WO2014024781A1

WO2014024781A1 - Method for manufacturing porous body, porous body, and structure

Info

Publication number: WO2014024781A1
Application number: PCT/JP2013/070944
Authority: WO
Inventors: 智資平野; 優瀧本
Original assignee: 日本発條株式会社
Priority date: 2012-08-08
Filing date: 2013-08-01
Publication date: 2014-02-13
Also published as: JPWO2014024781A1; JP6182140B2

Abstract

Provided are a method for manufacturing a porous body, a porous body, and a structure, the method for manufacturing a porous body being capable of readily controlling pore diameter and porosity, and being capable of forming a porous body having a smaller pore diameter and higher porosity than a conventional porous body. The method for manufacturing a porous body comprises: a film formation step (S3) for forming a film composed of a composite powder, the film having a first layer composed of a material soluble in a predetermined solution and a second layer, which formed by coating at least a portion of the outer side of the first layer with a metal or alloy and which is less soluble in the solution than is the first layer; and a pore formation step (S4) for forming pores in the film by immersing the film in the solution to remove the material from the film.

Description

Porous body manufacturing method, porous body, and structure

The present invention relates to a method for producing a porous body, a porous body, and a structure including the porous body.

In recent years, members having a porous structure made of an inorganic material such as metal (hereinafter also referred to as a porous body) have been used in various applications such as electrode members for automobile batteries, filters, and catalyst carriers. As a method for producing a porous body made of metal (hereinafter also referred to as a metal porous body), the core metal is plated on the core resin, and the core material is removed by heating to form pores (holes). Plating method, foaming method in which metal and foaming agent to be aggregated are mixed and foamed by overheating to form pores, metal powder to be aggregated and spacer powder are mixed and sintered, then spacer powder is A spacer method that forms pores by removing by heating is known (see Non-Patent Document 1). For example, Patent Document 1 discloses a method of performing metal plating on a resin-made three-dimensional network porous body made of resin foam, nonwoven fabric, felt, woven fabric, or the like.

JP 2012-82483 A

However, in the plating method, pores are the gaps in the network-like three-dimensional structure formed by the resin and the space after the three-dimensional structure is removed. For this reason, the shape of some of the pores becomes a linear shape, and it is difficult to form, for example, minute cellular pores whose diameter is controlled to 0.3 mm or less.

Also, in the foaming method, it is difficult to form minute pores having a diameter of, for example, 0.3 mm or less, and it is also difficult to control the pore diameter.

On the other hand, in the spacer method, it is possible to form pores having a smaller diameter (for example, about several tens of μm to 0.3 mm) than the plating method or the foaming method by adjusting the diameter of the spacer powder. However, in the case of the spacer method, the porosity of the metal porous body cannot be made very high, and remains at, for example, about 70% even if it is high.

Also, when producing a porous body made of a material that is not as large as a metal, such as ceramics, it is difficult to form minute pores or control the pore diameter.

The present invention has been made in view of the above, and it is possible to easily control the pore diameter and the porosity, and to form a porous body having a smaller pore diameter and a higher porosity than before. An object of the present invention is to provide a method for producing a porous body, a porous body, and a structure including such a porous body.

In order to solve the above-described problems and achieve the object, a method for producing a porous body according to the present invention includes a first layer made of a material that can be dissolved in a predetermined solution, and an outer side of the first layer. Forming a film formed by coating at least a part with a metal or an alloy, and forming a film composed of a composite powder having a second layer that is less soluble in the solution than the first layer. And a pore forming step of forming pores in the coating by immersing the coating in the solution and removing the material from the coating.

The method for producing a porous body of the present invention is formed by coating a first layer made of a material that can be thermally decomposed at a predetermined temperature and at least a part of the outside of the first layer with a metal or an alloy. A film forming step of forming a film composed of a composite powder having a second layer that does not melt at the temperature, and heating the film to the temperature to remove the material from the film, And a pore forming step of forming pores in the film.

In the method for producing a porous body, the composite powder is formed by cutting a composite wire obtained by coating a wire made of the material of the first layer with a material of the second layer. And

In the method for producing a porous body, the film forming step includes accelerating the composite powder together with a gas and spraying and depositing on the surface of the base material while maintaining at least the surface of the composite powder in a solid state. Features.

In the method for producing a porous body, the film forming step is characterized in that the composite powder is mixed with a powder consisting only of the same kind of metal or alloy as the outermost layer metal or alloy and sprayed onto the base material. To do.

In the method for producing a porous body, the film forming step is characterized in that the composite powder is filled in a mold and pressure is applied.

In the method for manufacturing a porous body, the material is a metal or an alloy different from the second layer.

The method for producing a porous body further includes a step of heat-treating the film before the pore forming step.

In the method for producing a porous body, the solution is an acidic solution, and the ionization tendency of the metal or alloy forming the second layer is smaller than the ionization tendency of the material.

In the method for producing a porous body, the material is aluminum or an aluminum alloy, and the metal or alloy forming the second layer is copper or a copper alloy.

In the method for producing a porous body, the solution is an acidic solution, the second layer is made of a valve metal, and the material is more soluble than the passive film formed on the surface of the second layer. It is easily dissolved in liquid.

In the method for producing a porous body, the material is copper or a copper alloy, and the metal or alloy forming the second layer is aluminum, an aluminum alloy, nickel, a nickel alloy, titanium, a titanium alloy, chromium, or chromium. It is one of alloys.

In the method for producing a porous body, the material is a chloride that is soluble in water or an aqueous solution.
In the method for producing a porous body, the chloride is sodium chloride.

In the method for producing a porous body, the material is a resin that is soluble in an organic solvent.
In the method for producing a porous body, the material is a resin that is soluble in an alkaline solution.

In the method for producing a porous body, the composite powder is a third layer provided outside the second layer, and is different from the metal or alloy forming the second layer. And a third layer that is more difficult to dissolve in the solution than the first layer.

In the method for producing a porous body, the material is a resin.
In the method for producing a porous body, the composite powder is a third layer provided outside the second layer, and is made of a second metal or alloy different from the metal or alloy. And a third layer that does not melt at the temperature.

The method for producing a porous body further includes a step of forming a plating layer on the film in which the pores are formed after the pore forming step.

The porous body according to the present invention has a cell wall made of a metal, an alloy or an intermetallic compound, and pores are formed between the cell walls, and the average pore diameter of the pores is 0.01 mm. The ratio of the pore volume to the porous body is 30% or more and less than 100%.

The porous body according to the present invention has a cell wall made of a metal, an alloy or an intermetallic compound, and pores are formed between the cell walls, and the average pore diameter of the pores is 0.01 mm. The ratio of the pore volume to the porous body is 85% or more and less than 100%.

