High temperature humidifier (sea condition) Far infrared dryer temperature ° c Humidity Y % Dwell time minutes Heater concentration ° C Atmospheric temperature ° c Using the high-temperature humidifier of the present invention 1 0.10 35 95 15 140 40 2 0.10 50 75 15 140 40 3 0.30 65 80 5 160 45 4 0.30 40 95 20 140 40 5 0.50 35 90 30 140 40 6 0.50 50 70 15 160 45 7 0.10 25 65 10 140 40 8 0.30 30 60 20 140 40 9 0.50 30 65 15 160 45 Not used 1 1 0.10 20 55 5 140 40 1 2 0.30 20 55 15 140 40 1 3 0.30 20 55 30 160 45 1 4 0.50 20 55 60 160 45 •-(Please read the precautions on the back before fl page) Packing · The size of the paper is applicable to the Chinese National Standard (CNS) A4 (210 ' 〆297 mm) ·
A B7 經濟部中央標隼局員工消費合作社印製 五、發明説明（令没） 表 4 樣品 金屬泡沬特性 多孔性 % 孔隙大小 β m 使用本 發明高 溫濕潤器 1 97.5 206 2 97.7 210 3 97.1 180 4 98.4 225 5 98.7 262 6 97.4 214 7 95.5 255 8 96.3 218 9 96.1 216 不使用 11 92.5 265 12 94.6 286 13 95.5 314 14 96.0 328 (請先閱讀背面之注意事項再#氣本頁) .裝. 訂 本紙張尺度適用中國國家操準（CNS ) A4規格（210X 297公釐） -4./ 經濟部中央標準局員工消費合作社印製 A7 B7 五、發明説明（39 ) 第五具體化實例 第五具體化實例包括一種脫脂並燒結第一具體化實例 中成型之未燒結金屬泡沬製造燒結多孔性金屬板之方法和 裝置，以及形成之燒結多孔性金屬板》 圖1 2是顯示製造本發明第五具體化實例燒結之多孔 性金屬板方法之流程圖。 燒結多孔性金屬板係將圖2所示經由脫模劑製膜，脫 模膜乾燥，成型，起泡和乾燥步驟製成之未燒結金屬泡沬 經由圖1 2所示之脫脂和燒結步驟製得》 圖1 3是進行圖1 2方法製造燒結多孔性金屬板之裝 置剖面圖。圖1. 3與圖1相同，但是另外包括用於脫脂和 燒結步驟之機器。本方法中，製造未繞.結金屬泡沬之裝置 和操作基本上與第一具體化實例相同。 脫脂>驟係指預浸燒結步驟，因爲其爲一種烘烤步驟 ，因此，正式燒結步驟稱爲最終燒結步驟。 脫脂步驟 脫脂步驟中，以300至700 °C溫度下，於空氣或 還原氣氛諸如氫中烘烤未燒結蜂窩狀物件1 0至6 0分鐘 ，以揮發有機材料。 TF式燒結步驟 正式燒結步驟中，以8 0 0至1 4 0 0°C溫度於一種 氨分解氣氛，一種還原氣氛諸如氫，於真空或於空氣中， 冢紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐）_ 42 _~ (請先閱讀背面之注意事項再貧鳥本頁) :裝· 訂 經濟部中央標準局舅工消費合作社印製 A7 ____B7_ 五、發明説明（40 ) 依使用之金屬特性供烤該脫脂蜂窩狀物件2 0至1 2 0分 鐘，以燒結該金屬粉末。因爲脫脂和燒結時體積縮小大約 2 0%，所以這些步驟最好在一個可滑動板上進行。該燒 結物件之厚度可由表層滾動途徑等控制。該脫脂和燒結作 用可以依序進行。 第艽县體化實例之裝置 如圖1 3所示之第五具體化實例之裝置包括一個成型 機部分2 0 1 ，其如第一具體化實例圖1中所示之裝置， 以及第五具體化實例中加入之燃燒部分2 0 2。圖1 3之 圖亦包括一個運送系統。 成型機部.分2 0 1與圖1用於製造未燒結金屬泡沫者 相同。該成'型機由第一輥1 5 3之側至第二輥1 5 4之側 ，其包括脫模劑膜塗覆機1 1，暖氣乾燥機i 0 0，漿體 貯存器3 0，漿體成型用刮刀，起泡用高溫濕潤器4 0 , 和製得該未燒結金屬泡沬之乾燥機5 0。 該成型機部分201具有第一輥153(相當於圖1 之輥20)與第二輥154(相當於圖1輥21)以運送 鋼運送板1 51。該運送板1 5 1在第一輥和第二輥 1 5 3，1 5 4之間運送，充作運輸帶（運輸裝置）.。 脫模劑塗覆機1 1具有脫模劑貯存器8 0和塗覆脫模 劑用之刮刀9 0 ，如第一具體化實例。.該脫模劑貯存器 8 0是長方形平行六面體，其安裝於接近第一輥1 5 3之 運送板1 .5 1上，而該刮刀安裝於脫模劑貯存器8 0之下 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） 71 ~ -4〇 - (請先閲讀背面之注意事項再irt本頁) 裝. 訂 經濟部中央標準局員工消費合作社印製 A7 B7 五、發明説明（41 ) 游壁，如此使其與運送板1 5 1維持預定間隙。當脫模劑 0"諸如氟碳分散劑進料到漿體貯存器1 5 1 ’並使 運送帶1 5 1運送時，該脫模劑’80'由刮刀90與運 送板1 5 1之間隙擠出，形成預定厚度之膜。該塗覆腠沿 著運送板1 5 1移到下一個脫模劑乾燥機1 00。 同第一具體化實例，可以使用諸如暖氣乾燥機和遠紅 外線乾燥機等乾燥機充作脫模劑乾燥機1 〇 〇，以固化脫 模劑之塗覆膜。形成之脫模劑膜充作燒結多孔性金屬板之 運送帶，並且於燒結步驟中將其燒掉去除之。進行脫模劑 膜生成作用使下文所述易碎乾燥胚板容易處理。 漿體貯存器（室）3 0是長方形平行六面體，其安裝 於脫模劑乾燥機1 0 0下游之運送片1 5 1上’與第一具 體化實例相同。該漿體貯存器3 0之上游壁具有與運送板 〃 1 5 1 "具有預定間隙之刮刀6 0。成型物件1 A之厚 度可以藉由刮刀6 0與運送板151之間隙調整之。當泡 沬漿體進料到漿體貯存器3 0並移動運送板1 5 1時，該 泡沬漿體係.由介於刮刀6 0與運送板1 5 1之間隙擠出， 製成預定厚度之板狀物件1 A。在漿體貯存器3 0上方具 有製備進料到該漿體貯存器3 0之泡沫漿體之泡沫漿體混 合器》該泡沫漿體混合器具有含起泡劑溶液之貯存器 1 13，合金屬粉末溶液貯存器11 2，以及混合這二個 貯存器進料之材料製成泡沬漿體S之捏合機1 1 〇。將泡 沫漿體之組份分成二種溶液，並在該漿體進料到刮刀之前 才混合之可以有效避免起泡劑揮發。 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） " -44 - (請先閲讀背面之注意事項再¥烏本頁.) 裝. 訂_ A7 _______ B7 五、發明説明（42) 泡沬漿體可以以與第一或第二具體化實例相同之方式 製備》 該高溫濕潤器4 0與具體化實例1中圖7所述者相同 。圖1 3之高溫濕潤器4 0具有長方形平行六面體爐4 6 ，其包圍運送板1 5 1之運送途徑並形成運送板1 51上 方和下方之封閉空間。爐4 6之上游（第一輥1 5 3之側 )壁上具有運送板1 5 1用之入口。另一方面，爐4 6之 下游（第二輥1 5 4之側）壁具有一個運送板1 5 1用之 出口。運送板1 5 1下方之下層空間充作貯水器，其含有 既定數量的水4 5充作濕度來度。其它構造和操作與圖7 所示者相同。 將起泡物件1 B由起泡用之高溫濕潤器4 0運至包括 乾燥機5 0之乾燥區》 該乾燥機5 0與圖8所示者相同。乾燥條件與第一具 體化實例相周。圖1 3具體化實例中，當第二輥1 5 4轉 動時該胚板或乾燥板狀物件與向下彎曲之運送板分離》 經濟部中央標準局員工消費合作社印製 (請先閲讀背面之注意事項再伊#本頁) 將乾燥胚板1 C送到燃燒部分2 0 2。在燃燒部分進 行之金屬泡沬燒結作用包括二個步驟，例如去除有機組份 ，諸如黏合劑之第一或去脂步驟，和燒結該金屬粉末之第 二或正式燒結步驟。在同一個平面上依序進行這些步驟， 其中該板狀物件爲極易碎狀態之時間縮短，因此，形成之 燒結物件品質穩定。 