Method for producing porous metal body and method for producing electrode catalyst

Patent metadata

Field	Value
Publication number	US-10873091-B2
Application number	US-201716311733-A
Country	US
Kind code	B2
Filing date	Mar 28, 2017
Priority date	Jun 23, 2016
Publication date	Dec 22, 2020
Grant date	Dec 22, 2020

Abstract

The present invention is a method for producing a porous metal body or a method for producing an electrode catalyst, which is capable of simplifying the production process and improving the production efficiency by not requiring a step of immersion in an acid treatment solution. A method for producing a porous metal body according to the present invention comprises: a step for forming a metal resin-containing layer, which contains a metal and a resin that has a lower melting point than the metal, on a base; and a step for obtaining a porous metal body by subjecting the metal resin-containing layer to a heat treatment, thereby sintering the metal and removing the resin from the metal resin-containing layer.

First claim

The invention claimed is:

1. A method for producing a porous metal body, comprising the steps of:
forming a metal-resin-containing layer containing a metal and a resin on a base, a melting point of the resin being lower than that of the metal; and
heat-treating the metal-resin-containing layer, thereby sintering the metal and removing the resin from the metal-resin-containing layer, to obtain the porous metal body, wherein in the step of forming the metal-resin-containing layer, a metal layer containing the metal and a resin layer containing the resin are stacked alternately to form the metal-resin-containing layer.

2. The method according to claim 1 , wherein in the step of forming the metal-resin-containing layer, the metal-resin-containing layer is formed by at least one of sputtering and vapor deposition.

3. The method according to claim 1 , further comprising:
controlling a porosity of the porous metal body by modulating a thickness ratio between the metal layer and the resin layer.

4. A method for producing an electrode catalyst, comprising the steps of:
forming a metal-resin-containing layer containing a metal catalyst and a resin on a base, a melting point of the resin being lower than that of the metal catalyst; and
heat-treating the metal-resin-containing layer, thereby sintering the metal catalyst and removing the resin from the metal-resin-containing layer, to obtain a porous electrode catalyst, wherein in the step of forming the metal-resin-containing layer, a metal layer containing the metal catalyst and a resin layer containing the resin are stacked alternately to form the metal-resin-containing layer.

5. The method according to claim 4 , wherein in the step of forming the metal-resin-containing layer, the metal-resin-containing layer is formed by at least one of sputtering and vapor deposition.

6. The method according to claim 4 , wherein a gas diffusion layer is used as the base.

7. The method according to claim 4 , further comprising:
controlling a porosity of the porous electrode catalyst by modulating a thickness ratio between the metal layer and the resin layer.

Assignees

• Honda Motor Co Ltd

Inventors

• KOUKETSU Seiichi
• Matsumoto Kei
• WAKAKUWA Yu

Classifications

• C22C1/08

  Alloys with open or closed pores · CPC title

• B22F7/08

  with one or more parts not made from powder {(B22F7/062 takes precedence)} · CPC title

• B22F3/1121 Primary

  by using decomposable, meltable or sublimatable fillers · CPC title

• H01M4/8621 Primary

  containing only metallic or ceramic material, e.g. made by sintering or sputtering · CPC title

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title