WO2008050753A1 - Procédé et appareil de production d'un corps poreux - Google Patents
Procédé et appareil de production d'un corps poreux Download PDFInfo
- Publication number
- WO2008050753A1 WO2008050753A1 PCT/JP2007/070627 JP2007070627W WO2008050753A1 WO 2008050753 A1 WO2008050753 A1 WO 2008050753A1 JP 2007070627 W JP2007070627 W JP 2007070627W WO 2008050753 A1 WO2008050753 A1 WO 2008050753A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- slurry
- foamable
- porous body
- sheet
- powder
- Prior art date
Links
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/11—Making porous workpieces or articles
- B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
- B22F3/1125—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers involving a foaming process
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/003—Apparatus, e.g. furnaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/006—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of flat products, e.g. sheets
Definitions
- the present invention relates to a porous body manufacturing apparatus and a porous body manufacturing method for manufacturing a sheet-like porous body having a three-dimensional network structure.
- Patent Document 1 when manufacturing a sheet-like porous body used for a filter, a gas diffusion member, a heat radiating member, a water absorbing member, etc., as in Patent Document 1, for example, an inorganic powder, a foaming agent, an organic binder, After forming a foamable slurry containing a solder, a liquid solvent or the like into a sheet, the foamable slurry is foamed with a foaming agent, and the foamed slurry is dried and fired.
- the foamable slurry is formed into a sheet, the foamable slurry is passed between a carrier sheet that conveys the foamable slurry using a belt conveyor and a doctor blade disposed above the carrier sheet.
- an open chamber for storing foaming slurry is arranged on the upstream side of the doctor blade. The upper part of this open chamber is open to the atmosphere so that foaming slurry can be supplied to the open chamber.
- the sheet-like foaming slurry is continuously added over a long period of time by replenishing the foaming slurry intermittently or continuously into the open chamber. It becomes possible to mold.
- Patent Document 1 Japanese Patent No. 3282497
- the foaming slurry supplied to the open chamber contains air bubbles
- the upper part of the open chamber is open to the atmosphere, so that the air bubbles accumulate on the upper part of the open chamber by buoyancy.
- the size of the foam increases due to coalescence of bubbles accumulated in the upper part. Become.
- the number of large bubbles increases, there is a problem that these large bubbles pass between the carrier sheet and the doctor blade.
- the present invention has been made in view of such circumstances, and even if a sheet-like foamable slurry is continuously formed over a long period of time, the bubble distribution in the porous body can be kept uniform. It is an object of the present invention to provide a porous body manufacturing apparatus and a porous body manufacturing method capable of manufacturing a porous body.
- the present invention provides the following apparatuses and methods.
- a foamable slurry containing at least an inorganic powder, a foaming agent and a binder is formed into a sheet shape, the sheet-shaped foamable slurry is foamed, and fired.
- a porous body manufacturing apparatus for manufacturing a porous body, the mixer containing the inorganic powder, the foaming agent, and the binder to prepare the foamable slurry, and the foamability supplied from the mixer A die coater for molding having a discharge port for discharging the slurry in the form of a sheet to the outside, and a carrier for conveying the foaming slurry discharged from the discharge port, with the discharge port of the die coater being opposed to each other with a gap.
- the foaming slurry force discharged on the carrier sheet from the die coater discharge passage, and the gap between the discharge port and the carrier sheet are passed, and this gap size is met.
- a sheet-like foamable slurry having a thickness dimension is formed.
- the sheet-like foaming slurry is continuously formed over a long period of time by continuously discharging the foaming slurry from the discharge port of the die coater. Can do.
- a powder slurry obtained by kneading the inorganic powder and the binder is prepared and deaerated, and the powder slurry and the foaming agent are supplied to the mixer and the mixer is mixed.
- Gas mixing means for mixing the controlled amount of gas into the degassed powder slurry or the foamable slurry in the mixer It is a porous body manufacturing apparatus provided.
