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1. WO2015086703 - CORPS EN MOUSSE MÉTALLIQUE À TAILLE DE GRAINS CONTRÔLÉE SUR SA SURFACE, SON PROCÉDÉ DE PRODUCTION ET UTILISATION

Note: Texte fondé sur des processus automatiques de reconnaissance optique de caractères. Seule la version PDF a une valeur juridique

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Patent claims

Metallic foam body, comprising

(a) a metallic foam body substrate made of at least one metal or metal alloy A; and

(b) a layer of a metal or metal alloy B present on at least a part of the surface of the metallic foam body substrate (a), wherein A and B differ in their chemical composition and/or in the grain size of the metal or metal alloy, and wherein the metal or metal alloy A and B is selected from a group consisting of Ni, Cr, Co, Cu, Ag, and any alloy thereof;

obtainable by a process comprising the steps

(i) provision of a porous organic polymer foam;

(ii) deposition of at least one metal or metal alloy A on the porous organic polymer foam;

(iii) burning off of the porous organic polymer foam to obtain the metallic foam body substrate (a); and

(iv) deposition by electroplating of the metallic layer (b) of a metal or metal alloy B at least on a part of the surface of the metallic foam body (a).

Metallic foam body according to claim 1 , wherein step (ii) comprises the steps

(N1 ) deposition of a first metallic layer containing a metal or metal alloy A1 by a chemical or physical vapor deposition method; and

(N2) deposition of a second metallic layer containing a metal or metal alloy A2 by electroplating;

wherein the metal or metal alloy A1 and A2 is selected from a group consisting of Ni, Cr, Co, Cu, Ag, and any alloy thereof, and wherein A1 and A2 are identical or different.

3. Metallic foam body according to claim 2, wherein the average thickness of the first metallic layer is up to 0.1 μηη and the average thickness of the second metallic layer is from 5 to 50 μηη.

4. Metallic foam body according to any of claims 1 to 3, wherein the porous organic polymer foam is selected from the group consisting of polyurethane (PU) foam, poly ethylene foam and polypropylene foam.

Metallic foam body according to any of claims 1 to 4, wherein the thickness of struts in the metallic foam body substrate (a) is in the range of from 5 to 100 μηη.

Metallic foam body according to any of claims 1 to 5, wherein the average thickness of the layer (b) of the metal or metal alloy B is from 5 to 200 μηη.

Metallic foam body according to any of claims 1 to 6, wherein A2 and B are silver.

Metallic foam body according to claim 7, wherein the contents of silver is at least 99.999 atom% and the contents of the elements Al, Bi, Cu, Fe, Pb, and Zn is not more than 0.001 atom%.

Metallic foam body according to any of claims 1 to 8 having a pore size of from 100 and 5000 μηη, a strut thickness in the range of from 5 to 100 μηη, an apparent density in the range of from 300 to 1200 kg/m3, a specific geometric surface area in the range of from 100 to 20000 m2/m3 and a porosity in the range of from 0.50 to 0.95.

Metallic foam body according to any of claims 1 to 9, wherein the layer (b) of the metal or metal alloy B is present on the entire surface of the metallic foam body substrate (a).

Process for the production of a metallic foam body, wherein the metallic foam body comprises

(a) a metallic foam body substrate made of at least one metal or metal alloy A; and

(b) a layer of a metal or metal alloy B present on at least a part of the surface of the metallic foam body substrate (a), wherein A and B differ in their chemical composition and/or in the grain size of the metal or metal alloy, and wherein the metal or metal alloy A and B is selected from a group consisting of Ni, Cr, Co, Cu, Ag, and any alloy thereof;

comprising the steps

(i) provision of a porous organic polymer foam;

(ii) deposition of at least one first metal or metal alloy A on the porous organic polymer foam;

(iii) burning off of the porous organic polymer foam to obtain the metallic foam body substrate (a); and

(iv) deposition by electroplating of the metallic layer (b) of a metal or metal alloy B at least on a part of the surface of the metallic foam body substrate (a).

Process according to claim 1 1 , comprising the steps

(i1 ) provision of a porous polyurethane foam;

(N3) deposition of Ag in a thickness of 5 to 50 μηη onto the polyurethane foam; and (Nil ) burning off the polyurethane foam at a temperature in the range of from 300 to

850°C to obtain the metallic foam body substrate (a); and

(iv1 ) deposition of Ag in a thickness of 1 to 200 μηη by electroplating onto the metallic foam body substrate (a) obtained in step (Nil ).

13. Use of the metallic foam body of any of claims 1 to 10 in a physical adsorption or absorption process or in a chemical process.

Use according to claim 13, wherein the metallic foam body of any of claims 1 to 10 is used as a precursor for a catalyst or as a catalyst in a process for the production of formaldehyde by oxidation of methanol.

15. Use according to claim 14, wherein the metallic foam body contains at least 99.999 atom% silver and not more than 0.001 atom% of the elements Al, Bi, Cu, Fe, Pb, and Zn.