JP2007204350A - 複合材用プリフォーム及びその製造方法 - Google Patents
複合材用プリフォーム及びその製造方法 Download PDFInfo
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Abstract
【解決手段】セラミックス繊維2又は/及びセラミックス粒子3,5とシリカゾル7と炭酸カルシウム4とを混合して、所定温度で焼結することによって、該シリカゾル7と炭酸カルシウム4とからカルシウム−ケイ素焼結体11が生成し、このカルシウム−ケイ素焼結体11によりセラミックス繊維2又は/及びセラミックス粒子3,5を被覆して、繊維2又は/及び粒子3,5を相互に結合した複合材用プリフォーム1を得る。この複合材プリフォーム1は、高い強度と優れた通気性とを有し、高い生産性を発揮し得る高速ダイカスト成形法に適用可能である。
【選択図】図3
Description
図1は、複合材用プリフォーム1を製造する工程を表した図であり、このプリフォーム製造工程は、混合工程、脱水工程、乾燥工程、焼結工程から構成されている。図1(A)は混合工程であって、所定の容器21内で、各材料を水中で攪拌棒31により攪拌してほぼ均質に混合させて混合水溶液8をつくる。そして、この混合水溶液8を、容器21から吸引成形器22に移す。図1(B)は脱水工程であって、混合水溶液8から、フィルター24を介して真空ポンプ23によって水分を吸引し、混合物9を得る。そして、この混合物9を、吸引成形器22から取り出して充分に乾燥させる乾燥工程を行う(図示省略)。図1(C)は焼結工程であって、この混合物9を加熱炉25内のテーブル32に設置し、該加熱炉25に接続された真空ポンプ29によって加熱炉25の内部を真空状態とした後、所定雰囲気中で加熱して焼結させることにより、所望の複合材用プリフォーム1を得る。
(i)アルミナ短繊維2(平均繊維径5μm、平均嵩比20cc/5gf)
(ii)ホウ酸アルミニウム粒子3(9Al2O3・2B2O3、平均粒径30μm)
(iii)炭酸カルシウム粒子4(CaCO3、平均粒子径0.3μm)
(iv)黒鉛粒子5(平均粒径20μm)
(v)シリカゾル7(SiO2、濃度約40%のコロイド状水溶液)
ここで、平均繊維径、平均嵩比、平均粒径は、それぞれ繊維径、嵩比、粒径の平均値であり、バラツキを有している。尚、アルミナ短繊維2が、本発明にかかるセラミック繊維であり、ホウ酸アルミニウム粒子3及び黒鉛粒子5が、本発明にかかるセラミック粒子である。そして、これらセラミック繊維やセラミック粒子が、所謂強化材である。
(i)アルミナ短繊維2(平均繊維径5μm、平均嵩比20cc/5gf)
(ii)ホウ酸アルミニウム粒子3(9Al2O3・2B2O3、平均粒径3μm)
(iii)炭酸カルシウム粒子4(CaCO3、平均粒子径0.3μm)
(iv)黒鉛粒子5(平均粒径20μm)
(v)シリカゾル7(SiO2、濃度約40%のコロイド状水溶液)
ここで、ホウ酸アルミニウム粒子をその平均粒子径が3μmであるものとした以外は、実施例1と同じとしている。尚、このホウ酸アルミニウム粒子の混合量は、実施例1のホウ酸アルミニウム粒子3と同じ混合量としている。以下、実施例1と同じ工程及び構成の説明は適宜省略し、同じ構成には同じ符号を記している。
また、比較例1として、炭酸カルシウム粒子4を混合せずに、シリカゾル7を無機バインダーとして混合した、従来構成の複合材用プリフォーム61を製造した。
この複合材用プリフォーム61は、上述した実施例1と同様のプリフォーム製造工程で製造する。混合工程(図1(A)参照)で、下記(i)〜(iv)以下の各材料等を容器21の水中で攪拌して混合水溶液(図示省略)を得る。
(i)アルミナ短繊維2(平均繊維径5μm、平均嵩比20cc/5gf)
(ii)ホウ酸アルミニウム粒子3(9Al2O3・2B2O3、平均粒径30μm)
(iii)黒鉛粒子5(平均粒径20μm)
(iv)シリカゾル7(SiO2、濃度約40%のコロイド状水溶液)
ここで、比較例1は、炭酸カルシウム粒子4を混合しないこと以外は実施例1と同じとしている。したがって、以下、実施例1と同じ工程及び構成の説明は適宜省略し、同じ構成には同じ符号を記している。
2 アルミナ短繊維(セラミック繊維)
3 ホウ酸アルミニウム粒子(セラミック粒子)
4 炭酸カルシウム粒子
6 アルミニウム合金の溶湯
7 シリカゾル
8 混合水溶液
9 混合物
10,10A,10B 金属複合材
11 カルシウム−ケイ素焼結体(Ca−Si焼結体)
12 カルシウム−ホウ素−ケイ素焼結体(Ca−B−Si焼結体)
14 空隙
Claims (8)
- セラミック繊維又は/及びセラミックス粒子を焼結してなるものであって、軽金属の溶湯が含浸されることにより金属複合材を成形するための複合材用プリフォームにおいて、
セラミック繊維又は/及びセラミック粒子に、シリカゾル及び炭酸カルシウムを混合して、所定温度で焼結したものであり、該焼結によりシリカゾルと炭酸カルシウムから分解された一酸化カルシウムとが反応して生成されるカルシウム−ケイ素焼結体によって、セラミック繊維又は/及びセラミック粒子が相互に結合され、かつ該繊維又は/及び粒子間に空隙が形成されていることを特徴とする複合材用プリフォーム。 - セラミック繊維又は/及びセラミック粒子に混合するシリカゾルが、その含有するシリカの重量を、セラミック繊維及びセラミック粒子の合計重量に対して0.01以上かつ0.15以下の重量比となるようにしたものであると共に、
セラミック繊維又は/及びセラミック粒子に混合する炭酸カルシウムが、その重量を、セラミック繊維及びセラミック粒子の合計重量に対して0.001以上かつ0.15以下の重量比となるようにしたものである請求項1に記載の複合材用プリフォーム。 - セラミック繊維又は/及びセラミック粒子に、シリカゾルと共に混合する炭酸カルシウムが、粒径10μm以下のものである請求項1又は請求項2に記載の複合材用プリフォーム。
- 焼結前のセラミック粒子として、粒径10μm以下のホウ酸アルミニウム粒子を用いてなる請求項1乃至請求項3のいずれかに記載の複合材用プリフォーム。