- Another aspect of the present invention is a porous body manufacturing apparatus in which a flow path of the powder slurry reaching the mixer is sealed to the outside.
- Another aspect of the present invention is a porous body manufacturing apparatus including a Mono pump that pumps the foamable slurry from the mixer to a discharge port of the die coater.
- Another aspect of the present invention is a porous body manufacturing apparatus including a linear pump in which the inorganic powder has conductivity and pressure-feeds the foamable slurry from the mixer to a discharge port of the die coater.
- Another embodiment of the present invention is porous by forming a foamable slurry containing at least an inorganic powder, a foaming agent and a binder into a sheet shape, foaming the sheet-like foamable slurry, and firing the foamed slurry.
- a porous body manufacturing method for manufacturing a body from the preparation of the foamable slurry with the inorganic powder, the foaming agent and the binder to the molding of the foamable slurry into a sheet. In the meantime, it is a method for producing a porous body in which the foamable slurry is not exposed to the atmosphere.
- Another aspect of the present invention is to degas the powder slurry obtained by kneading the inorganic powder and the binder, and then kneading the powder slurry and the foaming agent to prepare the foamable slurry.
- the foamable slurry does not come into contact with the atmosphere from the inside of the mixer to the discharge port, that is, until the foamable slurry is formed and then formed into a sheet shape. Even if bubbles are included in the porous slurry, it is possible to prevent the bubbles from coalescing and becoming larger in size until the foamable slurry is formed into a sheet. Therefore, even if a sheet-like foaming slurry is continuously formed over a long period of time, it is possible to prevent variation in the size of foamed bubbles in this foaming slurry, and It is possible to uniformly maintain the bubble distribution of the porous body obtained by firing the foamy slurry.
- foaming of the foamable slurry includes the force S generated by growing the bubbles contained in the foamable slurry with the foaming agent, as described above, and the degassed powder slurry or the like.
- the amount of gas mixed into the foamable slurry By controlling the amount of gas mixed into the foamable slurry, the amount of foam contained in the foamable slurry can be controlled. Therefore, the volume of bubbles grown by foaming can be easily controlled, and the porosity of the porous body can be easily controlled.
- the flow path of the powder slurry from the slurry storage tank to the mixer is sealed to the outside, the powder slurry is surely prevented from being inadvertently mixed into the powder slurry by touching the atmosphere. Therefore, the porosity of the porous body can be controlled with particularly high accuracy.
- the bubble distribution in the porous body can be kept uniform.
- FIG. 1 is a schematic cross-sectional view showing a porous body manufacturing apparatus according to an embodiment of the present invention.
- FIG. 2 is a schematic plan view showing a die coater in the porous body manufacturing apparatus of FIG. Explanation of symbols
- the porous body manufacturing apparatus 1 is a sheet of foamable slurry S1 containing metal powder (inorganic powder), foaming agent, organic binder (binder), liquid solvent (binder), etc. Then, a green sheet G is produced by foaming and drying a sheet-like foaming slurry (hereinafter referred to as foaming slurry sheet S2), and this green sheet G is further degreased and fired. A sheet-like porous body having a three-dimensional network structure is manufactured.
- the metal powder contained in the foamable slurry S1 for example, nickel, copper, iron, S US, chromium, cobalt, gold, silver and the like S, all that can be powdered and sintered You can power to use any metal.
- the foaming agent include water-insoluble hydrocarbon organic solvents having 5 to 8 carbon atoms (for example, neopentane, hexane, heptane) and the like. It is sufficient to use various compounds that decompose at a predetermined temperature and generate volatile organic solvents and volatile organic solvents.
- examples of the organic binder include a water-soluble organic binder such as methylcellulose or hydroxypropylmethylcellulose.
- any material can be used as long as it has a function of retaining the shape of the green sheet when S2 is dried.