The porous body according to the present invention has a cell wall made of a metal, an alloy, or an intermetallic compound, and pores are formed between the cell walls, the pores being in the thickness direction of the porous body. A flat shape having a larger diameter in a plane orthogonal to the thickness direction than the diameter in is formed.

In the porous body, an average pore diameter in a cross section perpendicular to the thickness direction of the pores is 0.01 mm or more and 1 mm or less, and a volume ratio of the pores to the porous body is 30% or more and less than 100%. Features.

In the porous body, the cell wall has a layer structure in which a plurality of different metals or alloys are stacked.

The porous body further includes a plating layer formed on the cell wall.

The porous body is characterized in that the cell wall is made of a metal or an alloy and further has an intermetallic compound layer formed on the surface of the cell wall.

In the porous body, the pores are formed by covering a first layer made of a material that can be dissolved in a predetermined solution and at least a part of the outside of the first layer with a metal or an alloy, The composite powder having the second layer, which is less soluble in the solution than the first layer, is accelerated together with the gas, and at least the surface of the composite powder is kept in a solid-phase state. The film is formed by spraying on the surface and depositing the film, immersing the film in the solution, and removing the material from the film.

In the porous body, the cell wall is made of a metal or an alloy, and the pores are made of a first layer made of a material that can be thermally decomposed at a predetermined temperature and at least a part of the outside of the first layer made of metal or A composite powder formed by coating with an alloy and having a second layer that does not melt at the temperature is accelerated together with a gas, and at least the surface of the composite powder is kept in a solid phase state on the surface of the substrate. The film is formed by spraying and depositing, and the film is heated to the temperature to remove the material from the film.

The structure according to the present invention includes a base material formed of a metal or an alloy, and the porous body formed on the base material.

According to the present invention, a film made of a composite powder having a first layer and a second layer is formed, and pores are formed in the film by removing the material forming the first layer from the film. The diameter and porosity of the pores formed in the porous body can be easily controlled, and a porous body having a smaller pore diameter and higher porosity than before can be formed.

FIG. 1 is a flowchart showing a method for manufacturing a porous body according to Embodiment 1 of the present invention. FIG. 2 is a cross-sectional view showing a composite powder used in the method for producing a porous body shown in FIG. FIG. 3 is a schematic view showing an outline of a cold spray apparatus used in the film forming step shown in FIG. FIG. 4 is a cross-sectional view schematically showing a film formed by the film forming process shown in FIG. FIG. 5 is a cross-sectional view schematically showing a structure including a porous body according to Embodiment 1 of the present invention. FIG. 6 is a cross-sectional view showing a composite powder used in Embodiment 4 of the present invention. FIG. 7 is a cross-sectional view schematically showing a structure including a porous body according to Embodiment 4 of the present invention. FIG. 8 is a flowchart showing a method for manufacturing a porous body according to the fifth embodiment of the present invention. FIG. 9 is a flowchart showing a method for manufacturing a porous body according to the sixth embodiment of the present invention. FIG. 10 is a schematic diagram for explaining a porous body manufacturing method according to Embodiment 6 of the present invention. FIG. 11: is sectional drawing which shows typically the structure provided with the porous body which concerns on Embodiment 6 of this invention. FIG. 12 is a cross-sectional view schematically showing a structure including a porous body according to Embodiment 7 of the present invention. FIG. 13 is a schematic diagram for explaining a method for producing a composite powder used in the method for producing a porous body according to Embodiment 9 of the present invention. FIG. 14 is an electron micrograph of a cross section of the film formed by the film forming process. FIG. 15 is an electron micrograph of a cross section of the porous body according to the example.

Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the drawings. In addition, this invention is not limited by the following embodiment. The drawings referred to in the following description only schematically show the shape, size, and positional relationship so that the contents of the present invention can be understood. That is, the present invention is not limited only to the shape, size, and positional relationship illustrated in each drawing.

(Embodiment 1)
FIG. 1 is a flowchart showing a method for manufacturing a porous body according to Embodiment 1 of the present invention.
First, in step S1, a composite powder that is a raw material for the porous body is produced. FIG. 2 is a cross-sectional view schematically showing the composite powder used in step S1. As shown in FIG. 2, the composite powder 10 is a powder having a particle size of, for example, about 5 to 100 μm, and includes an inner core material layer 11 and a coating layer 12 covering the periphery of the core material layer 11. The core material layer 11 is formed of a material such as a metal or alloy, chloride, or resin, and the coating layer 12 is formed of a metal or alloy. In addition, when the core material layer 11 is formed of a metal or an alloy, a metal or alloy different from the coating layer 12 is used. The composite powder 10 will be described in detail later.

In the subsequent step S2, a base material serving as a base of the porous body is produced. The material of the base material is not particularly limited as long as it is a material capable of forming a film by a cold spray method described later. Preferably, the base material is formed of a metal or an alloy. In this case, the material of the base material may be the same as the metal or alloy forming the coating layer 12 (and the metal or alloy forming the core material layer 11 when the core material layer 11 is a metal or alloy). May be of different types. Further, the size and shape of the substrate are not particularly limited as long as it has a surface on which a film can be formed by the cold spray method.

In the subsequent step S3, a film is formed on the substrate by a cold spray method using the composite powder 10. The cold spray method is a film forming method for forming a film by accelerating the raw material powder together with a gas and spraying and depositing on the surface of the base material in the solid state, for example, a cold spray shown in FIG. This is done by the device 60.

FIG. 3 is a schematic diagram showing an outline of the cold spray device 60. As shown in FIG. 3, the cold spray device 60 includes a gas heater 61 that heats the compressed gas, a powder supply device 62 that contains the composite powder 10 and supplies the powder 10 to the spray gun 63, the heated compressed gas, and A gas nozzle 64 for injecting the composite powder 10 supplied thereto toward the base 21 and

valves

65 and 66 for adjusting the amount of compressed gas supplied to the gas heater 61 and the powder supply device 62 are provided.

As the compressed gas, helium, nitrogen, air or the like is used. The compressed gas supplied to the gas heater 61 is, for example, 50 ° C. or higher, heated to a temperature in a range lower than the melting point of the coating layer 12, and then supplied to the spray gun 63. The heating temperature of the compressed gas is preferably 300 to 900 ° C.

On the other hand, the compressed gas supplied to the powder supply device 62 supplies the composite powder 10 in the powder supply device 62 to the spray gun 63 so as to be discharged from the spray gun 63 at a predetermined discharge amount.

The heated compressed gas is made a supersonic flow (about 340 m / s or more) by the gas nozzle 64 having a divergent shape. At this time, the gas pressure of the compressed gas is preferably about 1 to 5 MPa. This is because by adjusting the pressure of the compressed gas to this level, it is possible to improve the adhesion strength between the base material 21 and the coating film 22 formed thereon. These spray conditions (temperature and pressure of the compressed gas, the discharge amount of the composite powder 10 and the like) are determined according to the characteristics of the coating layer 12 that is the outermost layer in direct contact with the compressed gas.

