Method for producing metal shaped article having porous structure

Patent metadata

Field	Value
Publication number	US-11534826-B2
Application number	US-202016937789-A
Country	US
Kind code	B2
Filing date	Jul 24, 2020
Priority date	Jul 25, 2019
Publication date	Dec 27, 2022
Grant date	Dec 27, 2022

Abstract

A method for producing a metal shaped article having a porous structure includes a mold formation step of forming a mold having a plurality of columnar structures extending from a substrate by performing a resin material supply step of supplying a liquid containing a resin material to a plurality of places of the substrate at intervals in two directions crossing each other, and a curing step of curing the liquid, a sintering target material supply step of supplying a sintering target material to the mold, a removal step of removing the substrate, a degreasing step of degreasing the columnar structures, and a sintering step of sintering the sintering target material.

First claim

What is claimed is:

1. A method for producing a metal shaped article having a porous structure, comprising:
placing a substance on a stage;
forming a mold having a plurality of columnar structures extending from the substrate by:
ejecting a liquid from a head as a liquid droplet containing a resin material to a plurality of places of the substrate at intervals in two directions crossing each other, and
curing the liquid;

supplying a target material to the mold, the target material being one of:
magnesium (Mg), iron (Fe), cobakt (Co), chromium (Cr), aluminium (Al), titanium (Ti), copper (Cu), nickel (Ni); or
a mixture containing one or more of the magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminium (Al), titanium (Ti), copper (Cu), and nickel (Ni);

removing the substrate from the stage;
degreasing the columnar structures with an external heating device; and
sintering the target material with the external heating device to produce the metal shape article.

2. The method for producing a metal shaped article having a porous structure according to claim 1 , wherein
the target material is in a paste state containing a solvent, and
further comprising drying the solvent in the target material after the ejecting of the target material to the substrate.

3. The method for producing a metal shaped article having a porous structure according to claim 1 , wherein
the target material contains a magnetic powder, and
further comprising generating a magnetic field that attracts the magnetic powder to the substrate during or after the ejecting of the target material to the substrate.

4. The method for producing a metal shaped article having a porous structure according to claim 1 , further comprising:
pressurizing the target material toward the substrate during or after the ejecting of the target material to the substrate.

5. The method for producing a metal shaped article having a porous structure according to claim 1 , further comprising
forming a liquid repellent film on the substrate, and
wherein the liquid is ejected onto the liquid repellent film.

6. The method for producing a metal shaped article having a porous structure according to claim 5 , wherein
the liquid repellent film is made of a resin, and
during the degreasing of the columnar structures, the liquid repellent film is also degreased.

7. The method for producing a metal shaped article having a porous structure according to claim 1 , wherein
the target material is supplied to the mold during the ejecting od the liquid so that a thickness of the target material from the substrate is less than a length of the columnar structure from the substrate.

8. The method for producing a metal shaped article having a porous structure according to claim 1 , wherein
the target material is supplied to the mold during the ejecting of the liquid so that a thickness of the target material from the substrate exceeds a length of the columnar structure from the substrate, and
further comprising grinding the target material at an opposite side of the substrate until the columnar structures are exposed before the degreasing of the columnar structures.

Assignees

• Seiko Epson Corp

Inventors

• Okamoto Eiji
• Uechi Ichiro

Classifications

• Y02P10/25

  Process efficiency · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B29C64/10

  Processes of additive manufacturing · CPC title

• B22F3/11

  Making porous workpieces or articles · CPC title

• B33Y40/20

  Post-treatment, e.g. curing, coating or polishing · CPC title