EP3143621B1 - Matériaux composites à matrice métallique pour applications acoustiques - Google Patents

Matériaux composites à matrice métallique pour applications acoustiques Download PDF

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EP3143621B1
EP3143621B1 EP15792910.0A EP15792910A EP3143621B1 EP 3143621 B1 EP3143621 B1 EP 3143621B1 EP 15792910 A EP15792910 A EP 15792910A EP 3143621 B1 EP3143621 B1 EP 3143621B1
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metal matrix
ceramic particles
micrometers
vol
aluminum
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German (de)
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EP3143621A4 (fr
EP3143621A1 (fr
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Gordon B. SIMMONS
Andrew D. Tarrant
Peter John Andrews
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Materion Corp
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Materion Corp
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent
    • C22C21/18—Alloys based on aluminium with copper as the next major constituent with zinc
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/006—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of flat products, e.g. sheets
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent
    • C22C21/16—Alloys based on aluminium with copper as the next major constituent with magnesium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/005—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides comprising a particular metallic binder
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/001—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/001—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides
    • C22C32/0015—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides with only single oxides as main non-metallic constituents
    • C22C32/0031—Matrix based on refractory metals, W, Mo, Nb, Hf, Ta, Zr, Ti, V or alloys thereof
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/001—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides
    • C22C32/0015—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides with only single oxides as main non-metallic constituents
    • C22C32/0036—Matrix based on Al, Mg, Be or alloys thereof

Definitions

  • This disclosure relates generally to members having a high stiffness such as used in acoustical transducers.
  • this disclosure relates to a lightweight, high stiffness speaker diaphragm member and a method for making the same.
  • Acoustic speaker diaphragms are well-known in the prior art and are used to match the relatively low acoustic impedance of air to the relatively high mechanical impedance of a voice coil (e.g., acoustic drive system).
  • the driver for an acoustic speaker generally can deliver a force of large magnitude but delivers a relatively small displacement.
  • An acoustic speaker diaphragm having a large area results in a large volume of air being moved by a driver having a relatively small displacement.
  • a speaker diaphragm is generally constructed of a material as stiff and as light as possible so that minimal mechanical energy is used to accelerate the diaphragm mass thereby providing rapid response of the diaphragm to driver inputs.
  • Speaker diaphragms can be made from a variety of materials ranging from inexpensive paper-based materials to various metals.
  • a particularly popular metal for high-end speaker diaphragms is beryllium, which has a very high specific stiffness but is also very expensive. While beryllium diaphragms are popular for many high-end acoustic speakers, the cost generally prohibits its use in low and mid-end speakers.
  • US 2008/124566 A1 describes audio components having high rigidity and low mass as well as methods of manufacturing such components. These components have a foil body formed of a metal or metal alloy matrix that is embedded with ultra-hard particles or grit, such as diamond and/or cBN.
  • JP H 06 276 596 A discloses a diaphragm being formed by using material where the high hardness grain of at least one material of diamond, c-BN, SiC and B4C is dispersed in low hardness matrix components. Thereby, a diaphragm for speaker having high rigidity, high yield, long life and a high tone characteristic could be obtained.
  • an extrudable and weldable matrix alloy composite comprising a base material metal of about 50 to 99.9% by weight, boron carbide or silicon carbide of about 0.1 to 50% by weight, less than about 3.0% by weight of at least one metal having an intermetallic phase temperature lower than the melting point of the base material metal and a reinforcement agent of up to about 5% by weight, is disclosed.
  • JP S 54 111 818 A describes a diaphragm of low density and high elasticity for acoustic transducers by molding the mixture of boron compound powder and aluminum (or magnesium) powder to a desired shape and sintering the same.
  • FR 2 607 741 discloses a process for obtaining composite materials, in particular with an aluminum alloy matrix, by powder metallurgy, in which a powdery reinforcing product belonging to the group consisting of oxides, carbides, nitrides. Their compound is added to the powder alloy mixtures in the form of grains or short fibers, in an amount such that the volume fraction of the addition is between 5 and 40% and then grinds all the powders. The grinding is maintained for a period sufficient to obtain a distribution of the reinforcing product over the entire mass of metal used within each alloy grain but without exceeding the time beyond which the reduction ratio of the particle size of the product reinforcement is greater than 5.