The composite powder 10 supplied to the spray gun 63 is injected into a supersonic flow of compressed gas and accelerated to collide with the base material 21 at a high speed while maintaining at least the surface of the composite powder 10 in a solid state. To form a film 22.

In addition, as long as it is an apparatus which can form the membrane | film | coat 22 by making the composite powder 10 collide with the base material 21 with at least the surface of the composite powder 10 maintained in a solid-phase state, it is limited to the cold spray apparatus 60 shown in FIG. Is not to be done.

FIG. 4 is a cross-sectional view schematically showing a structure in which the film 22 is formed on the base material 21 in step S3. In step S3, since the powder obtained by coating the core material layer 11 with the coating layer 12 is deposited on the base material 21, the coating 22 is formed between the cell walls 24 formed of the metal or alloy forming the coating layer 12 (that is, It has a structure in which the material 23 forming the core material layer 11 is filled in the cell). In addition, since the composite powder 10 is deformed by an impact when the composite powder 10 collides with the base material 21 when the coating 22 is formed, each cell filled with the material 23 has a thickness direction (composite). It has a flat shape in which the diameter on the surface orthogonal to the thickness direction (film forming surface of the base material 21) is larger than the diameter in the powder 10 deposition direction.

In the subsequent step S4, pores (holes) are formed in the coating 22 by immersing the coating 22 in a predetermined solution to remove the material 23 forming the core material layer 11.

The solution is prepared according to the type of the material 23 forming the core material layer 11 and the metal or alloy forming the coating layer 12. That is, the components, concentration, temperature, and the like are determined so that the core material layer 11 is dissolved and the coating layer 12 is difficult to dissolve. As a specific example, when the core material layer 11 is aluminum and the coating layer 12 is copper, hydrochloric acid is used as the solution. When the core material layer 11 is copper or a copper alloy and the coating layer 12 is nickel or a nickel alloy, concentrated nitric acid is used as a solution.

FIG. 5 is a cross-sectional view schematically showing the structure of the film after the material 23 is removed, and shows the structure including the porous body according to the first embodiment. By removing only the material 23 from the coating 22 while leaving the cell walls 24, the cells filled with the material 23 become pores 25. Thereby, the porous body 26 having a cell structure is produced. As described above, since each cell filled with the material 23 has a flat shape, the pores 25 after the material 23 is removed also have a flat shape.

The thus produced porous body 26 may be applied to various uses in the state of the structure 1 fixed on the substrate 21. At this time, the substrate 21 may be cut into a desired shape or thickness. Alternatively, the substrate 21 may be removed from the porous body 26 by cutting or dissolving it, and the porous body 26 may be used alone. When the base material 21 is dissolved, the base material 21 may be made of the same material (metal or alloy) as the core material layer 11, and the base material 21 may be dissolved together with the core material layer 11 in step S4. In addition, when cutting the base material 21 into a desired shape or thickness, it may be cut before removing the material 23 in step S4.

Next, the composite powder 10 shown in FIG. 2 will be described in detail.
The composite powder 10 is produced by coating the periphery of a powder formed of a material such as a metal or alloy, chloride, or resin with a metal or alloy. In addition, as a coating method, well-known various methods, such as a plating method and CVD method, can be used. At this time, in order to suppress the formation of an intermetallic compound by heating, it is preferable to use a coating method (for example, a plating method) in which the temperature of the metal or alloy does not increase as much as possible.

Examples of the material of the core layer 11 include magnesium, magnesium alloy, aluminum, aluminum alloy, copper, copper alloy, zinc, zinc alloy, nickel, nickel alloy, iron, iron alloy, titanium, titanium alloy, tin, tin alloy, and the like. Metals or alloys, chlorides such as sodium chloride, and resins such as urethane are used.

Examples of the material of the coating layer 12 include aluminum, aluminum alloy, copper, copper alloy, zinc, zinc alloy, nickel, nickel alloy, iron, iron alloy, titanium, titanium alloy, chromium, chromium alloy, niobium, niobium alloy, Molybdenum, molybdenum alloy, silver, silver alloy, tin, tin alloy, tantalum, tantalum alloy, tungsten, or tungsten alloy is used. In addition, when the core material layer 11 is formed of a metal or an alloy, a metal or alloy having a different type from the core material layer 11 is used as the covering layer 12.

The combination of the material forming the core material layer 11 and the metal or alloy forming the coating layer 12 is determined in consideration of the solution used in step S4. For example, when the core material layer 11 is formed of a metal or alloy, an acidic solution is used as a solution so that the metal or alloy forming the coating layer 12 has a lower ionization tendency than the metal or alloy forming the core material layer 11. Each material should be selected. Specifically, a combination of aluminum or an aluminum alloy as the core material layer 11, copper or a copper alloy as the coating layer 12, and hydrochloric acid as the solution is mentioned.

Alternatively, an oxidizing strong acid solution is used as the solution, a so-called valve metal that forms a passive film on the surface is used as the coating layer 12, and a metal or an alloy that is easily dissolved in the strong acid solution is used as the core layer 11. May be. Specifically, copper or copper alloy as the core material layer 11, aluminum, aluminum alloy, nickel, nickel alloy, titanium, titanium alloy, chromium and chromium alloy as the coating layer 12, or a combination of concentrated nitric acid as the solution. Can be mentioned.

Alternatively, the core material layer 11 may be formed of chloride that is soluble in water or an aqueous solution. In this case, the type of metal or alloy forming the coating layer 12 is not particularly limited. Specifically, for example, when sodium chloride is used as the core material layer 11, water may be used as the solution.

The core material layer 11 may be formed of a resin that can be dissolved in an organic solvent. Also in this case, the type of metal or alloy forming the coating layer 12 is not particularly limited. As an organic solvent, arbitrary things, such as acetone, ethanol, toluene, can be used. As a specific combination, for example, when a polyethylene resin is used as the core material layer 11, acetone may be used as a solution.

Further, the core material layer 11 may be formed of a resin that can be dissolved in an alkaline solution. In this case, the components, concentration, temperature, etc. of the alkaline solution are determined so that the core material layer 11 is dissolved and the coating layer 12 is difficult to dissolve. As a specific combination, when the core material layer 11 is a polyethylene resin and the coating layer 12 is nickel, a sodium hydroxide aqueous solution heated to about 90 ° C. is used as a solution.