該脫脂和預燒結步驟可以在空氣，氮氣氛或一種還原 氣氛諸如氫氣（視情況需要含有氮）下*以3 0 0至 本紙張尺度適用中國國家標隼（CNS ) A4規格（210X 297公釐） 』「 -45 一 經濟部中央標準局員工消費合作社印製 A7 B7 五、發明説明（43 ) 9 0 0 °C溫度或7 0 0至9 0 0°C下進行1 0至6 0分鐘 製備多孔性金屬板。該正式燒結步驟視使用之金屬而定， 最好在還原氣氛”諸如分解氨氣或氫氣，於真空，於空氣 或於氮氣下，以800至14 0 0 °C或1000至1 0°c溫度下進行2 0至1 2 0分鐘製備多孔性金屬板。 圖1 3中，燃燒部分具有脫脂/預燒結爐1 7 0和沿 著運送方向之正式燒結爐1 8 0。該脫脂/預燒結爐 1 7 0具有一個鋼帶之運送板，其由具有驅動單位之第一 輥和第二輥驅動，並充作輸送帶（運輸裝置）。該脫脂/ 預燒結爐1 7 0是長方形隧道式爐，其在運送板17 4上 方形成封閉空間。.運送板1 74之入口位於該爐第一輥 172之上游側壁，出口176位於該爐第二輥173之 下游側壁。_ 脫脂/預燒結爐1 7 0視燒結金屬而定，可能以一種 .鎳鉻合金線路加熱器，一種Mo加熱器，一和S i C加熱 器或一種W加熱器加熱。 潤滑劑.塗覆機1 61位於第一輥下方，與運送板 1 7 4連接，因此在運送乾燥胚板1 C之前在運送板 1 7 4表面塗上潤滑劑。 去脂/預燒結步驟用意在使有機組份諸如胚板1.C之 黏合劑揮發。因爲本步驟中胚板會產生輕微收縮，塗於運 送板1 7 4表面之潤滑劑使運送板1 74和乾燥胚板1 C 之間滑動順利，因此吸收該胚板因收縮導致之變形。適用 之潤滑劑實例包括液態和固態石墨，瀝青，矽，氮化硼和 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） ~ -46 - (請先閲讀背面之注意事項再#寫本頁) -裝- ί訂 經濟部中央標準局員工消費合作社印製 A7 _B7_ 五、發明説明（44 ) 碳化矽》 雖然使用鋼帶充作本具體化實例之運送板’但是亦可 使用更耐熱之金屬’諸如不録鋼’以鎮爲底之耐熱合金和 組合金。 在脫脂/預燒結爐1 7 0中將乾燥胚板1 C脫脂並預 燒結，形成脫脂板1 D。將脫脂板1 D自第二輥1 7 3上 運送板1 7 4移動分離’並進料到正式燒結爐1 8 0 ° 正式燒結作用 正式燒結爐1 8 0是長方形隧道式爐，其形成一個密 、閉空間，與脫脂/預燒結爐1 7 〇相同。脫脂板1 D之入 口 1 8 5位於正式爐1 8 0之上游側壁，而出口1 8 6位 於正式爐下游側壁》在正式爐1 8 0中自入口 1 8 5至出 口 1 8 6依序安裝許多運送輥1 8 2，形成一個作爲連續 繞結爐床之輥狀爐床1 8 3。每一個運送輥1 8 2由驅動 單位（該圖未顯示）獨立地，部分地或者全部一起依運送 方向轉動。該輥狀爐床1 8 3延伸到脫脂/預燒結爐 1 7 0之第二輥附近，並延伸至出口 1 8 6外面。該脫脂 板1 D在許多依運送方向旋轉之運送輥1 8 2上移動，並 與該運送輥接觸。 輥狀爐床1 8 3之運送輥1 8 2間距係依脫脂板1 D 之厚度和孔率，其燒結狀態等決定。因.爲間距過大會無法 充分支撐該脫脂板，所以必須決定適當距離。例如，該間 距大約爲2 5至7 0 mm範圍內。在入口 1 8 5及其附近 本紙張尺度適用中國國家標準（CNS〉A4規格（210Χ297公釐） (請先閲讀背面之注意事項再矿^-本頁) •裝. 訂 -47 - 經濟部中央樣準局員工消費合作社印製 A7 B7 五、發明説明（45 ) ，運送輥之間距必須較短。 亦可使用許多球形或橢圓球形元件代替運送輥’充作 —種運輸裝置，其以一個接觸點支撐該脫脂板1 D。此種 線或點接觸裝置僅於造成脫脂板1 D大幅縮小部份使角， 其它部分可以使用任何慣用運輸裝置，諸如輸送帶。該線 或點接觸裝置可充作脫脂/預燒結爐1 7 0之運輸裝置。 當鎳泡沬於1 2 0 0 °C燃燒時，該金屬板因燒結而縮 小大約2 0%。使用慣用帶狀爐時，製得之燒結多孔性金 屬板長度至多數公分。相對的，本具體化實例中，由上述 運輸裝置可以製得長形燒結多孔性金屬板1E。詳細地說 ，因爲蜂窩狀物件在許多滾動物件上以線或點接觸方式移 動，該蜂窩狀物件與該運輸裝置之間的揆觸阻力很小，該 蜂窩狀物件'在滾動物件上容易滑動，因此該蜂窩狀物件之 收縮容易達成。因爲收縮造成之變形已被吸收，可以避免 因收縮造成之裂化。 每一個轉動元件1 8 2之轉動速率最好依收縮量調整 。例如將出口之轉動速率設定得比入口小，容易進行不會 產生變形之收縮。 正式燒結爐18 0分成許多隔間，特別是至少3個隔 間，其中這些隔間之溫度依運送方向升高逐漸燒結該蜂窩 狀物件。在此種正式燒結爐18 0中，可以避免迅速加熱 造成之裂化，因此可以穩定進行燒結作用》 該正式燒結爐1 8 0中依該運送方向其加速速率由2 升至5 0 °C /分鐘較佳，由3至30°C/分鐘更佳。 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） ~ ~ -48 - (請先閱讀背面之注意事項再#幕本頁) -裝. 訂 經濟部中央標準局負工消費合作社印製 A7 __B7___ 五、發明説明（仙） 該正式爐1 8 0中裝置之加熱器並不限定於脫脂/預 燒結爐1 7 0所用者，而且可以由例如鎳鉻合金加熱器， Mo加熱器，S i‘C加熱器和W加熱器中適當選擇之。 形成之燒結金屬板1 E由正式燒結爐1 8 0送出，以 一個捲動機191捲成連續捲式長條192。 燒結金屬板1 E之厚度視情況需要，可以由滾動表層 途徑等控制。輥之滾動速率72由下列等式表示： ν2=ν!Χ (100-S)/100 其中S表示燒結金屬之最終收縮率，而Vi表示燃燒 機中運送板移動速度。 可以以'此種方式製造具有立體骨架結構和比表面積大 之燒結多孔性金屬板。形成之燒結多孔性金屬板視其漿體 製備起泡條件，乾燥條件和燃燒條件而定，具有圖9 A和 9 D所示之下列不同蜂窩狀結構；圖9 A所示之單一蜂窩 狀層結構，圖9 B所示多層封閉氣室結構，圖9 C所示， 表面封閉骨架結構和圖9 D所示表面開放骨架結構。 本發明燒結之多孔性金屬板之立體骨架本身亦爲多孔 狀，其係因爲該骨架由燒結金屬製成之故。因此，燒結多 孔性金屬板之比表面積，例如有3 0 〇至1 5 〇 0 c m2/c m3，作爲be T比表面積。.此外，容易形成非 常小之氣室’例如1 0 0 4 m或以下者。形成之燒結金屬 粉末平均顆粒大小爲6 0至6 0 0 ji/m，而孔率爲90至 本紙張尺度適用中國國家標準（CNS ) A4規格（210x297公董)~ ~ (請先閲讀背面之注意事項再寫本買) -裝· 訂· 經濟部中央標準局員工消費合作社印製 A7 _______B7__ 五、發明説明（47 ) 9 8體積百分比。 依下文製備一種燒結金屬板充作對照實例；鎳蒸發@ ，在市售賦予傳導性之聚胺甲酸酯泡沬內側表面成爲 0 · 5 厚，將該泡沬浸入一種硫酸鎳溶液中；以ϊ A/ dm2電流密度對該泡沫進行電鍍充作負極，在該泡 沬開放式電池表面形成平均厚度7 5〆〇!之鎳電鍍層，將 板狀泡沫停留在1 1 0 0°C氫氣流下0 . 5小時，去除該 聚胺甲酸酯泡沫。形成之燒結多孔性金屬板直徑5 〇mm ，長度1 0 Omm。以實施例1 一 1相同方法測量該燒結 金屬板孔隙大小’孔率和B E T比表面積。結果示於表2 〇 本發明具體化實例之燒結多孔性金屬板可以充作鹼性 蓄電池電極之活性材料載體，水解電極，油加熱器之噴霧 單位，磁性屏蔽包裝，使用爆炸物之空氣緩衝器之氣體膨 脹緩衝物，吸音絕緣材料，淨水器之水解過濾器，空氣清 淨器之靜電過濾器，排氣用之油霧過濾器，油加熱器等所 甩之除臭觸媒，高溫導管用之粉塵過濾器，高壓下孔隙中 裝填鋁之組成材料基板，以及工業觸媒和載體。 本發明並不限於前述具體化實例，而且可以在本發明 範疇中改良之。 第五具體化說明中，該燃燒機包括二個月於脫脂/預 燒結步驟和正式燒結步驟。然而，這二.個步驟可以在一個 以壁隔成二個空間之爐中達成。此外，脫脂步驟可以由燃 燒機淘汰。 本紙張尺度適用中國國家標準（CNS ) A4規格（210X297公釐） ~ 一 -50 - (請先閣讀背面之注意事項再^^本頁) •裝· 訂 A7 B7 五、發明説明（48 ) 第二至第四具體化實例亦可以適用於第五具體化實例 〇 第五具體化實例中之燒結方法亦適於與製造燒結多孔 性金屬板方法不同，用以製造封閉式金屬板和金屬箔蓮續 長條之方法。