  • US 6398843 B1 describes a method of manufacture of a dispersion-strengthened material comprising the steps of: (a) mixing the powdered or aluminum alloy matrix with ceramic particles added as a separate phase to the matrix and having a diameter of less than 30 nm wherein the ceramic particle content is in the range 1 to 25 volume percent; (b) blending of the resultant mixture to produce an essentially uniform dispersion of ceramic particles; and (c) consolidating the resultant blend to produce a solid material.
  • a loudspeaker diaphragm for use in producing sound from an electrical signal comprises a shaped metal matrix sheet of substantially uniform thickness wherein the metal matrix sheet comprises ceramic particles from 0.1 micrometers to 20 micrometers in size distributed in a metal matrix, the sheet having a substantially uniform thickness of 4 micrometers to 1,000 micrometers, wherein the shaped metal matrix sheet has an elastic modulus to weight ratio greater than 35 GPa/g/cc; and wherein the metal matrix is formed from aluminum or an aluminum alloy; and wherein the ceramic particles are selected from the group consisting of silicon carbide, titanium carbide, boron carbide, silicon nitride, titanium nitride, and zirconium oxide; and wherein the metal matrix sheet comprises from about 1 vol% to about 55 vol% of the ceramic particles.
  • the metal matrix can be aluminum metal.
  • the shaped metal matrix sheet can be rolled to thickness.
  • the metal matrix is formed from aluminum or an aluminum alloy.
  • the metal matrix can be formed from an aluminum alloy comprising at least one element selected from the group consisting of chromium, copper, lithium, magnesium, manganese, zinc, iron, nickel, silver, scandium, vanadium and silicon.
  • the metal matrix can be formed from an aluminum alloy comprising from about 91.2 wt% to about 98.6 wt% aluminum, from about 0.15 wt% to about 4.9 wt% copper, from about 0.1 wt% to about 1.8 wt% magnesium, and from about 0.1 wt% to about 1 wt% manganese.
  • the metal matrix can be formed from an aluminum alloy comprising from about 91.2 wt% to about 94.7 wt% aluminum, from about 3.8 wt% to about 4.9 wt% copper, from about 1.2 wt% to about 1.8 wt% magnesium, and from about 0.3 wt% to about 0.9 wt% manganese.
  • the metal matrix can be formed from an aluminum alloy comprising from about 92.8 wt% to about 95.8 wt% aluminum, from about 3.2 wt% to about 4.4 wt% copper, from 0 to about 0.2 wt% iron, from about 1.0 to about 1.6 wt% magnesium, from 0 to about 0.6 wt% oxygen, from 0 to about 0.25 wt% silicon, and from 0 to about 0.25 wt% zinc.
  • the metal matrix can be formed from an aluminum alloy comprising from about 95.8 wt% to about 98.6 wt% aluminum, from about 0.8 wt% to about 1.2 wt% magnesium, and from about 0.4 wt% to about 0.8 wt% silicon.
  • the metal matrix sheet may comprise from about 1 vol% to about 45 vol% of the ceramic particles.
  • the metal matrix sheet can be shaped in the form of a dome or cone.
  • the ceramic particles may have an average particle size from 2 micrometers to 20 micrometers.
  • a sheet material for use in loudspeaker diaphragms for use in producing sound from an electrical signal comprises a metal matrix sheet of substantially uniform thickness wherein the metal matrix sheet comprises ceramic particles from 0.1 micrometers to 20 micrometers in size distributed in a metal matrix wherein the substantially uniform thickness is of 4 micrometers to 1,000 micrometers.
  • the metal matrix can be aluminum metal.
  • the metal matrix sheet can be rolled to thickness.
  • a method of making a loudspeaker diaphragm for use in producing sound from an electrical signal comprises providing a mass of metal particles, providing a mass of ceramic particles of a selected size distribution, mixing the metal particles and ceramic particles to achieve a uniform distribution of ceramic particles, forging a billet from the mixture, and rolling the billet into a sheet with a substantially uniform thickness and forming a loudspeaker diaphragm from the sheet.
  • the substantially uniform thickness is 4 micrometers to 1,000 micrometers.
  • the sheet comprises the ceramic particles distributed in a metal matrix and has an elastic modulus to weight ratio greater than 35 GPa/g/cc.
  • the metal matrix is formed from aluminum or an aluminum alloy.
  • the ceramic particles are selected from the group consisting of silicon carbide, titanium carbide, boron carbide, silicon nitride, titanium nitride, and zirconium oxide.
  • the sheet comprises from about 1 vol% to about 55 vol% of the ceramic particles.
  • the ceramic particles can have a size from 0.1 micrometers to 20 micrometers.
  • the metal can be an aluminum metal.
