JP5035756B2 - Porous body and method for producing the porous body - Google Patents
Porous body and method for producing the porous body Download PDFInfo
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- JP5035756B2 JP5035756B2 JP2008110028A JP2008110028A JP5035756B2 JP 5035756 B2 JP5035756 B2 JP 5035756B2 JP 2008110028 A JP2008110028 A JP 2008110028A JP 2008110028 A JP2008110028 A JP 2008110028A JP 5035756 B2 JP5035756 B2 JP 5035756B2
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- 238000004519 manufacturing process Methods 0.000 title claims description 9
- 229910052751 metal Inorganic materials 0.000 claims description 46
- 239000002184 metal Substances 0.000 claims description 46
- 239000006260 foam Substances 0.000 claims description 44
- CAVCGVPGBKGDTG-UHFFFAOYSA-N alumanylidynemethyl(alumanylidynemethylalumanylidenemethylidene)alumane Chemical compound [Al]#C[Al]=C=[Al]C#[Al] CAVCGVPGBKGDTG-UHFFFAOYSA-N 0.000 claims description 37
- 229910052782 aluminium Inorganic materials 0.000 claims description 22
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical group [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 20
- 229930195733 hydrocarbon Natural products 0.000 claims description 15
- 150000002430 hydrocarbons Chemical class 0.000 claims description 15
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 11
- 238000010438 heat treatment Methods 0.000 claims description 11
- 239000000126 substance Substances 0.000 claims description 11
- 239000004215 Carbon black (E152) Substances 0.000 claims description 9
- 229910052759 nickel Inorganic materials 0.000 claims description 4
- 239000006262 metallic foam Substances 0.000 claims description 3
- 230000001590 oxidative effect Effects 0.000 claims description 3
- 238000000034 method Methods 0.000 description 10
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 8
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 6
- 239000002912 waste gas Substances 0.000 description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 239000011148 porous material Substances 0.000 description 4
- OTMSDBZUPAUEDD-UHFFFAOYSA-N Ethane Chemical compound CC OTMSDBZUPAUEDD-UHFFFAOYSA-N 0.000 description 3
- 229910052799 carbon Inorganic materials 0.000 description 3
- 239000010419 fine particle Substances 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 239000001294 propane Substances 0.000 description 3
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- OFBQJSOFQDEBGM-UHFFFAOYSA-N Pentane Chemical compound CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 2
- 229920005830 Polyurethane Foam Polymers 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- -1 ethylene, propylene, butene Chemical class 0.000 description 2
- NNPPMTNAJDCUHE-UHFFFAOYSA-N isobutane Chemical compound CC(C)C NNPPMTNAJDCUHE-UHFFFAOYSA-N 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- 238000007747 plating Methods 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 239000011496 polyurethane foam Substances 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- HSFWRNGVRCDJHI-UHFFFAOYSA-N alpha-acetylene Natural products C#C HSFWRNGVRCDJHI-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 229910001873 dinitrogen Inorganic materials 0.000 description 1
- 239000007772 electrode material Substances 0.000 description 1
- 238000007772 electroless plating Methods 0.000 description 1
- 238000009713 electroplating Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 125000002534 ethynyl group Chemical group [H]C#C* 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 239000001282 iso-butane Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 230000001376 precipitating effect Effects 0.000 description 1
- 238000000746 purification Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
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- Exhaust Gas Treatment By Means Of Catalyst (AREA)
- Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)
- Carbon And Carbon Compounds (AREA)
- Powder Metallurgy (AREA)
- Filtering Materials (AREA)
Description
本発明は、極めて大きな表面積を有する多孔体に関する。より詳しくは、発泡金属の骨格表面に微細な髭状物質を形成した多孔体に関する。 The present invention relates to a porous body having an extremely large surface area. More specifically, the present invention relates to a porous body in which a fine rod-like substance is formed on the surface of a foam metal skeleton.