此外，該燒結方法亦適用於製造具有均勻部 面之長形燒結體，諸如桿子或管子。除此之外，該燒結方 法亦適用於製造長形燒結陶瓷物件之方法。 依第五具體化實例，可以容易而且穩定製造一種比表 面積大，而且金屬組成自由度高之燒結多孔性金屬板。此 外，容易以一種粉末冶金方法等製得長形燒結物件。 (請先聞讀背面之注意事項再積窝本頁) •堯' 言 經濟部中央標準局員工消費合作社印製 1紙張尺度適用中關家標準（{：叫八4規格（21()><297公瘦)-51 -A B7 Printed by the Consumers' Cooperative of the Central Bureau of Standards, Ministry of Economic Affairs. 5. Description of the invention (Lim) Table 4 Sample metal foam characteristics Porosity% Pore size β m Using the high temperature humidifier of the present invention 1 97.5 206 2 97.7 210 3 97.1 180 4 98.4 225 5 98.7 262 6 97.4 214 7 95.5 255 8 96.3 218 9 96.1 216 Not used 11 92.5 265 12 94.6 286 13 95.5 314 14 96.0 328 (Please read the precautions on the back before ## this page). Binding. Order This paper size applies to China National Standards (CNS) A4 (210X 297 mm) -4./ Printed by the Consumers' Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs A7 B7 V. Description of the invention (39) Fifth specific example Fifth specific Examples include a method for degreasing and sintering the unsintered metal foam formed in the first embodiment to produce a sintered porous metal plate, and the formed sintered porous metal plate. FIG. 12 shows the fifth method of manufacturing the present invention. A flowchart illustrating a method for sintering a porous metal plate. The sintered porous metal plate is made of the unsintered metal foam produced in the steps shown in FIG. 2 through a release agent, and the release film is dried, molded, foamed and dried. Figure 13 is a sectional view of an apparatus for manufacturing a sintered porous metal plate by the method shown in Figure 12. Figure 1.3 is the same as Figure 1, but additionally includes a machine for degreasing and sintering steps. In this method, the device and operation for manufacturing an unwound metal junction are basically the same as those of the first embodiment. The degreasing step refers to a prepreg sintering step because it is a baking step, so the formal sintering step is called the final sintering step. Degreasing step In the degreasing step, the unsintered honeycomb article is baked at a temperature of 300 to 700 ° C in air or a reducing atmosphere such as hydrogen for 10 to 60 minutes to volatilize the organic material. TF-type sintering step In the formal sintering step, an ammonia decomposition atmosphere and a reducing atmosphere such as hydrogen are used at a temperature of 800 to 14 0 ° C, a vacuum or in the air. The Chinese paper standard (CNS) A4 specifications (210X297mm) _ 42 _ ~ (Please read the precautions on the back and then the poor bird page): Binding and ordering printed by the Central Standards Bureau of the Ministry of Economic Affairs and Consumer Cooperatives A7 ____B7_ V. Description of the invention (40) The metal characteristics used are to bake the defatted honeycomb article for 20 to 120 minutes to sinter the metal powder. Because the volume is reduced by approximately 20% during degreasing and sintering, these steps are best performed on a slideable plate. The thickness of the sintered object can be controlled by the surface rolling path and the like. The degreasing and sintering actions can be performed sequentially. The device of the first embodiment of the second embodiment is shown in FIG. 13. The device of the fifth embodiment includes a molding machine section 2 01, which is the device shown in the first embodiment of FIG. 1, and the fifth embodiment. The combustion part 2 02 was added in the example. Figure 13 also includes a delivery system. The molding machine section 2 0 1 is the same as that used in FIG. 1 for manufacturing green metal foam. The forming machine