- the liquid solvent include water, and any liquid solvent can be used as long as it can be volatilized into the atmosphere by heating at a high temperature and has a lower volatility and a higher boiling point than the blowing agent.
- the foaming slurry S1 for example, the one disclosed in Japanese Patent No. 3282497 is more preferable!
- the porous body manufacturing apparatus 1 includes a kneading unit 3 for preparing the foamable slurry S1, a die coater 5 for discharging the foamable slurry S1 supplied from the kneading unit 3, and the die coater 5 Carrier sheet for transporting foamable slurry S 1 discharged from 7 is provided.
- the kneading unit 3 includes a slurry storage tank 11 for storing a powder slurry 9 prepared by kneading a metal powder excluding a foaming agent, an organic binder, and a liquid solvent, a foaming agent storage tank 13 for storing a foaming agent, and a powder slurry. 9 and a mixer 15 for containing a foaming agent and preparing a foamable slurry S 1 by kneading.
- the powder slurry 9 supplied to the slurry storage tank 11 is deaerated.
- a first pumping pump 17 for pumping the powder slurry 9 toward the mixer 15 from the slurry storage tank 11 force.
- the first pump 17 does not generate pulsation in the powder slurry 9 to be pumped, and examples thereof include a Mono pump and a linear pump.
- the flow path of the powder slurry 9 from the slurry storage tank 11 to the mixer 15 via the first pressure pump 17 is sealed to the outside.
- a second pumping pump 19 for pumping the foaming agent from the foaming agent storage tank 13 toward the mixer 15 is also provided between the foaming agent storage tank 13 and the mixer 15. Similar to the first pumping pump 17, the second pumping pump 19 does not generate pulsation in the foaming agent to be pumped, and examples thereof include a Mono pump and a linear pump. Note that the flow path of the foaming agent from the foaming agent storage tank 13 to the mixer 15 via the second pumping pump 19 is also sealed to the outside.
- the kneading unit 3 also includes gas mixing means 21 for mixing a controlled amount of gas into the foamable slurry S 1 in the mixer 15, and the gas mixing means 21 is provided in the mixer 15 for example.
- a gas supply unit 23 such as a compressor for supplying gas, a flow meter 25 for measuring the flow rate of the gas flowing into the mixer 15 from the gas supply unit 23, and the gas flowing into the mixer 15 by stirring or vibration
- a homogenizing mechanism (not shown) force for uniformly mixing into the slurry S1 is also configured. Therefore, the gas mixed into the foamable slurry S1 by the gas mixing means 21 is present in the foamable slurry S1 with a uniform distribution as fine bubbles.
- the operation of the gas supply unit 23 is controlled based on the amount of the powder slurry 9 and the foaming agent supplied into the mixer 15 and the measurement value of the flow meter 25.
- Mi The volume ratio of the gas mixed into the foamable slurry S 1 in the xer 15 can be set to a desired value. That is, the amount of bubbles contained in the foamable slurry S1 can be controlled.
- the carrier sheet 7 is made of, for example, a PET film or the like, and is conveyed in the longitudinal direction (A direction) by a plurality of rollers 27.
- the die coater 5 is disposed so as to face one roller 27A disposed on the upstream side in the conveying direction (A direction) of the carrier sheet 7.
- the die coater 5 has the structure disclosed in Japanese Patent No. 314060 and Japanese Patent Publication No. 6-223. That is, the die coater 5 has a manifold 5a as a space for expanding the foaming slurry S1 supplied from the mixer 15 in the width direction of one roller 27A, and the foaming slurry S1 is sealed to the outside from the manifold 5a. It is equipped with a fine slit for discharging in the shape of a groove and a groove-shaped slit (discharge port) 5b.
- a communication pipe 29 is provided between the mixer 15 and the die coater 5 so as to allow the inside of the mixer 15 and the manifold 5a to communicate with each other.
- the slip of the die coater 5 from the mixer 15 is provided.