ＮiやＦeを主成分とした発泡金属は気孔率が高く、三次元に連結した骨格組織を持つ、公知の多孔体材料で、高気孔率で通気性が高いことから各種の濾過フィルタとして、あるいはその高表面積を利用して電極材料等に応用されており、近年の環境問題から益々重要性が増大している。 Foamed metal mainly composed of Ni or Fe is a known porous material having a high porosity and a three-dimensionally connected skeletal structure, and has high porosity and high air permeability. The high surface area has been applied to electrode materials and the like, and it has become increasingly important due to recent environmental problems.
しかし、通常の発泡金属の細孔径は５０μｍ程度までしか小さくならないために、例えばフィルタとして使用する場合、骨格の表面積が小さく、これよりも小さな微粒子の捕集が困難であるし、また、電極用としても表面積不足は否めなかった。 However, since the pore diameter of ordinary foamed metal is only reduced to about 50 μm, for example, when used as a filter, the surface area of the skeleton is small, and it is difficult to collect fine particles smaller than this. However, the lack of surface area could not be denied.
そこで本発明は上記問題点に鑑みて、骨格の表面積が極めて大きな多孔体及び該多孔体の製造方法を提供することを課題とする。 In view of the above problems, an object of the present invention is to provide a porous body having a very large skeleton surface area and a method for producing the porous body.
本発明は、発泡金属の骨格表面に微細な髭状材料を形成し、大きな表面積を持つ多孔体を提供する。本発明は以下の構成からなる。 The present invention provides a porous body having a large surface area by forming a fine bowl-shaped material on the surface of a skeleton of a foam metal. The present invention has the following configuration.
（１）本発明に係る多孔体は、三次元網目構造を持つ発泡金属の骨格の表面に、炭化アルミニウムウィスカーが形成されたことを特徴とする。
（２）上記（１）に記載の多孔体であって、前記発泡金属がＮi、Ｃr又はＦeであることを特徴とする。
（３）上記（１）又は（２）に記載の多孔体であって、前記発泡金属の骨格表面に炭化アルミニウム相が形成されていることを特徴とする。
（４）上記（３）に記載の多孔体であって、前記発泡金属の骨格表面の炭化アルミニウム相から、複数の前記炭化アルミニウムウィスカーが成長していることを特徴とする。
（５）上記（１）〜（４）のいずれか一に記載の多孔体であって、前記炭化アルミニウムウィスカーが、前記発泡金属の骨格表面から外側に延びるように形成されて層を形成し、前記発泡金属の骨格表面に炭化アルミニウムウィスカー層が形成されていることを特徴とする。
（６）上記（３）〜（５）のいずれか一に記載の多孔体であって、前記炭化アルミニウム相が、前記発泡金属の表面の少なくとも一部の領域に形成されていることを特徴とする。
(1) The porous body according to the present invention is characterized in that aluminum carbide whiskers are formed on the surface of a skeleton of a foam metal having a three-dimensional network structure.
(2) The porous body according to the above (1), wherein the foam metal is Ni, Cr or Fe.
(3) The porous body according to (1) or (2) above, wherein an aluminum carbide phase is formed on the surface of the skeleton of the foam metal.
(4) The porous body according to (3), wherein a plurality of the aluminum carbide whiskers are grown from an aluminum carbide phase on the surface of the foam metal.
(5) The porous body according to any one of (1) to (4) above, wherein the aluminum carbide whisker is formed to extend outward from the skeleton surface of the foam metal to form a layer, An aluminum carbide whisker layer is formed on the surface of the skeleton of the foam metal.
(6) The porous body according to any one of (3) to (5), wherein the aluminum carbide phase is formed in at least a partial region of the surface of the foam metal. To do.
（７）本発明に係る多孔体の製造方法は、少なくとも三次元網目構造の骨格の表面がアルミニウムである発泡金属を、炭化水素含有物質を含む空間に配置して加熱して、該発泡金属の骨格の表面に炭化アルミニウムウィスカーを形成する第一の工程を有することを特徴とする。
（８）上記（７）に記載の多孔体の製造方法であって、前記第一の工程の後に、前記第一の工程を経た後の発泡金属を酸化雰囲気中で加熱して、前記炭化アルミウィスカーをアルミナウィスカーに転化する第二の工程を行うことを特徴とする。
(7) In the method for producing a porous body according to the present invention, a foam metal having at least a three-dimensional network structure skeleton surface made of aluminum is placed in a space containing a hydrocarbon-containing substance and heated, It has the 1st process of forming an aluminum carbide whisker in the surface of frame | skeleton.