The total size of the composite powder 10 is not particularly limited as long as it is a size applicable to the above-described cold spray method (for example, about 10 to 300 μm). Further, the diameter D of the core material layer 11 and the thickness d of the covering layer 12 are the diameter of the pores 25 (pore diameter) to be realized in the porous body 26, the thickness of the cell wall 24 (wall thickness), and the porous body 26. It is determined according to the volume ratio (porosity) of the pores 25 and the like. That is, in order to control the pore diameter, the diameter D of the core material layer 11 may be adjusted. In addition, when it is desired to control the thickness of the cell wall 24, the thickness d of the coating layer 12 may be adjusted. Furthermore, when it is desired to control the porosity, the ratio between the diameter D of the core material layer 11 and the thickness d of the covering layer 12 may be adjusted. As a specific example, a porosity of about 95% can be realized by using the core material layer 11 as an aluminum powder having an average particle size of about 30 μm and the coating layer 12 as a copper plating layer having a thickness of about 0.5 μm. .

As described above, according to the first embodiment, the material 23 that forms the core material layer 11 is removed from the coating 22 formed by the cold spray method using the composite powder 10, on the base material 21. A porous body 26 can be produced.

Further, according to the first embodiment, by adjusting the diameter D of the core layer 11 in the composite powder 10, the thickness d of the coating layer 12, and the ratio thereof, the pore diameter in the porous body 26, the cell wall The thickness of 24 and the porosity can be easily controlled. In the first embodiment, the pore diameter is given by 1 / (√k), where k is the number of pores 25 counted per 1 mm ² cross section perpendicular to the thickness direction of the porous body 26. The average pore diameter.

Specifically, according to Embodiment 1, the pore diameter can be controlled in the range of about 0.01 mm to about 1 mm. Therefore, it is possible to form minute pores that are difficult to realize in the past, for example, 0.3 mm or less, 0.02 mm or less, and 0.01 mm or less. For example, when the porous body 26 having a small pore diameter of preferably 0.01 mm or more and 0.1 mm or less is applied to, for example, a catalyst or a heat radiating member, a large specific surface area can be ensured. It is possible to improve the performance of the heat dissipation member and the like.

Further, according to the first embodiment, the porosity can be controlled in a range of about 30% or more and less than 100%. Therefore, it is possible to achieve a high porosity of 75% or more, or 85% or more, which has been difficult to realize in the past. For example, when the high porosity porous body 26 having a porosity of preferably 75% or more is applied to, for example, a filter, the pressure loss of the fluid can be kept low.

Furthermore, according to Embodiment 1, the pore diameter and the porosity can be simultaneously controlled within the above-described range. For example, the porosity can be controlled within a desired range of 30% or more and less than 100% while the pore diameter is set to a minute diameter of 0.01 mm or more and 0.3 mm or less. Alternatively, the pore diameter can be controlled to a desired diameter of 0.01 mm or more and 1 mm or less while the porosity is set to a high porosity of 85% or more and less than 100%. Therefore, for example, it is possible to produce a porous body having a small pore diameter and a high porosity of 0.01 mm or more and 0.3 mm or less and a porosity of 85% or more.

The porous body 26 has a cell structure in which pores 25 are formed inside (inside the cell) the cell wall 24 made of metal or alloy. In such a cell structure, the ratio of the surface area of the cell wall 24 to the porosity is higher than that of other porous structures such as a mesh shape. Therefore, by using such a porous body 26 as a catalyst carrier, for example, the efficiency of the catalytic action can be improved.

Further, in the porous body 26, since the cell wall 24 is formed by the cold spray method, the cell wall 24 itself is very dense and is in close contact with the base material 21. Therefore, good electrical conductivity and thermal conductivity can be obtained in the cell wall 24, and good electrical conductivity and thermal conductivity can be ensured between the cell wall 24 and the substrate 21. Therefore, by using such a porous body 26 or the structure 1 including the porous body 26 as an electrode member in a battery or the like, the efficiency of the battery or the like can be improved. Moreover, it becomes possible to improve the heat exchange efficiency of the circuit board provided in a heat sink by using the structure 1 as a heat sink.

Further, as described above, since the cell wall 24 in the porous body 26 is very dense and is in close contact with the base material 21, higher durability than that of the conventional porous body can be obtained. Therefore, when such a porous body 26 or the structure 1 including the porous body 26 is applied to various modules, it is possible to extend the lifetime of the module as compared with the related art.

Further, according to the first embodiment, a porous body can be produced on a desired base material, regardless of the shape and size of the base material, as long as the base material can form a film by the cold spray method. Accordingly, it is possible to increase the degree of freedom in designing a module using a porous body.

(Embodiment 2)
Next, a second embodiment of the present invention will be described.
In the second embodiment, when a film is formed by a cold spray method (see step S3 in FIG. 1), a powder (hereinafter referred to as a single layer) consisting only of a metal or an alloy that forms the coating layer 12 (see FIG. 2). It is characterized by using a mixed powder obtained by mixing a composite powder 10). For example, when using the composite powder 10 in which the core material layer 11 is made of aluminum and the coating layer 12 is made of copper, the composite powder 10 is mixed with copper powder.

Thus, the ratio of the material 23 and the cell wall 24 in the coating 22 (see FIG. 4) can be changed by mixing the single layer powder into the composite powder 10. Thus, the thickness and porosity of the cell wall 24 in the porous body 26 (see FIG. 5) after removing the material 23 from the coating 22 can be controlled more easily.

(Embodiment 3)
Next, a third embodiment of the present invention will be described.
The third embodiment is characterized in that, when the material forming the core material layer 11 (see FIG. 2) is removed (see step S4 in FIG. 1), the film is heated instead of immersing the film in the solution. To do.

In the third embodiment, the core material layer 11 of the composite powder 10 is formed of a material that can be thermally decomposed at a predetermined temperature, and the coating layer 12 is formed of a metal or alloy that does not melt at the temperature. Specifically, polyethylene that thermally decomposes at about 500 ° C. is used as the core material layer 11, and copper that does not melt at 500 ° C. is used as the coating layer 12.

In step S3, after forming the film 22 on the base material 21 using the composite powder 10 (see FIG. 4), in step S4, for example, the film 22 is heated to about 500 ° C. by an electric furnace, and the material 23 is Remove by pyrolysis. Thereby, the porous body 26 (refer FIG. 5) which has a cell structure can be obtained.

(Modification)
Next, a modification of the third embodiment of the present invention will be described.
As the core material layer 11 of the composite powder 10, for example, a resin material that can be hydrolyzed by steam may be used. A specific example of such a resin material is polyethylene terephthalate (PET). Moreover, as the coating layer 12, a metal or an alloy that is not highly reactive in the hydrolysis treatment for the resin material can be used.

In this case, after forming the film 22 on the base material 21 with the composite powder 10 using PET as the core material layer 11, the base material 21 and the film 22 are placed in a chamber filled with water vapor heated to 150 ° C. or higher. And coat 22 is exposed to water vapor. Thereby, the material 23 made of PET in the coating 22 is hydrolyzed and removed. The raw material material before the polymerization of PET remaining in the film 22 by hydrolysis may be removed by washing the film 22.