is from the side of the first roller 153 to the side of the second roller 154, and includes a mold release film coating machine 1 1, a heating dryer i 0 0, and a slurry reservoir 30. A scraper for slurry forming, a high-temperature humidifier 40 for foaming, and a dryer 50 for preparing the unsintered metal foam. The forming machine section 201 has a first roller 153 (corresponding to the roller 20 in Fig. 1) and a second roller 154 (corresponding to the roller 21 in Fig. 1) to convey the steel conveying plate 151. The transport plate 1 5 1 is transported between the first roller and the second roller 1 5 3, 1 5 4 and serves as a transport belt (transport device). The release agent coating machine 11 has a release agent reservoir 80 and a blade 90 for applying the release agent, as in the first embodiment. The release agent reservoir 80 is a rectangular parallelepiped, which is mounted on a transport plate 1.5 which is close to the first roller 153, and the scraper is installed below the release agent reservoir 80. The paper size applies the Chinese National Standard (CNS) A4 specification (210X297 mm) 71 ~ -4〇- (Please read the precautions on the back before irt this page). Order. Printed by the Consumers Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs. Printed A7 B7 V. Description of the invention (41) Swimming wall, so that it maintains a predetermined gap with the transport plate 151. When the release agent 0 " such as a fluorocarbon dispersant is fed to the slurry reservoir 1 5 1 'and the conveyer belt 1 5 1 is conveyed, the release agent' 80 'is removed by the gap between the scraper 90 and the conveyer plate 1 5 1 Extruded to form a film of a predetermined thickness. The coating roller moves along the conveying plate 1 51 to the next release agent dryer 100. As in the first embodiment, a dryer such as a heating dryer and a far-infrared dryer can be used as the release agent dryer 100 to cure the coating film of the release agent. The formed release agent film was used as a conveyor belt for sintering a porous metal plate, and it was burned off in the sintering step to remove it. Performing the release agent film-forming action makes the fragile, dry slabs described below easy to handle. The slurry reservoir (chamber) 30 is a rectangular parallelepiped, and it is installed on the transport sheet 15 1 downstream of the mold release dryer 100 0 ', which is the same as the first embodiment. An upstream wall of the slurry reservoir 30 has a scraper blade 60 having a predetermined gap with the conveying plate 〃 1 5 1. The thickness of the molded article 1 A can be adjusted by the gap between the scraper 60 and the transport plate 151. When the foam slurry is fed to the slurry reservoir 30 and the conveying plate 15 is moved, the foam slurry system is extruded from the gap between the scraper 60 and the conveying plate 1 51 to make a predetermined thickness. Plate-like pieces 1 A. Above the slurry reservoir 30, there is a foam slurry mixer for preparing foam slurry to be fed into the slurry reservoir 30. The foam slurry mixer has a reservoir 1 13 containing a foaming agent solution. A metal powder solution reservoir 112, and a kneader 1 1 0 for mixing the materials fed from the two reservoirs to make a foam slurry S. Separating the components of the foam slurry into two solutions and mixing the slurry before feeding it to the doctor blade can effectively prevent the foaming agent from evaporating. This paper size applies Chinese National Standard (CNS) A4 specification (210X297mm) " -44-(Please read the precautions on the back before the ¥ Usage page.) Binding. Order _ A7 _______ B7 V. Description of the invention (42 ) The foam paste can be prepared in the same manner as the first or second embodiment. The high-temperature humidifier 40 is the same as that described in FIG. 7 in embodiment 1. The high-temperature humidifier 40 of FIG. 13 has a rectangular parallelepiped furnace 46, which surrounds the conveying path of the conveying plate 151 and forms a closed space above and below the conveying plate 151. The wall upstream of the furnace 46 (side of the first roller 153) has an inlet for the conveying plate 151. On the other hand, the wall downstream of the furnace 46 (on the side of the second roller 154) has an outlet for the conveying plate 151. The lower space below the transport plate 1 5 1 is used as a water reservoir, which contains a predetermined amount of water 4 5 for humidity. Other constructions and operations are the same as those shown in FIG. The foaming object 1 B is transported from the high-temperature humidifier 40 for foaming to a drying area including a dryer 50. The dryer 50 is the same as that shown in FIG. 8. The drying conditions were similar to those of the first embodiment. Figure 13 In the embodiment, when the second roller 1 5 4 is rotated, the blank or dried plate is separated from the downwardly bent transport plate. Printed by the Consumer Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs (please read the back Cautions #I) This page) Send the dried blank 1 C to the combustion section 2 02. The sintering of metal foam in the combustion section includes two steps, such as the removal of organic components, such as a first or degreasing step of a binder, and a second or formal sintering step of sintering the metal powder. These steps are sequentially performed on the same plane, wherein the time for the plate-like object to be extremely fragile is shortened, and therefore, the quality of the sintered object formed is stable. The degreasing and pre-sintering steps can be performed in air, nitrogen atmosphere or a reducing atmosphere such as hydrogen (containing nitrogen as needed) * 300 to this paper size. Applicable to China National Standard (CNS) A4 (210X 297 mm) ） "-45 A7 B7 printed by the Consumer Cooperatives of the Central Bureau of Standards of the Ministry of Economic Affairs 5. Description of the invention (43) 90 ° C or 70 ° C to 90 ° C for 10 to 60 minutes Porous metal plate. This formal sintering step depends on the metal used, preferably in a reducing atmosphere "such as decomposing ammonia or hydrogen, under vacuum, in air or under nitrogen at 800 to 1 400 ° C or 1000 to A porous metal plate was prepared at a temperature of 10 ° C for 20 to 120 minutes. In Fig. 13, the combustion section has a degreasing / pre-sintering furnace 170 and a formal sintering furnace 180 in the conveying direction. The degreasing / pre-sintering furnace 170 has a steel belt conveyor plate, which is driven by a first roller and a second roller having a driving unit, and serves as a conveyor belt (transport device). This degreasing / pre-sintering furnace 170 is a rectangular tunnel furnace, which forms a closed space above the conveying plate 17 4. The entrance of the transport plate 1 74 is located on the upstream side wall of the first roller 172 of the furnace, and the exit 176 is located on the downstream side wall of the second roller 173 of the furnace. _ Degreasing / pre-sintering furnace 170 Depending on the sintered metal, it may be heated by a .nickel-chromium alloy line heater, a Mo heater, a S i C heater or a W heater. Lubricant. The applicator 1 61 is located below the first roller and is connected to the