- the flow path of the foaming slurry S1 leading to the outlet of G 5b is sealed to the outside.
- the communication pipe 29 is connected to the central portion of the manifold 5a in the width direction, and the foamable slurry S1 supplied from the communication pipe 29 into the manifold 5a is evenly distributed in the width direction of the manifold 5a. It has become possible to spread.
- the foaming slurry S 1 in the mixer 15 is pumped from the mixer 15 to the outlet of the slit 5 b of the die coater 5 through the communication pipe 29 by the two pumps 17 and 19 described above.
- the outlet of the slit 5b is disposed to face the carrier sheet 7 wound around the one roller 27A with a gap, and the foaming slurry discharged onto the carrier sheet 7 from this outlet As S 1 passes through the gap between the outlet of the slit 5b and the carrier sheet 7 as the carrier sheet 7 is conveyed, the foamable slurry sheet S2 having a thickness corresponding to the gap dimension is formed. It has become.
- the porous body manufacturing apparatus 1 includes a foaming tank 31 and a heating furnace 33 that are sequentially arranged downstream of the one roller 27A in the conveying direction (A direction) of the carrier sheet 7.
- the carrier sheet 7 and the foaming slurry sheet S2 pass through the foaming tank 31 and the heating furnace 33. It is comprised so that.
- the foaming tank 31 heats the foamable slurry sheet S2 in a high humidity atmosphere to promote foaming of the foamable slurry sheet S2.
- the heating furnace 33 heats and dries the foamable slurry sheet S2 foamed in the foaming tank 31 to form the green sheet G.
- an expandable slurry S1 containing a metal powder, a foaming agent, an organic binder, a liquid solvent, and the like is prepared (slurry preparation step).
- a metal slurry excluding the foaming agent, an organic binder, a liquid solvent, and the like are kneaded to prepare a powder slurry 9, and the degassed powder slurry 9 is supplied to the slurry storage tank 11.
- the deaerated powder slurry 9 is supplied into the mixer 15 by the first pressure pump 17 and the foaming agent stored in the foaming agent storage tank 13 in advance is mixed by the second pressure pump 19 by the mixer 15.
- the powder slurry 9 and the foaming agent are mixed in the mixer 15 to prepare a foamable slurry S1.
- the flow path of the powder slurry 9 and the foaming agent from the slurry storage tank 11 and the foaming agent storage tank 13 to the mixer 15 is sealed to the outside, that is, from the slurry storage tank 11 and the foaming agent storage tank 13 to the mixer.
- the powder slurry 9 and the foaming agent are not exposed to the atmosphere until they reach the inside, so the powder slurry 9 and the foaming agent supplied into the mixer 15 are not mixed with gas.
- an amount of gas controlled by the gas supply unit 23 is supplied into the mixer 15 and mixed into the foamable slurry S1.
- the gas mixed here is present in the foaming slurry S 1 with a uniform distribution as fine bubbles. Further, the amount of gas mixed into the foamable slurry S 1 is controlled so that the volume ratio of the gas to the foamable slurry S1 becomes a predetermined value (for example, 10 to 25%).
- the foamable slurry S 1 prepared as described above is molded into a sheet (molding process).
- the carrier sheet 7 is conveyed in the A direction while 17 and 19, the foamable slurry SI is pumped to the slit 5b of the die coater 5 from the internal force of the mixer 15 and continuously discharged from the slit 5b, so that the foamable slurry S1 becomes the outlet of the slit 5b.
- the foamable slurry sheet S2 is continuously formed through the gap with the carrier sheet 7.
- the foamable slurry S1 Since the flow path of the foamable slurry S1 from the mixer 15 to the slit 5b outlet of the die coater 5 is sealed to the outside, the foamable slurry S1 is prepared after the foamable slurry S1 is prepared in the mixer 15. The foamable slurry S 1 does not come into contact with the atmosphere until it is formed into a sheet.