(8) The method for producing a porous body according to (7) above, wherein after the first step, the foam metal after the first step is heated in an oxidizing atmosphere, and the aluminum carbide is obtained. A second step of converting whiskers into alumina whiskers is performed.
本発明に係る多孔体は、発泡金属を構成する骨格の表面に微細なウィスカーを無数に有するため、極めて表面積が大きくなる。また、該ウィスカー層と微細な粒子との密着力が高くなるため、微粒子を捕捉しやすくなる。本発明に係る多孔体は、ＤＰＦ等のフィルタや電池の電極として有望である。 Since the porous body according to the present invention has countless fine whiskers on the surface of the skeleton constituting the foam metal, the surface area becomes extremely large. Moreover, since the adhesive force between the whisker layer and the fine particles is increased, the fine particles can be easily captured. The porous body according to the present invention is promising as a filter such as a DPF or an electrode of a battery.
図１に本発明に係る多孔体の概念構造を示す。
発泡金属は、その骨格表面に微細な髭状物質である炭化アルミニウムウィスカーまたはアルミナウィスカーが形成されることにより、極めて高い表面積となる。本発明者は、背景技術の問題点を解決するために鋭意研究を重ねた結果、少なくとも表面にアルミニウム層を有する発泡金属を、炭化水素を含有する雰囲気化で加熱して炭化アルミニウムウィスカー層を形成することが有効であることを見出した。このような発明者の知見に基づいて本発明はなされたものである。
FIG. 1 shows a conceptual structure of a porous body according to the present invention.
The foam metal has a very high surface area when aluminum carbide whisker or alumina whisker, which is a fine soot-like substance, is formed on the surface of the skeleton. As a result of intensive research to solve the problems of the background art, the present inventor formed an aluminum carbide whisker layer by heating a foam metal having an aluminum layer on at least the surface in an atmosphere containing a hydrocarbon. I found it effective. The present invention has been made based on such knowledge of the inventors.
本発明に従った多孔体は、三次元骨格構造を持つ発泡金属と、該発泡金属の骨格表面に形成されたウィスカー状物質とを備え、以下の手法により合成される。
すなわち、発泡金属の骨格にアルミニウムをコーティングしておき、その後、該発泡金属を、炭化水素含有物質を含む空間に配置して加熱することにより、該発泡金属の骨格表面に炭化アルミウィスカーが形成される。この工程だけで、発泡金属の表面に、表面積の大きな炭化アルミニウムウィスカーからなる層が形成されるのである。該炭化アルミニウムウィスカーは、微細な髭状物質であり、発泡金属骨格の表面に無数に形成されるため、本発明に係る多孔体の表面積は極めて大きなものとなる。
さらには、炭化アルミニウムウィスカーをアルミナウィスカーに転化することもできる。このためには、上記工程の後に、骨格表面に炭化アルミニウムウィスカー層が形成された発泡金属を、酸化雰囲気中で加熱するという第二の工程を行えばよい。
The porous body according to the present invention comprises a foam metal having a three-dimensional skeleton structure and a whisker-like substance formed on the skeleton surface of the foam metal, and is synthesized by the following method.
That is, aluminum foam is formed on the surface of the foam metal skeleton by coating aluminum with the metal skeleton and then placing the foam metal in a space containing a hydrocarbon-containing substance and heating. The By this process alone, a layer made of aluminum carbide whiskers having a large surface area is formed on the surface of the foam metal. The aluminum carbide whisker is a fine soot-like substance and is formed innumerably on the surface of the foam metal skeleton, so that the surface area of the porous body according to the present invention is extremely large.
Furthermore, aluminum carbide whiskers can be converted into alumina whiskers. For this purpose, a second step of heating the foam metal having the aluminum carbide whisker layer formed on the skeleton surface in an oxidizing atmosphere after the above step may be performed.