  • the term “comprising” may include the embodiments “consisting of” and “consisting essentially of.”
  • the terms “comprise(s),” “include(s),” “having,” “has,” “can,” “contain(s),” and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that require the presence of the named components/steps and permit the presence of other components/steps.
  • compositions or processes as “consisting of” and “consisting essentially of” the enumerated components/steps, which allows the presence of only the named components/steps, along with any impurities that might result therefrom, and excludes other components/steps.
  • the present disclosure also refers to particles as having an average particle size.
  • the average particle size for particles is defined as the particle diameter at which a cumulative percentage of 50% by volume of the particles are attained. In other words, 50 vol% of the particles have a diameter above the average particle size, and 50 vol% of the particles have a diameter below the average particle size.
  • the speaker 110 includes a speaker housing 112 in which various speaker electronics (e.g., voice coil, etc.) are supported.
  • a loudspeaker diaphragm 114 is secured to the housing 112.
  • the loudspeaker diaphragm in accordance with the present disclosure, is comprised of a metal matrix composite material.
  • the loudspeaker diaphragm has a high modulus of elasticity (i.e. Young's modulus) and a low weight, or put another way a high elastic modulus to weight ratio.
  • Young's modulus i.e. Young's modulus
  • Beryllium has the desired high ratio, but is very expensive, and thus not suitable for low-end to medium-end speakers.
  • Metal matrix composites are composite materials including a metal matrix and a reinforcing material (e.g., a ceramic material) dispersed in the metal matrix.
  • the metal matrix phase is typically continuous whereas the reinforcing dispersed phase is typically discontinuous.
  • the reinforcing material may serve a structural function and/or change one or more properties of the material.
  • Metal matrix composites can provide combinations of mechanical and physical properties that cannot be achieved through conventional materials or process techniques. These property combinations make metal matrix composites particularly useful in applications where weight, strength, and stiffness are important, such as loudspeaker diaphragms.
  • Powder metallurgy is a process by which powdered materials are compacted into a desired shape and sintered to produce desired articles. Powder metallurgy allows for a faster quenching rate of the metal from the melt which typically results in smaller grain sized, increased solid solubility of most solute elements, and reduced segregation of intermetallic phases. These results may lead to beneficial properties in the produced articles, such as high strength at normal and elevated temperatures, high modulus values, good fracture toughness, low fatigue crack growth rate, and high resistance to stress corrosion cracking.
  • the loudspeaker diaphragm 114 is formed from a shaped metal matrix sheet having a substantially uniform thickness of 4 micrometers to 1,000 micrometers.
  • the metal matrix sheet comprises ceramic particles distributed in a metal matrix phase.
  • the ceramic particles have an average particle size from 0.1 micrometers to 20 micrometers.
  • the loudspeaker diaphragm has an elastic modulus to weight ratio which is greater than 35 GPa/g/cc.
  • the metal matrix is formed from aluminum or an aluminum alloy.
  • the ceramic particles are selected from the group consisting of silicon carbide, titanium carbide, boron carbide, silicon nitride, titanium nitride, and zirconium oxide.
  • the metal matrix sheet comprises from about 1 vol% to about 55 vol% of the ceramic particles.
  • a 4:1 (w/w) ratio of metal matrix to ceramic particles yields an elastic modulus to weight ratio of 39 GPa/g/cc.
  • a 2:5 (w/w) ratio of metal matrix material to ceramic particles yields an elastic modulus to weight ratio of 48 GPa/g/cc.
  • Adding the ceramic particles to the metal matrix increases the modulus of elasticity over that of the matrix metal without ceramic particle reinforcement, while maintaining the relatively low weight of the matrix material. In this manner, the less expensive matrix material can achieve properties that approach beryllium or other high-end speaker diaphragm materials.
  • the matrix metal is aluminum or an aluminum alloy.
  • the aluminum alloy may include at least one element selected from chromium, copper, lithium, magnesium, nickel, and silicon. It is noted that "aluminum,” as used here, refers to aluminum with only impurities present, i.e. pure aluminum, whereas the term “aluminum alloy” is used to refer to alloys containing majority aluminum with a significant amount of another element.
  • the aluminum alloy is a 1000 series alloy ( ⁇ 99 wt% aluminum), a 2000 series alloy (including copper as an alloying component), a 3000 series alloy (including manganese as an alloying component), a 4000 series alloy (including silicon as an alloying component), a 5000 series alloy (including magnesium as an alloying component), a 6000 series alloy (including magnesium and silicon as alloying components), a 7000 series alloy (including zinc as an alloying component), or an 8000 series alloy (e.g., aluminum-lithium alloys).