(Embodiment 4)
Next, a fourth embodiment of the present invention will be described.
Embodiment 4 is characterized in that a composite powder composed of multiple layers is used in the method for manufacturing a porous body shown in FIG.

FIG. 6 is a cross-sectional view showing the structure of the composite powder 30 used in the fourth embodiment. The composite powder 30 shown in FIG. 6 has a core material layer 31 and a first coating layer 32 and a second coating layer 33 formed around the core material layer 31. Like the core material layer 11 shown in FIG. 2, the core material layer 31 is made of a material such as a metal or an alloy, chloride, or resin that can be dissolved in a predetermined solution. On the other hand, the 1st coating layer 32 and the 2nd coating layer 33 are hard to melt | dissolve with respect to the said solution than the core material layer 31, and consist of a mutually different kind of metal or alloy. The first coating layer 32 and the second coating layer 33 are formed by sequentially coating the core material layer 31 by a plating method or the like.

In the fourth embodiment, the composite powder 30 is used to form a film on the base material by a cold spray method (step S3), and the material that forms the core layer 31 by immersing the film in the solution. By removing, pores are formed (step S4). Details of the steps S3 and S4 are the same as those in the first embodiment.

FIG. 7 is a cross-sectional view showing the structure 2 including the porous body 42 produced in step S4. By removing the material forming the core material layer 31 from the film formed on the base material 41, a porous body 42 in which pores 44 are formed between the cell walls 43 as shown in FIG. The cell wall 43 has a layer structure composed of a metal or alloy 45 forming the first coating layer 32 and a metal or alloy 46 forming the second coating layer 33.

In such a porous body 42, for example, the second coating layer 33 (metal or alloy 46) is formed of a highly conductive metal or alloy such as copper, and the first coating layer 32 (metal or alloy 45) is platinum or the like. By forming the catalyst metal, a porous body carrying the catalyst can be easily produced. In this case, the core material layer 31 of the composite powder 30 may be formed of aluminum having a higher ionization tendency than copper and platinum, for example.

As described above, according to the fourth embodiment, by increasing the number of layers of the composite powder 30, it is possible to easily produce a porous body composed of cell walls having a layer structure. In addition, it is also possible to make a cell wall further multilayer by making the coating layer in composite powder into three or more layers.

(Modification)
Also in the fourth embodiment, similarly to the third embodiment, the core material layer 31 may be formed of a thermally decomposable material (for example, a resin such as polyethylene). In this case, in step S4, the film may be heated to remove the material forming the core layer 31 by thermal decomposition. Alternatively, similarly to the modification of the third embodiment, the core material layer 31 may be formed of a hydrolyzable material (for example, PET).

(Embodiment 5)
Next, a fifth embodiment of the present invention will be described.
FIG. 8 is a flowchart showing a method for manufacturing a porous body according to the fifth embodiment. Steps S1 to S4 shown in FIG. 8 are the same as those described in the first embodiment.

In step S5 subsequent to step S4, the cell wall 24 (see FIG. 5) remaining on the substrate 21 is plated to form a plating layer, and the cell wall 24 is coated. The metal or alloy forming the plating layer is not particularly limited, and may be selected according to the use of the porous body. For example, it can be used as a negative electrode material of a nickel metal hydride battery by performing palladium plating on the cell wall 24 formed of copper.

As described above, by performing the plating process on the porous body 26 in which the pores 25 are formed, the cell wall can be multilayered (multiple layers) as in the porous body 42 shown in FIG.
Note that step S5 in the fifth embodiment may be applied to the second to fourth embodiments.

(Embodiment 6)
Next, a sixth embodiment of the present invention will be described.
FIG. 9 is a flowchart showing a method for manufacturing a porous body according to the sixth embodiment. FIG. 10 is a schematic diagram for explaining a method for manufacturing a porous body according to the sixth embodiment. Note that steps S1 to S3 shown in FIG. 9 are the same as those described in the first embodiment. However, as the composite powder 10, the core material layer 11 and the coating layer 12 formed of different metals or alloys are used. More specifically, the composite powder 10 comprising the core material layer 11 and the coating layer 12 is a combination of metals or alloys capable of forming an intermetallic compound at the interface contacting each other, such as aluminum and copper or aluminum and nickel. Prepare.

In step S6 following step S3, heat treatment is performed on the film 22 (see FIG. 4) formed on the substrate 21. As a result, as shown in FIG. 10, an intermetallic compound layer 51 is formed at the interface between the material (alloy or metal) 23 forming the core layer 11 and the cell wall 24 formed of the metal or alloy forming the coating layer 12. Is done. For example, when the core layer 11 is formed of aluminum and the coating layer 12 is formed of nickel, an intermetallic compound is formed at the interface between the material 23 and the cell wall 24 by heating at 500 to 600 ° C.

In the subsequent step S7, pores are formed in the coating 22 by immersing the coating 22 on which the intermetallic compound layer 51 is formed in a predetermined solution and removing the material 23 of the unreacted portion. A specific example of the solution for dissolving the material 23 of the unreacted portion is the same as that described in step S4 of the first embodiment.

FIG. 11 is a cross-sectional view showing the structure 3 including the porous body formed thereby. By removing the material 23, a porous body 53 in which the surface layer of the cell wall 24 (the contact surface with the pores 52) is covered with the intermetallic compound layer 51 is formed.

The thickness of the intermetallic compound layer 51 can be controlled by the time and temperature of the heat treatment in step S6. For example, FIG. 11 shows the case where only the surface layer of the cell wall 24 is reacted with the material 23 to form the intermetallic compound layer 51. However, by sufficiently performing the heat treatment in step S6, the entire cell wall 24 is reacted. You may let them. In this case, the cell wall 24 (porous body) made only of the intermetallic compound can be formed on the substrate 21.

For example, in the case of using a composite powder 10 composed of an aluminum core layer 11 and a coating layer 12 formed by nickel plating, the intermetallic compound layer formed by the reaction between aluminum and nickel is resistant to corrosion like ceramics. And it becomes a layer excellent in heat resistance. Since such intermetallic compounds are generally brittle compared to metals, it is usually difficult to make them porous. However, according to the sixth embodiment, a porous body made of an intermetallic compound having excellent corrosion resistance and heat resistance and having a small pore diameter can be produced relatively easily.

The porous body manufacturing method according to the sixth embodiment may be combined with the second, fourth, and fifth embodiments. When combining the manufacturing method of the porous body which concerns on Embodiment 6 with Embodiment 2, for example, the quantity of the powder of the single layer mixed with the composite powder 10 is adjusted, and the thickness of the cell wall 24 in the film | membrane 22 is controlled. At the same time, the thickness of the intermetallic compound layer 51 can be more easily adjusted by controlling the heat treatment conditions (time and temperature) in step S6.