transport plate 1 7 4. Therefore, the surface of the transport plate 1 7 4 is coated with lubricant before the dry blank 1 C is transported. The degreasing / pre-sintering step is intended to evaporate the binder of organic components such as the blank plate 1.C. Because the slab shrinks slightly in this step, the lubricant applied to the surface of the slab 1 74 makes the sliding between the slab 1 74 and the dried slab 1 C smooth, so it absorbs the deformation of the slab due to shrinkage. Examples of suitable lubricants include liquid and solid graphite, bitumen, silicon, boron nitride, and this paper is compliant with China National Standard (CNS) A4 (210X297 mm) ~ -46-(Please read the precautions on the back before # (Write this page)-Packing-Printed by the Consumer Standards Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs A7 _B7_ V. Description of the Invention (44) Silicon Carbide "Although steel strips are used as the shipping board for this embodiment, it can also be used. Heat-resistant metals such as non-recordable steels are town-based heat-resistant alloys and combinations of gold. The dried blank 1 C was degreased and pre-sintered in a degreasing / pre-sintering furnace 170 to form a degreased plate 1D. The degreasing plate 1 D is moved and separated from the second roller 1 7 3 and the plate 1 7 4 is moved and fed to the formal sintering furnace 180 °. The formal sintering effect The formal sintering furnace 180 is a rectangular tunnel furnace, which forms a dense The closed space is the same as the degreasing / pre-sintering furnace 170. The inlet 1 8 of the degreasing plate 1 D is located on the upstream side wall of the formal furnace 1 80, and the outlet 1 8 is located on the downstream side wall of the formal furnace. A plurality of conveying rollers 1 8 2 form a roller-shaped hearth 1 8 3 as a continuous sintering hearth. Each of the conveying rollers 1 8 2 is independently, partly or wholly rotated in the conveying direction by a driving unit (not shown in the figure). The roll-shaped hearth 1 8 3 extends to the vicinity of the second roll of the degreasing / pre-sintering furnace 170 and to the outside of the outlet 1 8 6. The degreasing plate 1D is moved on a plurality of conveying rollers 1 2 rotating in the conveying direction, and is in contact with the conveying rollers. The distance between the rollers 1 8 2 of the roller hearth 1 8 3 is determined by the thickness and porosity of the degreasing plate 1 D, the sintering state, and the like. As the distance is too large, the degreasing board cannot be fully supported, so an appropriate distance must be decided. For example, the distance is in the range of approximately 25 to 70 mm. At the entrance 1 8 5 and the vicinity of this paper standard Chinese national standards (CNS> A4 specifications (210 × 297 mm)) (Please read the precautions on the back before mining ^-this page) • Packing. Order -47-Ministry of Economy Central Sample A7 printed by the Consumer Cooperative of the Bureau of Standards. 5. Description of the invention (45), the distance between the transport rollers must be short. Many spherical or elliptical spherical elements can also be used instead of the transport rollers. Point to support the degreasing plate 1 D. This type of wire or point contact device only causes the degreasing plate 1 D to significantly reduce the angle of the part, and the other parts can use any conventional transportation device, such as a conveyor belt. The line or point contact device can be charged It is used as a transport device for degreasing / pre-sintering furnace 170. When the nickel foam is burned at 