図２に本発明の一つの実施の形態として、上記多孔体の製造方法の一例を多孔体の断面構造を用いて模式的に示す。
少なくとも表面の一部がアルミニウムである発泡金属を、炭化水素を含む雰囲気で加熱することにより、発泡金属表面の少なくとも一部には、炭化アルミニウムを主成分とする相が形成される。該炭化アルミニウム相の表面からは、ウィスカー状の形態で延びるように複数の炭化アルミニウムウィスカーが形成され、多孔体表面には炭化アルミニウムを主成分とする相が層状に形成される。炭化アルミニウムウィスカーを主成分とする相とは、例えば、Ａl4Ｃ3結晶を含むものであるが、非晶質を含む場合がある。またのアルミに含まれる各種不純物を含む場合がある。
FIG. 2 schematically shows an example of a method for producing the porous body using a cross-sectional structure of the porous body as an embodiment of the present invention.
By heating the foam metal whose surface is at least part of aluminum in an atmosphere containing hydrocarbon, a phase mainly composed of aluminum carbide is formed on at least part of the surface of the foam metal. A plurality of aluminum carbide whiskers are formed so as to extend in a whisker-like form from the surface of the aluminum carbide phase, and a phase mainly composed of aluminum carbide is formed in layers on the porous body surface. The phase mainly composed of aluminum carbide whiskers includes, for example, Al 4 C 3 crystals, but may include amorphous. In addition, various impurities contained in aluminum may be included.
アルミニウムが炭化されて炭化アルミニウムに転化する時、図２（ｂ）の組織となる。図２（ｂ）の組織は、加熱温度が３００℃以上で得られる。反応効率を考えると４５０℃以上が好ましく、上限はアルミニウムの融点以下である。アルミニウムには種々の合金があり、それぞれの融点よりも低温にすればよい。 When aluminum is carbonized and converted into aluminum carbide, the structure shown in FIG. 2B is obtained. The structure of FIG. 2B is obtained when the heating temperature is 300 ° C. or higher. Considering the reaction efficiency, 450 ° C. or higher is preferable, and the upper limit is below the melting point of aluminum. There are various alloys of aluminum, and the temperature may be lower than the melting point of each.
用いられる炭化水素含有物質の種類は特に限定されない。たとえば、メタン、エタン、プロパン、ｎ−ブタン、イソブタンおよびペンタン等のパラフィン系炭化水素、エチレン、プロピレン、ブテンおよびブタジエン等のオレフィン系炭化水素、アセチレン等のアセチレン系炭化水素等、またはこれらの炭化水素の誘導体が挙げられる。これらの炭化水素の中でも、メタン、エタン、プロパン等のパラフィン系炭化水素は、アルミニウム箔を加熱する工程においてガス状になるので好ましい。さらに好ましいのは、メタン、エタンおよびプロパンのうち、いずれか一種の炭化水素である。最も好ましい炭化水素はメタンである。 The kind of the hydrocarbon-containing substance used is not particularly limited. For example, paraffinic hydrocarbons such as methane, ethane, propane, n-butane, isobutane and pentane, olefinic hydrocarbons such as ethylene, propylene, butene and butadiene, acetylenic hydrocarbons such as acetylene, etc., or these hydrocarbons And derivatives thereof. Among these hydrocarbons, paraffinic hydrocarbons such as methane, ethane, and propane are preferable because they become gaseous in the process of heating the aluminum foil. More preferred is any one of methane, ethane and propane. The most preferred hydrocarbon is methane.
また、アルミニウムを配置する空間に導入される炭化水素含有物質の質量比率は、特に限定されないが、通常はアルミニウム１００質量部に対して炭素換算値で０．１質量部以上５０質量部以下の範囲内にするのが好ましく、特に０．５質量部以上３０質量部以下の範囲内にするのが好ましい。 Moreover, the mass ratio of the hydrocarbon-containing substance introduced into the space in which aluminum is arranged is not particularly limited, but is usually in the range of 0.1 to 50 parts by mass in terms of carbon with respect to 100 parts by mass of aluminum. It is preferable that the content is within the range of 0.5 parts by mass or more and 30 parts by mass or less.