- the formed foamable slurry sheet S2 is foamed to form a porous body (foaming step).
- foaming step when the foamable slurry sheet S2 conveyed from the one roller 27A side by the carrier sheet 7 is passed through the foaming tank 31, it is heated in a high humidity atmosphere.
- the foaming agent when the foaming agent is heated, minute bubbles contained in the foamable slurry sheet S2 grow by the foaming agent, whereby the foamable slurry sheet S2 is formed into a porous body.
- the heating in the foaming tank 31 is performed in a high humidity atmosphere, it is possible to prevent the foaming slurry sheet S2 from being cracked due to the foaming described above.
- the foamed slurry slurry S2 is dried to produce a green sheet G (drying step).
- the foamable slurry sheet S2 conveyed from the foaming tank 31 by the carrier sheet 7 is heated and dried when passing through the heating furnace 33, so that the liquid solvent contained in the foamed foamable slurry sheet S2 is reduced.
- the green sheet G is formed in a state where it is volatilized and the metal powder is bonded by the organic binder.
- the green sheet G is degreased and fired (baking process) in a vacuum furnace (not shown) provided in the porous body manufacturing apparatus 1, thereby removing the organic binder and sintering the metal powder.
- a sheet-like porous body having a network structure is obtained.
- porous body manufacturing apparatus 1 it is possible to continuously manufacture a sheet-like porous body for a long time by continuously performing the above-described steps.
- the foamable slurry sheet S2 is formed after the foamable slurry S1 is prepared.
- the foamable slurry SI does not come into contact with the atmosphere, it is possible to prevent the microbubbles from coalescing and increasing in size.
- the foamed slurry sheet S2 is prevented from being dispersed in the foamed foam size, and the foamed foamable slurry sheet S2 is dried.
- the bubble distribution in the porous body obtained by firing can be kept uniform.
- the amount of gas mixed into the degassed foamable slurry S1 can be controlled, that is, the bubbles grown by foaming can be controlled. Since the volume can be controlled, the porosity of the porous body can be easily controlled. Furthermore, by sealing the powder slurry 9 and the foaming agent flow path from the slurry storage tank 11 and the foaming agent storage tank 13 to the mixer 15, the gas slurry 9 and the foaming agent are mixed with an unexpected gas. Therefore, the porosity of the porous body can be controlled particularly accurately.
- the foaming slurry S1 when using a mono pump or linear pump as the pumping pump 17, 19 that pumps the powder slurry 9, foaming agent, and foaming slurry S1, pump from the mixer 15 to the slit 5b outlet of the die coater 5.
- the foaming slurry S1 can be prevented from pulsating, the foaming slurry S1 can be surely prevented from coalescence of bubbles contained in the foaming slurry S1 before reaching the outlet of the slit 5b. it can.
- the degassed powder slurry 9 is supplied to the slurry storage tank 11.
- a degassing means (not shown) for degassing the powder slurry 9 is directly connected to the mixer 15.
- the flow path of the powder slurry 9 from the deaeration means to the mixer 15 may be sealed to the outside.
- the porosity of the porous material can be controlled with higher accuracy and accuracy. Become.
- the gas mixing means 21 is configured to mix a controlled amount of gas into the foamable slurry S1 in the mixer 15, and is not limited to this.
- degassed powder It may be configured to mix a controlled amount of gas into the powdery slurry 9.
- the gas mixing means 21 is not limited to the configuration of the above-described embodiment, and, for example, the powder slurry 9 is stirred in a state where the powder slurry 9 is exposed to the atmosphere, and the amount of gas controlled by this stirring is mixed into the powder slurry 9. You may comprise.
- the amount of gas mixed into the powder slurry 9 is proportional to the stirring time of the powder slurry 9
- the amount of gas mixed into the powder slurry 9 can be controlled by defining this stirring time.
