Manufacturing method of aluminum structure and aluminum structure

Abstract

There is provided a manufacturing method of an aluminum structure, including a conductive treatment process of forming an electrically conductive layer made of aluminum on a surface of a resin molded body and a plating process of plating the resin molded body subjected to the conductive treatment process with aluminum in a molten salt bath. Even with a porous resin molded body having a three-dimensional network structure, the method allows the surface of the porous resin molded body to be plated with aluminum, thus forming a high-purity aluminum structure having a uniform thick film. Porous aluminum having a large area is also provided.

1 . A manufacturing method of an aluminum structure, comprising: a conductive treatment process of forming an electrically conductive layer made of aluminum on a surface of a resin molded body; and a plating process of plating the resin molded body subjected to the conductive treatment process with aluminum in a molten salt bath. 
     
     
         2 . The manufacturing method of an aluminum structure according to  claim 1 , further comprising an anode electrolysis process of performing electrolysis treatment using the electrically conductive layer as an anode between the conductive treatment process and the plating process. 
     
     
         3 . The manufacturing method of an aluminum structure according to  claim 1 , wherein the resin molded body subjected to the conductive treatment process is transported between the conductive treatment process and the plating process without being exposed to an oxidizing atmosphere. 
     
     
         4 . The manufacturing method of an aluminum structure according to  claim 1 , wherein the conductive treatment process is a process of depositing aluminum on the surface of the resin molded body by a gas phase method. 
     
     
         5 . The manufacturing method of an aluminum structure according to  claim 1 , wherein the conductive treatment process is a process of dipping the resin molded body in a coating material containing aluminum to deposit aluminum on the surface of the resin molded body. 
     
     
         6 . The manufacturing method of an aluminum structure according to  claim 1 , wherein the resin molded body is a porous resin article having a three-dimensional network structure. 
     
     
         7 . The manufacturing method of an aluminum structure according to  claim 1 , wherein the resin molded body is made of urethane or melamine. 
     
     
         8 . The manufacturing method of an aluminum structure according to  claim 1 , further comprising a process of removing the resin molded body after the plating process. 
     
     
         9 . An aluminum structure manufactured by the method according to  claim 1 . 
     
     
         10 . An aluminum structure, comprising an aluminum layer having a thickness in the range of 1 to 100 μm as a metal layer, wherein the metal layer has an aluminum purity of 99.0% or more and a carbon content of 1.0% or less and contains inevitable impurities as the balance. 
     
     
         11 . The aluminum structure according to  claim 10 , further comprising a resin molded body, on which the metal layer is disposed. 
     
     
         12 . The aluminum structure according to  claim 10 , wherein the aluminum layer has a tubular skeleton structure and forms a porous body having generally contiguous pores. 
     
     
         13 . The aluminum structure according to  claim 12 , wherein the skeleton structure has almost triangular sections, and the aluminum layer has a larger thickness at the vertexes of each of the triangular sections than at the middle of each side of the triangular sections.