120 ° C, the metal plate shrinks by about 20% due to sintering. When a conventional belt furnace is used, the sintering is obtained The length of the porous metal plate is up to a few centimeters. In contrast, in this embodiment, the elongated sintered porous metal plate 1E can be produced by the above-mentioned transportation device. In detail, because a honeycomb-like object is threaded on many rolling objects The contact mode moves, the contact resistance between the honeycomb object and the transport device is very small, and the honeycomb object is easy to slide on the rolling object, so the shrinkage of the honeycomb object is easily achieved. The deformation caused by the shrinkage has been affected. Absorption can avoid cracking caused by shrinkage. The rotation rate of each rotating element 1 8 2 is best adjusted according to the amount of shrinkage. For example, the rotation rate of the outlet is set to be smaller than the inlet, and it is easy to shrink without deformation. Formal sintering The furnace 180 is divided into many compartments, especially at least 3 compartments, in which the temperature of these compartments is gradually sintered in accordance with the conveying direction. In such a formal sintering furnace 180, rapid heating can be avoided Cracking, so that sintering can be performed stably. In the formal sintering furnace 180, the acceleration rate is preferably increased from 2 to 50 ° C / minute according to the conveying direction, and more preferably from 3 to 30 ° C / minute. This paper The scale is applicable to China National Standard (CNS) A4 specification (210X297 mm) ~ ~ -48-(Please read the precautions on the back before the # curtain page)-Installation. Order the central standard of the Ministry of Economic Affairs Printed by the Consumers' Cooperative A7 __B7___ V. Description of the invention (sen) The heaters installed in the formal furnace 180 are not limited to those used in the degreasing / pre-sintering furnace 170, and may be, for example, nickel-chromium alloy heaters. , Mo heater, Si'C heater, and W heater are appropriately selected. The formed sintered metal plate 1 E is sent out by a formal sintering furnace 180, and is wound into a continuous roll strip 192 by a winding machine 191. The thickness of the sintered metal plate 1 E can be controlled by the rolling surface path, etc. as required. The rolling speed 72 of the roller is expressed by the following equation: ν2 = ν! × (100-S) / 100 where S represents the final shrinkage of the sintered metal Rate, and Vi represents the moving speed of the conveying plate in the burner. In this way, a sintered porous metal plate having a three-dimensional skeleton structure and a large specific surface area can be manufactured. The formed sintered porous metal plate has the following different honeycomb structures shown in Figs. 9A and 9D depending on the foaming conditions, drying conditions and burning conditions of the slurry preparation; a single honeycomb layer shown in Fig. 9A The structure is shown in FIG. 9B as a multi-layer closed air cell structure, as shown in FIG. 9C, a surface closed skeleton structure and a surface open skeleton structure shown in FIG. 9D. The three-dimensional skeleton of the sintered porous metal plate of the present invention is also porous, because the skeleton is made of sintered metal. Therefore, the specific surface area of the sintered porous metal plate is, for example, 300 to 15 00 c m2 / c m3 as the be T specific surface area. In addition, it is easy to form a very small air chamber ', for example, 10 m or less. The average particle size of the