  • a 1000 series alloy ⁇ 99 wt% aluminum
  • a 2000 series alloy including copper as an alloying component
  • a 3000 series alloy including manganese as an alloying component
  • a 4000 series alloy including silicon as an alloying component
  • a 5000 series alloy including magnesium as an alloying component
  • a 6000 series alloy including magnesium and silicon as alloying components
  • a 7000 series alloy including zinc as an alloying component
  • an 8000 series alloy e.g., aluminum-lithium alloy
  • the metal particles may have an average particle size in the range of from about 5 ⁇ m to about 150 ⁇ m, including from about 15 ⁇ m to about 75 ⁇ m, about 20 ⁇ m to about 50 ⁇ m, from about 20 ⁇ m to about 40 ⁇ m, from about 20 ⁇ m to about 30 ⁇ m, and about 75 ⁇ m.
  • the aluminum alloy includes from about 91.2 wt% to about 94.7 wt% aluminum, from about 3.8 wt% to about 4.9 wt% copper, from about 1.2 wt% to about 1.8 wt% magnesium, and from about 0.3 wt% to about 0.9 wt% manganese.
  • the aluminum alloy includes from about 95.8 wt% to about 98.6 wt% aluminum, from about 0.8 wt% to about 1.2 wt% magnesium, and from about 0.4 wt% to about 0.8 wt% silicon. In additional embodiments, these aluminum alloys can also include from about 0.15 wt% to about 0.4 wt% copper, and 0.04 wt% to about 0.35 wt% chromium.
  • the aluminum alloy may be 2009.
  • the composition of 2009 aluminum alloy is as follows: Component Wt% Aluminum Remainder Copper 3.2-4.4 Iron Max 0.2 Magnesium 1.0-1.6 Oxygen Max 0.6 Silicon Max 0.25 Zinc Max 0.25
  • the aluminum alloy may be 2090.
  • the composition of 2090 aluminum alloy is as follows: Component Wt% Aluminum 93.2-95.6 Chromium 0.05 max Copper 2.4-3.0 Iron 0.12 max Lithium 1.9-2.6 Magnesium 0.25 max Manganese 0.05 max Other, each 0.05 max Other, total 0.15 max Silicon 0.10 max Titanium 0.15 max Zinc 0.10 max Zirconium 0.08-0.15
  • the aluminum alloy may be 2099.
  • the composition of 2099 aluminum alloy is as follows: Component Wt% Aluminum 92.51-95.35 Beryllium 0.0001 max Copper 2.4-3.0 Iron 0.07 max Lithium 1.6-2.0 Magnesium 0.10-0.50 Manganese 0.10-0.50 Other, each 0.05 max Other, total 0.15 max Silicon 0.05 max Titanium 0.10 max Zinc 0.40-1.0 Zirconium 0.05-0.12
  • the aluminum alloy may be 2124.
  • the composition of 2124 aluminum alloy is as follows: Component Wt% Aluminum 91.2-94.7 Chromium Max 0.1 Copper 3.8-4.9 Iron Max 0.3 Magnesium 1.2-1.8 Manganese 0.3-0.9 Other, each Max 0.05 Other, total Max 0.15 Silicon Max 0.2 Titanium Max 0.15 Zinc Max 0.25
  • the aluminum alloy may be 2618.
  • the composition of 2618 aluminum alloy is as follows: Component Wt% Aluminum Balance Copper 1.9-2.7 Iron 0.9-1.3 Magnesium 1.3-1.8 Nickel 0.9-1.2 Silicon Max 0.25 Titanium 0.04-0.1 Others, each Max 0.05 Others, total Max 0.15
  • the aluminum alloy may be 6061.
  • the composition of 6061 aluminum alloy is as follows: Component Wt% Aluminum 95.8-98.6 Chromium 0.04-0.35 Copper 0.15-0.4 Iron Max 0.7 Magnesium 0.8-1.2 Manganese Max 0.15 Other, each Max 0.05 Other, total Max 0.15 Silicon 0.4-0.8 Titanium Max 0.15 Zinc Max 0.25
  • the aluminum alloy may be 6082.