- セラミック繊維又は/及びセラミックス粒子を焼結してなり、該焼結後に軽金属の溶湯を含浸して金属複合材を成形するための複合材用プリフォームの製造方法において、
セラミック繊維又は/及びセラミック粒子に、シリカゾル及び炭酸カルシウムを水中で混ぜて混合水溶液を調合する混合工程と、
該混合水溶液から水分を除去して、混合物を形成する脱水工程と、
この混合物を所定温度で焼結することにより、シリカゾルと、炭酸カルシウムから分解された一酸化カルシウムとを反応させてカルシウム−ケイ素焼結体を生成し、該カルシウム−ケイ素焼結体によりセラミック繊維又は/及びセラミック粒子を相互に結合するようにした焼結工程と
を備えていることを特徴とする複合材用プリフォームの製造方法。 - 混合工程で混合するシリカゾルが、その含有するシリカの重量を、セラミック繊維及びセラミック粒子の合計重量に対して0.01以上かつ0.15以下の重量比となるようにしたものであると共に、混合工程で混合する炭酸カルシウムが、その重量を、セラミック繊維及びセラミック粒子の合計重量に対して0.001以上かつ0.15以下の重量比となるようにしたものである請求項5に記載の複合材用プリフォームの製造方法。
- 混合工程で混合する炭酸カルシウムが、粒径10μm以下のものである請求項5又は請求項6に記載の複合材用プリフォームの製造方法。
- 混合工程で、セラミック粒子として、粒径10μm以下のホウ酸アルミ粒子を混入して混合水溶液を調合するようにした請求項5乃至請求項7のいずれかに記載の複合材用プリフォームの製造方法。
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JP2006028698A JP4404862B2 (ja) | 2006-02-06 | 2006-02-06 | 複合材用プリフォーム及びその製造方法 |
PCT/JP2007/051663 WO2007091471A1 (ja) | 2006-02-06 | 2007-02-01 | 複合材用プリフォーム及びその製造方法 |
CNA2007800046022A CN101379211A (zh) | 2006-02-06 | 2007-02-01 | 复合材料用预成型体及其制造方法 |
EP07707849.1A EP2050836B1 (en) | 2006-02-06 | 2007-02-01 | Preform for composite material and process for producing the same |
US12/278,183 US20090035554A1 (en) | 2006-02-06 | 2007-02-01 | Preform for composite material and process for producing the same |
US12/977,385 US20110101575A1 (en) | 2006-02-06 | 2010-12-23 | Preform for composite material and process for producing the same |
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JP2017533829A (ja) * | 2014-10-20 | 2017-11-16 | インテレクチュアル プロパティ ホールディングス, エルエルシー | セラミックプリフォームおよび方法 |
CN109514696A (zh) * | 2018-11-23 | 2019-03-26 | 航天特种材料及工艺技术研究所 | 一种预成型复合材料成型过程的变形控制方法及该控制方法的应用 |
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JP3315659B2 (ja) * | 1998-01-30 | 2002-08-19 | マツダ株式会社 | 複合化用予備成形体及びその製造方法及び該予備成形体を用いた複合化部材 |
JPH11226719A (ja) * | 1998-02-16 | 1999-08-24 | Mazda Motor Corp | 耐摩耗性複合化用予備成形体及びその製造方法及び耐摩耗性複合化部材 |
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JP4338413B2 (ja) * | 2003-02-28 | 2009-10-07 | 中央精機株式会社 | 複合材用プリフォーム並びに該複合材用プリフォームを複合化してなるアルミニウム複合材及びこれらの製造方法 |
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JP2017533829A (ja) * | 2014-10-20 | 2017-11-16 | インテレクチュアル プロパティ ホールディングス, エルエルシー | セラミックプリフォームおよび方法 |
CN109514696A (zh) * | 2018-11-23 | 2019-03-26 | 航天特种材料及工艺技术研究所 | 一种预成型复合材料成型过程的变形控制方法及该控制方法的应用 |
CN112521782A (zh) * | 2021-01-06 | 2021-03-19 | 成都容浓伊涂料科技有限公司 | 一种高韧性水性耐磨陶瓷涂料的制备方法 |
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EP2050836A4 (en) | 2011-08-31 |
WO2007091471A1 (ja) | 2007-08-16 |
JP4404862B2 (ja) | 2010-01-27 |
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EP2050836B1 (en) | 2014-01-08 |
US20090035554A1 (en) | 2009-02-05 |
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