Moreover, when combining the manufacturing method of the porous body which concerns on this Embodiment 6 with Embodiment 4, it forms in process S3 by selecting suitably the metal or alloy which comprises each layer of the composite powder 30 (refer FIG. 6). A desired interface (the interface between the metal or alloy forming the core layer 31 and the metal or alloy forming the first coating layer 32, or the metal or alloy forming the first coating layer 32 and the second coating layer) An intermetallic compound layer can be formed at the interface between the metal 33 and the metal or the alloy 33. In the latter case, a composite powder 30 in which the core layer 31 is formed of a resin material can be used as the material.

Moreover, when the method for manufacturing a porous body according to the sixth embodiment is combined with the fifth embodiment, a porous body in which the surface of the intermetallic compound layer 51 is further covered by plating can be obtained.

(Embodiment 7)
Next, a seventh embodiment of the present invention will be described.
FIG. 12 is a cross-sectional view schematically showing a structure including a porous body according to the seventh embodiment. As shown in FIG. 12, the structure 4 includes a base material 21 and a porous body 26 formed on both surfaces of the base material 21.

As in the first embodiment, each porous body 26 is formed by sequentially forming the coating 22 on both surfaces of the base material 21 by the cold spray method using the composite powder 10 (see FIG. 2), and then dissolving each coating 22. It is produced by sequentially immersing in a liquid and removing the material forming the core material layer 11.

Such a structure 4 is formed by, for example, forming the base material 21 by a thin plate that can be wound, forming the porous body 26 on both surfaces of the base material 21, and then winding the base body 21 together with a sheet-like insulating member. It can be used as an electrode member.

(Embodiment 8)
Next, an eighth embodiment of the present invention will be described.
In the first to seventh embodiments, the film 22 is formed on the

base materials

21 and 41 by the cold spray method (see step S3 in FIG. 1). However, a technique other than the cold spray method may be used as long as a dense film composed of the

composite powders

10 and 30 can be formed. For example, a mold press in which the composite powders 10 and 30 are filled in a mold and the pressure is applied to compress the mold press, or a cold isotropic pressurization in which the composite powders 10 and 30 are filled in a mold and a pressure is applied. The composite powders 10 and 30 can be formed into a desired shape by a high pressure powder forming technique such as a pressure method. Under the present circumstances, the film | membrane which consists of the

composite powders

10 and 30 may be formed on the

base materials

21 and 41, and the film | membrane which consists of the

composite powders

10 and 30 may be produced as a single molded object.

In the same manner as in the first embodiment, the film composed of the

composite powders

10 and 30 is immersed in a solution selected according to the core material layers 11 and 31 and the coating layers 12, 32 and 33, and the core material layer 11 is immersed. By removing, a porous body can be produced. Or you may remove the core material layers 11 and 31 by thermal decomposition similarly to Embodiment 3. FIG.

According to the eighth embodiment, by adjusting the diameter D of the core material layers 11 and 31 in the

composite powders

10 and 30, the thickness d of the coating layers 12, 32 and 33, and the ratio thereof, The pore diameter, cell wall thickness, and porosity can be easily controlled.

Specifically, the pore diameter can be controlled in the range of about 0.01 mm to about 1 mm. Therefore, it is possible to form minute pores that are difficult to realize in the past, for example, 0.3 mm or less, 0.02 mm or less, and 0.01 mm or less. In the eighth embodiment, the pore diameter is an average pore diameter given by 1 / (√k) where k is the number of pores counted per 1 mm ² of a cross section of the porous body. Say.

Further, according to the eighth embodiment, the porosity can be controlled in the range of about 30% or more and less than 100%. Therefore, it is possible to achieve a high porosity of 75% or more, or 85% or more, which has been difficult to realize in the past.

Furthermore, according to the eighth embodiment, the pore diameter and the porosity can be controlled simultaneously within the above-described range. For example, the porosity can be controlled within a desired range of 30% or more and less than 100% while the pore diameter is set to a minute diameter of 0.01 mm or more and 0.3 mm or less. Alternatively, the pore diameter can be controlled to a desired diameter of 0.01 mm or more and 1 mm or less while the porosity is set to a high porosity of 85% or more and less than 100%. Therefore, for example, it is possible to produce a porous body having a small pore diameter and a high porosity of 0.01 mm or more and 0.3 mm or less and a porosity of 85% or more.

Further, in the case where a film composed of the

composite powders

10 and 30 is produced by the high-pressure powder molding technique, substantially equal pressure acts on the

composite powders

10 and 30 regardless of the direction. Will not deform in a specific direction. Therefore, it is possible to obtain a porous body having an average pore diameter substantially equal in the cross section in the thickness direction and the cross section orthogonal to the thickness direction.

(Modification)
Also in the above-described eighth embodiment, similarly to the fifth embodiment, the cell wall is multilayered (multi-layered) by further plating the porous body in which the pores are formed by removing the core material layer. )

(Embodiment 9)
Next, a ninth embodiment of the present invention will be described.
In the first to eighth embodiments, when the coating 22 (see FIG. 4) is formed on the substrate 21, the periphery of the core material layers 11 and 31 is the covering layer 12, or the first covering layer 32 and the second covering layer. The composite powders 10 and 30 coated with the coating layer 33 were used (see FIGS. 2 and 6). However, the entire periphery of the core material layers 11 and 31 is not necessarily covered with the coating layer 12 or the like, and the core material layers 11 and 31 may be exposed from a part of the coating layer 12 or the like. Alternatively, instead of the

composite powders

10 and 30, composite powder in which only the outer peripheral surface of the cylindrical core material layer is covered with the material of the coating layer may be used. Hereinafter, a method for producing such a composite powder will be described.

FIG. 13 is a schematic diagram for explaining a method for producing a composite powder in the ninth embodiment. First, magnesium, magnesium alloy, aluminum, aluminum alloy, copper, copper alloy, zinc, zinc alloy, nickel, nickel alloy, iron, iron alloy, titanium, titanium alloy, tin, tin alloy and other metals or alloys, sodium chloride, etc. A wire made of a resin such as chloride or urethane is prepared. These materials are the same as the material of the core material layer 11 in the first embodiment. The method for producing the wire is not particularly limited, and various known methods such as wire drawing and drawing can be used.