加熱時間は、加熱温度等にもよるが、一般的には１時間以上１００時間以下の範囲内である。また、発泡金属骨格の表面部を完全に炭化アルミニウムに転化させても構わない。この場合、炭化アルミニウムウィスカーの生成密度が増大するので、更に多孔体の表面積が大きくなる。（図２（ｃ）） Although the heating time depends on the heating temperature and the like, it is generally in the range of 1 hour to 100 hours. Further, the surface portion of the foam metal skeleton may be completely converted to aluminum carbide. In this case, since the generation density of aluminum carbide whiskers increases, the surface area of the porous body further increases. (Fig. 2 (c))
さらには、上記のとおり、炭化アルミニウムをアルミナに転化させることもできる（図２（ｄ）、（ｅ））。炭化アルミニウムは、大気中で加熱処理すると容易に酸化されてアルミナに転化する。アルミナは耐薬品製に優れることから、本発明に係る多孔体を酸性あるいはアルカリ性の薬品等の中で使用する場合はアルミナウィスカーにすることが好ましいと言える。 Furthermore, as described above, aluminum carbide can be converted to alumina (FIGS. 2D and 2E). Aluminum carbide is easily oxidized and converted to alumina when heat-treated in the atmosphere. Since alumina is excellent in chemical resistance, it can be said that when the porous body according to the present invention is used in acidic or alkaline chemicals, it is preferable to use alumina whiskers.
発泡金属は種々の公知の方法で製造されるが、例えば以下のようにして製造される。
まず、ポリウレタンフォームと呼ばれる三次元骨格構造を持つポリウレタンが原料とする。これを炭素粉末が分散されたスラリー状の液体に浸漬した後に乾燥させると、ポリウレタンフォーム骨格の表面に導電性の炭素が付着する。これをめっき処理して、炭素の表面にＮiやＣrなどを析出させることで発泡金属を製造することができる。
The foam metal is produced by various known methods. For example, the foam metal is produced as follows.
First, polyurethane having a three-dimensional skeleton structure called polyurethane foam is used as a raw material. When this is immersed in a slurry liquid in which carbon powder is dispersed and then dried, conductive carbon adheres to the surface of the polyurethane foam skeleton. A metal foam can be manufactured by plating this and precipitating Ni, Cr, etc. on the surface of carbon.
又は、ポリアクリロニトリル系の不織布を炭化して導電性を持たせ、これにめっき処理をしてＦeの発泡金属を作製する等の方法もある。ＦeにＣrやＡlを添加する場合は、Ｆe製発泡金属をＣrやＡlを含む高温のガス中で処理して合金化させることもできる。 Alternatively, there is a method in which a polyacrylonitrile-based non-woven fabric is carbonized to have conductivity, and this is plated to produce a foam metal of Fe. When Cr or Al is added to Fe, the Fe foam metal can be processed and alloyed in a high-temperature gas containing Cr or Al.
上記工程で作製できる発泡金属の細孔径は、使用するポリウレタンの構造に依存し、平均細孔径の下限は５０μｍ程度である。これ未満の場合は、スラリー付着時に目詰まりが起こりやすくなってしまう。 The pore diameter of the foam metal that can be produced in the above process depends on the structure of the polyurethane used, and the lower limit of the average pore diameter is about 50 μm. If it is less than this, clogging is likely to occur at the time of slurry adhesion.
本発明に係る多孔体の製造方法では、骨格の表面の少なくとも一部、より好ましくは前面が、アルミニウムである発泡金属を用いる。上記のようにウレタンフォームや不織布から作製された発泡金属の骨格表面に、電気めっきや無電界めっきでアルミニウムを直接析出させることは難しいので、これら発泡金属の表面に別途アルミニウムをコーティングしておけばよい。例えば、発泡金属を、溶融したアルミニウム液中に浸漬し、冷却固化しないように急速に引き上げる、等の方法がある（溶融アルミめっき）。もちろん、その他の方法でアルミニウムをコーティングしても構わない。 In the method for producing a porous body according to the present invention, a foam metal in which at least a part of the surface of the skeleton, more preferably the front surface, is aluminum is used. As described above, it is difficult to deposit aluminum directly on the surface of foam metal made from urethane foam or non-woven fabric by electroplating or electroless plating. Good. For example, there is a method of immersing a foam metal in a molten aluminum solution and pulling it up rapidly so as not to be cooled and solidified (molten aluminum plating). Of course, aluminum may be coated by other methods.