  • the composition of 6082 aluminum alloy is as follows: Component * Wt% Aluminum 95.2-98.3 Chromium Max 0.25 Copper Max 0.1 Iron Max 0.5 Magnesium 0.6-1.2 Manganese 0.4-1.0 Other, total Max 0.15 Silicon 0.7-1.3 Titanium Max 0.1 Zinc Max 0.2
  • the ceramic particles are selected from silicon carbide, titanium carbide, boron carbide, silicon nitride, titanium nitride, zirconium oxide, aluminum oxide, aluminum nitride, and titanium oxide. Particularly desired are silicon carbide and boron carbide.
  • the ceramic particles may have an average particle size in the range of from about 0.1 ⁇ m to about 20 ⁇ m, including from about 0.2 ⁇ m to about 20 ⁇ m, and from about 1 ⁇ m to about 4 ⁇ m. In other embodiments, the ceramic particles have an average particle size in the range of from about 0.2 ⁇ m to about 0.4 ⁇ m, or from about 0.5 ⁇ m to about 0.9 ⁇ m. It should be noted again that these are averages; some particles will be larger and some will be smaller.
  • the ceramic particles may make up to about 55 vol% of the overall metal matrix composite.
  • the composite includes from about 1 vol% to about 55 vol% of the ceramic dispersed phase, including from about 20 to about 50 vol%, from about 35 to about 45 vol%, and about 40 vol%.
  • the resulting composite has both a high elastic modulus and sufficient rolling/forming capability to make the dome/cone.
  • Figure 2 is a flow chart illustrating an exemplary method 200 of the present disclosure.
  • the method includes providing metal particles (e.g., aluminum or aluminum alloy particles) 205 and providing ceramic particles 210 to a high energy mixing stage 220.
  • Such particles are in the form of powders.
  • the metal and ceramic powders should be mixed 220 with a high energy technique to distribute the ceramic reinforcement particles into the metal matrix. Suitable techniques for this mixing include ball milling, mechanical attritors, teamer mills, rotary mills and other methods to provide high energy mixing to the powder constituents. Mechanical alloying should be completed in an atmosphere to avoid excessive oxidation of powders preferable in an inert atmosphere using nitrogen or argon gas. The processing parameters should be selected to achieve an even distribution of the ceramic particles in the metallic matrix.
  • the powder from the high energy mixing stage is degassed to remove any retained moisture from the powder surface, this may be completed at between 120°C to 500°C.
  • a forging step 230 may also be performed to increase density and produce a billet 240.
  • the hot compacting may be performed at a temperature in the range of from about 400 oC to about 600 oC, including from about 425 oC to about 550 oC and about 500 oC.
  • Hot compaction may include the use of hot die compaction, hot isostatic pressing or hot extrusion typically at pressures of between 30 to 150 MPa.
  • the billet may be subsequently rolled 250 to obtain a metal matrix sheet with a substantially uniform thickness.
  • the formed sheet can then be used to produce speaker diaphragms using conventional speaker diaphragm manufacturing techniques. Powder metallurgy techniques are well-suited for this method.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
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  • Manufacturing & Machinery (AREA)
  • Powder Metallurgy (AREA)

Claims (10)

  1. Membrane de haut-parleur destinée à être utilisée pour générer des sons à partir d'un signal électrique, comprenant une feuille à matrice métallique façonnée ;
    dans laquelle la feuille à matrice métallique comprend des particules céramiques réparties dans une matrice métallique, les particules céramiques ayant une taille moyenne de particules de 0,1 micromètre à 20 micromètres ; et
    dans laquelle la feuille à matrice métallique a une épaisseur sensiblement uniforme de 4 micromètres à 1 000 micromètres ; et
    dans laquelle la feuille à matrice métallique façonnée a un rapport entre le module d'élasticité et le poids supérieur à 35 GPa/g/cm3 ; et
    dans laquelle la matrice métallique est formée d'aluminium ou d'un alliage d'aluminium ; et
    dans laquelle les particules céramiques sont choisies dans le groupe constitué par le carbure de silicium, le carbure de titane, le carbure de bore, le nitrure de silicium, le nitrure de titane et l'oxyde de zirconium ; et
    dans laquelle la feuille à matrice métallique comprend d'environ 1 % en volume à environ 55 % en volume des particules céramiques.
  2. Membrane de haut-parleur selon la revendication 1, dans laquelle la matrice métallique est formée d'un alliage d'aluminium comprenant au moins un élément choisi dans le groupe constitué par le chrome, le cuivre, le lithium, le magnésium, le manganèse, le zinc, le fer, le nickel, l'argent, le scandium, le vanadium et le silicium.