Subsequently, as shown in FIG. 13 (a), the outer peripheral surface of the wire 71 made of the above material is made of aluminum, aluminum alloy, copper, copper alloy, zinc, zinc alloy, nickel, nickel alloy, iron, iron alloy, titanium. The coating layer 72 is made of titanium alloy, chromium, chromium alloy, niobium, niobium alloy, molybdenum, molybdenum alloy, silver, silver alloy, tin, tin alloy, tantalum, tantalum alloy, tungsten, tungsten alloy, or the like. Note that these materials are the same as the material of the coating layer 12 in the first embodiment. When the wire 71 is formed of a metal or an alloy, a metal or alloy having a different type from the wire 71 is used as the covering layer 72. Moreover, the formation method of the coating layer 72 is not specifically limited, Well-known various methods, such as a plating method and CVD method, can be used.

Subsequently, as shown in FIG. 13B, the composite wire 70 in which the wire 71 is covered with the coating layer 72 is cut into a desired length. Thereby, the outer peripheral surface of the cylindrical core material layer 74 is covered with the coating layer 75, and the composite powder 73 in which the end surface of the core material layer 74 is exposed is obtained.

Here, the combination of the material forming the wire rod 71 (core material layer 74) and the metal or alloy forming the coating layer 72 (coating layer 75) is the same as in the first or third embodiment, in the core material layer removing step (FIGS. 1 and 3). It is determined according to the type of solution used in step S4 in FIG. 8 or step S7 in FIG. Alternatively, as in the sixth embodiment, a combination of metals or alloys capable of forming an intermetallic compound at the interface may be selected.

Moreover, the coating layer formed around the wire 71 (core material layer 74) is not limited to one layer of the coating layer 72 (coating layer 75). That is, as in the fourth embodiment, one or more coating layers made of a metal or an alloy different from the coating layer 72 may be further formed on the outer peripheral surface of the coating layer 72.

The diameter d1 of the wire 71 and the thickness d2 of the covering layer 72 are determined according to the pore size, cell wall thickness, porosity, etc. that are desired to be realized in the completed porous body (for example, the porous body 26 shown in FIG. 5). Is done. For example, when controlling the pore size, the diameter d1 of the wire 71 and the length L of the composite powder 73 may be adjusted. In addition, when the thickness of the cell wall is controlled, the thickness d2 of the covering layer 72 may be adjusted. Further, in the case of controlling the porosity, the ratio of the diameter d1 of the wire 71 and the thickness d2 of the coating layer 72, or may be adjusting the ratio between the diameter D ₂ and a length L of the composite powder 73 .

The diameter D ₂ and the length L of the composite powder 73 are appropriately determined within a range (for example, about 10 to 300 μm) applicable to the cold spray method and the high pressure powder molding technique. For example, when the porosity is controlled by the ratio of the diameter D and the length L of the composite powder 73, the porosity can be decreased as the length L is increased, and the porosity is decreased as the length L is decreased. Can be high. However, if the length L is too short, the ratio of the surface area of the coating layer 75 to the surface area of the composite powder 73 decreases, and other composites are formed when the coating 22 is formed by the cold spray method or the high-pressure powder molding technique. There is a possibility that the coating layers 72 are difficult to bond with the powder 73. Therefore, in order to reliably bond the coating layers 72 of the composite powder 73 in the coating 22 and to stably produce the porous body 26, the ratio D ₂ of the diameter D ₂ and the length L of the composite powder 73. The range of / L is preferably about 0.5 ≦ D ₂ / L ≦ 2. For example, when the diameter D ₂ is about 30 μm, the length L is preferably about 15 to 60 μm.

As described above, according to the ninth embodiment, since the composite wire 70 in which the coating layer 72 is formed on the wire 71 is cut into a powder form, the coating layer is formed on the core material layer 11 that has been previously powdered. Compared with the case of forming No. 12, the composite powder 73 can be manufactured very easily, in a short time and at low cost. For example, according to the ninth embodiment, the composite powder 73 having the coating layer 75 made of aluminum can be easily manufactured. Therefore, it is possible to reduce the labor and cost of manufacturing the composite powder 73 and the porous body manufactured using the composite powder 73.

Further, according to the ninth embodiment, the size (diameter D and length L) of the composite powder 73, the diameter d1 of the core material layer 74, and the thickness d2 of the coating layer 75 can be adjusted easily and accurately. it can. Therefore, the pore size, cell wall thickness, and porosity in the porous body can be controlled easily and accurately.

Further, according to the ninth embodiment, any material that can be coated on the wire 71 can be used as the coating layer 72. Therefore, the combination of the material of the core layer 74 and the coating layer 75 in the composite powder 73 is used. Can be widened. Therefore, the range of selection of the method to be applied in the core material layer removing step can be expanded.

For example, when the composite powder 73 is produced by the composite wire 70 in which the coating layer 72 made of aluminum is formed on the wire 71 made of resin, the resin of the core material layer 74 is dissolved in an organic solvent in the core material layer removing step, or The porous body made of aluminum can be produced in a short time by pyrolysis.

Further, according to the ninth embodiment, even when a plurality of coating layers are provided outside the core material layer 74, the range of selection of the material of each coating layer can be increased, and the layer thickness and the number of layers of each layer can be increased. Can be easily controlled.

The porous body described in the first to ninth embodiments can be used for various applications exemplified below in addition to the application examples described in the respective embodiments.
For example, the heat exchange performance can be improved by forming the surface of the heat sink with the porous body according to Embodiments 1 to 5 or 8, 9 described above.

Further, by using the structure including the porous body according to Embodiments 1 to 6, 8, or 9 described above for a housing or a wall member of various devices, sound absorption or soundproof performance can be improved.
Further, by applying the porous body according to Embodiments 1 to 5, 8 or 9 to the catalyst filter, the thermal conductivity and the impact resistance can be improved.

Hereinafter, examples of the present invention will be described. In this example, an experiment for producing a porous body on a substrate was performed by the method for producing a porous body according to the first embodiment.

As the composite powder, a powder obtained by performing copper plating on an aluminum powder having an average particle diameter of about 30 μm was prepared. The average particle diameter of the composite powder as a whole was about 32 μm.

Using such a composite powder, spray conditions are set on a substrate made of pure aluminum (A1050) by a cold spray method with an inert gas (nitrogen) temperature of about 500 ° C. and a gas pressure of 5 MPa. A film was formed on.

FIG. 14 is a SEM (scanning electron microscope) photograph of a cross-section of the film formed on the substrate. As shown in FIG. 14, copper (Cu) forming a cell structure and aluminum (Al) filled between the cell structures (inside the cell) are observed inside the coating.

Thereafter, the film was immersed in a solution under the following conditions to remove aluminum.
Type of liquid: hydrochloric acid Concentration: 50%
Temperature: 30 ° C
Soaking time: 5 minutes

FIG. 15 is an SEM photograph of a cross section of the film after the aluminum has been removed. As shown in FIG. 15, the region after the aluminum was removed became pores, and only the cell walls made of copper remained on the substrate. In the porous body thus produced, the pore diameter (average value) in the thickness direction (film deposition direction) is about 10 μm, and the pore diameter (average value) in the plane perpendicular to the thickness direction is It was about 30 μm, and it was confirmed that flat pores were formed.