- the powder slurry 9 mixed with a controlled amount of gas is desirably supplied into the mixer 15 without being exposed to the atmosphere.
- the powder slurry 9, foaming agent, and foamable slurry S1 are taken care of after the degassing of the powder slurry 9 and before the foamable slurry S1 is formed into a sheet. If the amount of bubbles contained in the foamable slurry S1 is not controlled, at least the preparation of the foamable slurry S1 in the mixer 15 until the foamable slurry S1 is formed into a sheet During this period, the foamable slurry S1 should not be exposed to the atmosphere. Even in this case, it is possible to prevent the fine bubbles from coalescing and increase in size until the prepared foamable slurry S1 is formed into a sheet shape. Can be held in.
- the present invention even when a sheet-like foaming slurry is continuously formed over a long period of time, the bubble distribution in the porous body can be kept uniform. Therefore, the present invention is extremely useful industrially.
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2008540993A JP5157910B2 (ja) | 2006-10-23 | 2007-10-23 | 多孔質体製造装置及び多孔質体の製造方法 |
US12/446,625 US8303284B2 (en) | 2006-10-23 | 2007-10-23 | Apparatus for producing porous body and method for producing porous body |
EP07830361.7A EP2096183B1 (en) | 2006-10-23 | 2007-10-23 | Apparatus for producing porous body and method for producing porous body |
CN2007800393460A CN101528955B (zh) | 2006-10-23 | 2007-10-23 | 多孔体制造装置及多孔体的制造方法 |
US13/625,560 US8747710B2 (en) | 2006-10-23 | 2012-09-24 | Method for producing porous body |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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JP2006-287953 | 2006-10-23 | ||
JP2006287953 | 2006-10-23 |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/446,625 A-371-Of-International US8303284B2 (en) | 2006-10-23 | 2007-10-23 | Apparatus for producing porous body and method for producing porous body |
US13/625,560 Division US8747710B2 (en) | 2006-10-23 | 2012-09-24 | Method for producing porous body |
Publications (1)
Publication Number | Publication Date |
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WO2008050753A1 true WO2008050753A1 (fr) | 2008-05-02 |
Family
ID=39324550
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/JP2007/070627 WO2008050753A1 (fr) | 2006-10-23 | 2007-10-23 | Procédé et appareil de production d'un corps poreux |
Country Status (5)
Country | Link |
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US (2) | US8303284B2 (ja) |
EP (1) | EP2096183B1 (ja) |
JP (1) | JP5157910B2 (ja) |
CN (1) | CN101528955B (ja) |
WO (1) | WO2008050753A1 (ja) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN102802845A (zh) * | 2009-06-02 | 2012-11-28 | 巴斯夫欧洲公司 | 生产多孔金属熔结成型体的方法 |
Families Citing this family (3)
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JP2011235279A (ja) * | 2010-04-13 | 2011-11-24 | Fuji Kikai Kogyo Kk | 塗工装置 |
CN102312117B (zh) * | 2011-10-11 | 2013-05-08 | 大连交通大学 | 吹气发泡连续生产闭孔泡沫铝的方法及设备 |
CN106830876A (zh) * | 2017-02-21 | 2017-06-13 | 苏州蓝锐纳米科技有限公司 | 一种纳米泡沫材料及其发泡方法 |
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Also Published As
Publication number | Publication date |
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CN101528955A (zh) | 2009-09-09 |
EP2096183A1 (en) | 2009-09-02 |
US8747710B2 (en) | 2014-06-10 |
US8303284B2 (en) | 2012-11-06 |
JPWO2008050753A1 (ja) | 2010-02-25 |
JP5157910B2 (ja) | 2013-03-06 |
EP2096183A4 (en) | 2012-03-07 |
US20100289167A1 (en) | 2010-11-18 |
EP2096183B1 (en) | 2013-06-19 |
US20130015600A1 (en) | 2013-01-17 |
CN101528955B (zh) | 2011-03-09 |
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