  3. Membrane de haut-parleur selon la revendication 1, dans laquelle la matrice métallique est formée d'un alliage d'aluminium comprenant d'environ 91,2 % en poids à environ 98,6 % en poids d'aluminium, d'environ 0,15 % en poids à environ 4,9 % en poids de cuivre, d'environ 0,1 % en poids à environ 1,8 % en poids de magnésium et d'environ 0,1 % en poids à environ 1 % en poids de manganèse.
  4. Membrane de haut-parleur selon la revendication 1, dans laquelle la feuille à matrice métallique comprend d'environ 35 % en volume à environ 55 % en volume des particules céramiques.
  5. Membrane de haut-parleur selon la revendication 1, dans laquelle les particules céramiques sont choisies dans le groupe constitué par le carbure de silicium et le carbure de bore ; et
    la matrice métallique est formée d'un alliage d'aluminium ; et
    la feuille à matrice métallique comprend d'environ 35 % en volume à environ 55 % en volume des particules céramiques.
  6. Procédé pour fabriquer une membrane de haut-parleur destinée à être utilisée pour générer des sons à partir d'un signal électrique selon la revendication 1, comprenant ;
    mélanger (i) des particules métalliques avec (ii) des particules céramiques ayant une taille moyenne de particules de 0,1 micromètre à 20 micromètres ;
    traiter le mélange pour obtenir une distribution uniforme des particules céramiques ;
    forger une billette à partir du mélange ;
    laminer la billette en une feuille ;
    dans lequel la feuille comprend les particules céramiques distribuées dans une matrice métallique ; et
    dans lequel la feuille a une épaisseur sensiblement uniforme de 4 micromètres à 1 000 micromètres ; et
    dans lequel la feuille a un rapport entre le module d'élasticité et le poids supérieur à 35 GPa/g/cm3 ; et
    dans laquelle la matrice métallique est formée d'aluminium ou d'un alliage d'aluminium ; et
    dans lequel les particules céramiques sont choisies dans le groupe constitué par le carbure de silicium, le carbure de titane, le carbure de bore, le nitrure de silicium, le nitrure de titane et l'oxyde de zirconium ;
    dans lequel la feuille comprend d'environ 1 % en volume à environ 55 % en volume des particules céramiques ;
    former une membrane de haut-parleur à partir de la feuille.
  7. Procédé selon la revendication 6, dans lequel les particules métalliques sont un alliage d'aluminium comprenant au moins un élément choisi dans le groupe constitué par le chrome, le cuivre, le lithium, le magnésium, le manganèse, le zinc, le fer, le nickel, l'argent, le scandium, le vanadium et le silicium.
  8. Procédé selon la revendication 6, dans lequel les particules métalliques sont un alliage d'aluminium comprenant d'environ 91,2 % en poids à environ 98,6 % en poids d'aluminium, d'environ 0,15 % en poids à environ 4,9 % en poids de cuivre, d'environ 0,1 % en poids à environ 1,8 % en poids de magnésium et d'environ 0,1 % en poids à environ 1 % en poids de manganèse.
  9. Procédé selon la revendication 8, dans lequel la feuille comprend d'environ 35 % en volume à environ 55 % en volume des particules céramiques.
  10. Procédé selon la revendication 8, dans lequel les particules céramiques ont une taille moyenne de particules de 2 micromètres à 20 micromètres.
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Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
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JPS54111818A (en) * 1978-02-22 1979-09-01 Hitachi Ltd Diaphragm of acoustic transducers and production of the same
US4749545A (en) 1986-04-02 1988-06-07 British Petroleum Co. P.L.C. Preparation of composites
FR2607741B1 (fr) * 1986-12-04 1990-01-05 Cegedur Procede d'obtention de materiaux composites, notamment a matrice en alliage d'aluminium, par metallurgie des poudres
JPH06276596A (ja) * 1993-03-23 1994-09-30 Sumitomo Electric Ind Ltd スピ−カ−用振動板及びその製造方法
US6284014B1 (en) * 1994-01-19 2001-09-04 Alyn Corporation Metal matrix composite
US6404897B1 (en) * 1999-01-05 2002-06-11 Harman International Industries, Inc. Ceramic metal matrix diaphragm for loudspeakers
GB0426143D0 (en) 2004-11-26 2004-12-29 Element Six Ltd Rigid three-dimensional components
US9185492B2 (en) * 2009-04-10 2015-11-10 Immerz, Inc. Systems and methods for acousto-haptic speakers
WO2010136899A1 (fr) * 2009-05-29 2010-12-02 The Governors Of The University Of Alberta Composites renforcés et leurs procédés de fabrication et d'utilisation
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