formed sintered metal powder is 60 to 6 0 0 ji / m, and the porosity is 90 to this paper size. The Chinese National Standard (CNS) A4 specification (210x297) is applicable. ~ (Please read the back Note for reprinting)-Binding, binding, and printing of the A7 _______B7__ by the Consumer Cooperatives of the Central Standards Bureau of the Ministry of Economic Affairs 5. Description of the invention (47) 9 8 Volume percentage. As a comparative example, a sintered metal plate is prepared as follows; nickel is vaporized @ to make the inner surface of a commercially available polyurethane foam foam having a thickness of 0.5 mm thick, and the foam foam is immersed in a nickel sulfate solution;泡沫 A / dm2 current density, the foam was electroplated as a negative electrode, and a nickel plating layer with an average thickness of 7 5 〆! was formed on the surface of the 沬 open cell, and the slab foam was kept under a hydrogen flow of 1 100 ° C. 0.5 hours, the polyurethane foam was removed. The formed sintered porous metal plate had a diameter of 50 mm and a length of 100 mm. The sintered metal plate's pore size 'porosity and B E T specific surface area were measured in the same manner as in Example 1-1. The results are shown in Table 2. The sintered porous metal plate of the embodiment of the present invention can be used as an active material carrier for alkaline battery electrodes, hydrolysis electrodes, spray units for oil heaters, magnetic shielding packaging, and air buffers using explosives. Gas expansion buffers, sound-absorbing insulation materials, hydrolytic filters for water purifiers, electrostatic filters for air purifiers, oil mist filters for exhaust, oil heaters and other deodorizing catalysts, high-temperature ducts A dust filter, a substrate made of aluminum, and industrial catalysts and carriers. The present invention is not limited to the foregoing specific examples, but can be modified within the scope of the present invention. In the fifth embodiment, the burner includes a two-month degreasing / pre-sintering step and a formal sintering step. However, these two steps can be achieved in a furnace separated by walls into two spaces. In addition, the degreasing step can be eliminated by the burner. This paper size applies Chinese National Standard (CNS) A4 specification (210X297mm) ~ 1-50-(please read the precautions on the back first ^^ this page) • Binding and ordering A7 B7 V. Description of the invention (48) The second to fourth embodiments can also be applied to the fifth embodiment. The sintering method in the fifth embodiment is also suitable for manufacturing closed metal plates and metal foils, which is different from the method for manufacturing sintered porous metal plates. Lian continued the long method. In addition, this sintering method is also suitable for manufacturing an elongated sintered body having a uniform surface, such as a rod or a pipe. In addition, this sintering method is also applicable to a method for manufacturing a long sintered ceramic article. According to the fifth embodiment, a sintered porous metal plate having a large specific surface area and a high degree of freedom in metal composition can be manufactured easily and stably. In addition, it is easy to produce a long sintered article by a powder metallurgy method or the like. (Please read the precautions on the back first and then build this page) • Yao'yan printed by the Central Bureau of Standards of the Ministry of Economic Affairs and Consumer Cooperatives printed 1 paper standard applicable to the Zhongguanjia standard ({: called eight 4 specifications (21 () > < 297 male thin) -51-