1, 2, 3, 4

Structure

10, 30, 73

Composite powder

11, 31, 74

Core material layer

12, 72, 75

Cover layer

21, 41 Base material 22 Film 23

Material

24, 43

Cell wall

25, 44, 52

Pore

26, 42, 53 Porous body 32 First coating layer 33

Second coating layer

45, 46 Metal or alloy 51 Intermetallic compound layer 60 Cold spray device 61 Gas heater 62 Powder supply device 63 Spray gun 64

Gas nozzle

65, 66 Valve 70 Composite wire 71 Wire

Claims

A first layer made of a material that can be dissolved in a predetermined solution, and at least part of the outside of the first layer is coated with a metal or an alloy, and the solution is more than the first layer. A film forming step of forming a film made of a composite powder having a second layer that is difficult to dissolve,
A pore forming step of forming pores in the coating by immersing the coating in the solution and removing the material from the coating;
The manufacturing method of the porous body characterized by including.
A first layer made of a material that can be thermally decomposed at a predetermined temperature; and a second layer that is formed by coating at least a part of the outside of the first layer with a metal or an alloy, and does not melt at the temperature. A film forming step of forming a film made of a composite powder having:
A pore forming step of forming pores in the coating by heating the coating to the temperature and removing the material from the coating;
The manufacturing method of the porous body characterized by including.
3. The composite powder according to claim 1, wherein the composite powder is formed by cutting a composite wire obtained by coating a wire made of the material of the first layer with a material of the second layer. The manufacturing method of the porous body of description.
The film forming step includes accelerating the composite powder together with a gas and spraying and depositing at least the surface of the composite powder on the surface of the base material while keeping the surface of the composite powder in a solid state. The manufacturing method of the porous body of any one of these.
The porous film according to claim 4, wherein in the film forming step, the composite powder is mixed with a powder made of only the same kind of metal or alloy as the metal or alloy forming the outermost layer and sprayed onto the substrate. Body manufacturing method.
The method for producing a porous body according to any one of claims 1 to 3, wherein in the film forming step, the composite powder is filled in a mold and pressure is applied.
2. The method for producing a porous body according to claim 1, wherein the material is a metal or an alloy different in type from the second layer.
The method for producing a porous body according to claim 7, further comprising a step of heat-treating the film before the pore forming step.
The solution is an acidic solution;
The method for producing a porous body according to claim 7 or 8, wherein the ionization tendency of the metal or alloy forming the second layer is smaller than the ionization tendency of the material.
The material is aluminum or an aluminum alloy,
The method for producing a porous body according to claim 9, wherein the metal or alloy forming the second layer is copper or a copper alloy.
The solution is an acidic solution;
The second layer comprises a valve metal;
The method for producing a porous body according to claim 7, wherein the material is more easily dissolved in the solution than the passive film formed on the surface of the second layer.
The material is copper or a copper alloy,
The porous body according to claim 11, wherein the metal or alloy forming the second layer is any one of aluminum, aluminum alloy, nickel, nickel alloy, titanium, titanium alloy, chromium, and chromium alloy. Manufacturing method.
2. The method for producing a porous body according to claim 1, wherein the material is a chloride that is soluble in water or an aqueous solution.
The method for producing a porous body according to claim 13, wherein the chloride is sodium chloride.
The method for producing a porous body according to claim 1, wherein the material is a resin that is soluble in an organic solvent.
2. The method for producing a porous body according to claim 1, wherein the material is a resin that is soluble in an alkaline solution.
The composite powder is a third layer provided outside the second layer, and is composed of a second metal or alloy different in type from the metal or alloy forming the second layer, The method for producing a porous body according to any one of claims 1 and 7 to 16, further comprising a third layer that is less soluble in the solution than the first layer.
The method for producing a porous body according to claim 2, wherein the material is a resin.
The composite powder is a third layer provided outside the second layer, and is composed of a second metal or alloy different from the metal or alloy, and does not melt at the temperature. The method for producing a porous body according to claim 2, further comprising a layer.
The method for producing a porous body according to any one of claims 1 to 19, further comprising a step of forming a plating layer on the film in which the pores are formed after the pore forming step.
A porous body having a cell wall made of a metal or an alloy or an intermetallic compound, and pores formed between the cell walls,
A porous body, wherein an average pore diameter of the pores is 0.01 mm or more and 0.3 mm or less, and a volume ratio of the pores to the porous body is 30% or more and less than 100%.
A porous body having a cell wall made of a metal or an alloy or an intermetallic compound, and pores formed between the cell walls,
A porous body, wherein an average pore diameter of the pores is 0.01 mm or more and 1 mm or less, and a volume ratio of the pores to the porous body is 85% or more and less than 100%.
A porous body having a cell wall made of a metal or an alloy or an intermetallic compound, and pores formed between the cell walls,
The porous body has a flat shape in which a diameter in a surface orthogonal to the thickness direction is larger than a diameter in the thickness direction of the porous body.
The average pore diameter in a cross section perpendicular to the thickness direction of the pores is 0.01 mm or more and 1 mm or less, and the volume ratio of the pores to the porous body is 30% or more and less than 100%. 24. The porous body according to 23.
The porous body according to any one of claims 21 to 24, wherein the cell wall has a layered structure in which a plurality of different metals or alloys are stacked.
The porous body according to any one of claims 21 to 25, further comprising a plating layer formed on the cell wall.
The cell wall is made of metal or alloy,
The porous body according to any one of claims 21 to 26, further comprising an intermetallic compound layer formed on a surface of the cell wall.
The pores are formed by coating a first layer made of a material that can be dissolved in a predetermined solution and at least a part of the outside of the first layer with a metal or an alloy. In addition, the composite powder having the second layer that is hardly soluble in the solution is accelerated together with the gas, and at least the surface of the composite powder is kept in a solid state and sprayed onto the surface of the base material for deposition. The porous body according to claim 23 or 24, wherein the porous body is formed by forming a film by immersing the film, immersing the film in the solution, and removing the material from the film.
The cell wall is made of metal or alloy,
The pores are formed by coating a first layer made of a material that can be thermally decomposed at a predetermined temperature and at least a part of the outside of the first layer with a metal or an alloy, and do not melt at the temperature. The composite powder having two layers is accelerated together with the gas, and a film is formed by spraying and depositing on the surface of the base material while maintaining at least the surface of the composite powder in a solid phase, The porous body according to claim 23 or 24, which is formed by heating to a temperature and removing the material from the film.
A substrate formed of a metal or alloy;
The porous body according to claim 28 or 29, formed on the substrate;
A structure characterized by comprising.