熱力学的には炭化アルミニウムは室温でもアルミナに転化するが、プロセスの効率を考えるとアルミナに転化させるための温度は３００℃以上が好ましい。好ましくは４５０℃以上で、上限はアルミニウムの融点以下である。転化したアルミナウィスカーの主成分は非晶質である。 Thermodynamically, aluminum carbide is converted to alumina even at room temperature, but considering the efficiency of the process, the temperature for conversion to alumina is preferably 300 ° C. or higher. Preferably it is 450 degreeC or more, and an upper limit is below melting | fusing point of aluminum. The main component of the converted alumina whisker is amorphous.
（基材）
直径１００ｍｍ、厚さ０．４ｍｍの各種発泡金属を多孔体の基材として用いた。窒素ガス中で発泡金属を８００℃に保持した溶融アルミニウム中に浸漬した後、６０rpmで回転させながら引き上げた。
(Base material)
Various foamed metals having a diameter of 100 mm and a thickness of 0.4 mm were used as the porous substrate. The metal foam was immersed in molten aluminum maintained at 800 ° C. in nitrogen gas, and then pulled up while rotating at 60 rpm.
（ウィスカーの形成）
上記基材を、各種炭化水素ガスを含む雰囲気で加熱した。一部の試料は、その後、大気中で加熱した。加熱後の発泡金属の骨格表面にはウィスカーが生成していた。Ｘ線回折によりウィスカー相を同定した。
(Whisker formation)
The substrate was heated in an atmosphere containing various hydrocarbon gases. Some samples were then heated in air. Whiskers were formed on the surface of the skeleton of the foam metal after heating. The whisker phase was identified by X-ray diffraction.
（評価：捕集試験）
予め用意しておいた粒子径が０．００８〜０．１μｍのディーゼルパティキュレート（粒子）を、図３の汚濁ガス収納容器（５００リットル）に濃度５０００ppmで湿度１０％又は９０％の空気と共に３気圧まで充填した。その後、系にセットした廃ガス浄化装置を通して廃ガス収納容器（１００リットル）に移動させた。廃ガス収納装置は最初真空に保持しておき、廃ガスの濾過と共に、開閉コックを調整して廃ガス収納容器内が大気圧になるまで移動させた。
１００回後の廃ガス収納容器内の粒子濃度をパーティクルカウンターで測定し、濃度を算出した。
(Evaluation: Collection test)
A diesel particulate (particle) having a particle diameter of 0.008 to 0.1 μm prepared in advance is mixed with air having a concentration of 5000 ppm and a humidity of 10% or 90% in the polluted gas storage container (500 liters) of FIG. Filled to atmospheric pressure. Then, it moved to the waste gas storage container (100 liters) through the waste gas purification apparatus set in the system. The waste gas storage device was initially kept in a vacuum, and was moved until the inside of the waste gas storage container reached atmospheric pressure by adjusting the open / close cock together with the filtration of the waste gas.
The particle concentration in the waste gas storage container after 100 times was measured with a particle counter, and the concentration was calculated.
結果を表１に示す。
本発明に係る多孔体は捕集効率が高かった。第二の工程により、炭化アルミニウムを酸化させた試料では、湿度の高い雰囲気でも高い捕集効率を維持できた。これは、炭化アルミニウムを酸化アルミニウムに転化することにより、耐湿性が改善されたためと考えられる。
The results are shown in Table 1.
The porous body according to the present invention has a high collection efficiency. In the sample in which aluminum carbide was oxidized by the second step, high collection efficiency could be maintained even in a high humidity atmosphere. This is presumably because moisture resistance was improved by converting aluminum carbide to aluminum oxide.
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