JP2008526662A - 造型複合材料 - Google Patents
造型複合材料 Download PDFInfo
- Publication number
- JP2008526662A JP2008526662A JP2007548977A JP2007548977A JP2008526662A JP 2008526662 A JP2008526662 A JP 2008526662A JP 2007548977 A JP2007548977 A JP 2007548977A JP 2007548977 A JP2007548977 A JP 2007548977A JP 2008526662 A JP2008526662 A JP 2008526662A
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- 239000002131 composite material Substances 0.000 title claims abstract description 28
- 238000000465 moulding Methods 0.000 title claims description 5
- 239000000203 mixture Substances 0.000 claims abstract description 76
- 238000000034 method Methods 0.000 claims abstract description 50
- 239000000463 material Substances 0.000 claims abstract description 27
- 239000002344 surface layer Substances 0.000 claims abstract description 27
- 230000008569 process Effects 0.000 claims abstract description 18
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 42
- 229910052799 carbon Inorganic materials 0.000 claims description 42
- 239000010410 layer Substances 0.000 claims description 30
- 229910052710 silicon Inorganic materials 0.000 claims description 28
- 239000010703 silicon Substances 0.000 claims description 27
- 229920005989 resin Polymers 0.000 claims description 25
- 239000011347 resin Substances 0.000 claims description 25
- 239000002245 particle Substances 0.000 claims description 24
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- 239000012783 reinforcing fiber Substances 0.000 claims description 21
- 239000011230 binding agent Substances 0.000 claims description 17
- 238000010304 firing Methods 0.000 claims description 16
- FGUUSXIOTUKUDN-IBGZPJMESA-N C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 Chemical compound C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 FGUUSXIOTUKUDN-IBGZPJMESA-N 0.000 claims description 9
- 238000000197 pyrolysis Methods 0.000 claims description 9
- 239000000126 substance Substances 0.000 claims description 9
- 239000000654 additive Substances 0.000 claims description 7
- 239000000047 product Substances 0.000 claims description 7
- 238000003763 carbonization Methods 0.000 claims description 6
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- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 229920005749 polyurethane resin Polymers 0.000 claims description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 2
- 229910000676 Si alloy Inorganic materials 0.000 claims description 2
- 229910052782 aluminium Inorganic materials 0.000 claims description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 2
- 229910052802 copper Inorganic materials 0.000 claims description 2
- 239000010949 copper Substances 0.000 claims description 2
- 239000011261 inert gas Substances 0.000 claims description 2
- 239000012758 reinforcing additive Substances 0.000 claims description 2
- 229910010293 ceramic material Inorganic materials 0.000 abstract description 10
- 238000004519 manufacturing process Methods 0.000 abstract description 6
- 229910010271 silicon carbide Inorganic materials 0.000 description 42
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 31
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 24
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 7
- 238000001354 calcination Methods 0.000 description 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 6
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 6
- 238000006243 chemical reaction Methods 0.000 description 5
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- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 3
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- 239000004745 nonwoven fabric Substances 0.000 description 2
- -1 pitch Natural products 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 229920002239 polyacrylonitrile Polymers 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- GNFTZDOKVXKIBK-UHFFFAOYSA-N 3-(2-methoxyethoxy)benzohydrazide Chemical compound COCCOC1=CC=CC(C(=O)NN)=C1 GNFTZDOKVXKIBK-UHFFFAOYSA-N 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
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- BMCCWMIUYHAWDU-UHFFFAOYSA-N [Si+4].[O-][Si]([O-])([O-])[O-] Chemical compound [Si+4].[O-][Si]([O-])([O-])[O-] BMCCWMIUYHAWDU-UHFFFAOYSA-N 0.000 description 1
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- 238000001764 infiltration Methods 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
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- 230000003993 interaction Effects 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
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- 230000004048 modification Effects 0.000 description 1
- 229930014626 natural product Natural products 0.000 description 1
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
- F16D69/02—Composition of linings ; Methods of manufacturing
- F16D69/023—Composite materials containing carbon and carbon fibres or fibres made of carbonizable material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
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Abstract
【選択図】 なし
Description
フィラメントの束が凝集樹脂、ピッチおよび他の添加剤と混合され、その混合物は熱の助けおよび圧力の適用で造型される型内に置かれ、造型半完成品を産する。半完成品は、それから炉内にて樹脂の炭化または熱分解をもたらすような温度で第1焼成に供する。
・高温および圧縮ストレス耐性、
・材料の組成中への強化繊維の存在のために、構造を通しての損失の伝達、それによる完全な崩壊は回避される。
a)30mm以下の長さを有する予め決めた量の実質的にカーボンからなるフィラメントおよび予め決めた量の化学バインダを含む第1混合物を調製すること、
b)実質的にカーボンからなるフィラメント、SiCおよび樹脂を得るために望まれる摩擦係数に依存する種々の量で含む第2混合物を調製すること、
c)亀裂の成長を遅らせるように前記形状に沿って伸びる前記支持層の第1混合物に複数の強化繊維を任意に組み込むこと、
d)前記第1混合物および前記第2混合物を、得るために必要とする製造品の形状を有する型に前記第1混合物が支持層を構成し、かつ前記第2混合物が前記支持層の2側面の少なくとも1つの上に少なくとも1つの表面層を構成するような手法で設置すること、
e)前記第1混合物および前記第2混合物を前記型内で造型し、半完成品を得ること、
f)前記半完成品を前記化学バインダの炭化または熱分解を本質的にもたらすような温度での第1焼成に供すること、
g)前記焼成半完成品をシリコンの存在で前記シリコンの溶融および前記半完成品に同様の浸潤をもたらすような温度の第2焼成に供し、本質的にある期間にわたって一定のままである高、中または低の摩擦係数を持つ前記造型複合材料を得ること
の工程を含む。
摩擦係数が要求される種々のブレーキ性能に関連して選択できることの事実は、買い手の要求に対して個人専用にする乗り物を製造することができる。例えば、レイシングカーはユーザの安全を保証するために非常に高い摩擦係数を要求する。
混合物の体積あたり体積パーセントとして、65%の0.3mm〜0.5mmの径および7mm〜10mmの長さ有するカーボンフィラメント、23%の乾式フェノール樹脂および12%の炭化ケイ素粉末を含む第1混合物は、エライ(Erigh)混合器として知られる混合器中、従来法で調製した。
Claims (33)
- 支持層および少なくとも1つの表面層を備え、高、中または低の摩擦係数を持つ造型複合材料の製造方法であって、次の工程:
a)実質的にカーボンからなるフィラメントおよび化学バインダを含む第1混合物の調製、
b)SiCおよび樹脂と共に実質的にカーボンからなるフィラメントを含み、実質的にカーボンからなるフィラメント、SiCおよび樹脂の量、実質的にカーボンからなるフィラメントの長さおよびSiCの粒子寸法は得るために望まれる摩擦係数の関係で選択され、かつ実質的にカーボンからなる前記フィラメントの量およびそれらの長さは得るために望まれる摩擦係数の値に対し正比例であり、同時にSiCの量およびその粒子寸法は得るために望まれる摩擦係数の値に対しそれぞれ逆比例および正比例である、第2混合物の調製、
c)前記第1混合物a)および前記第2混合物b)を、得るために必要とする製造品の形状を有する型に前記第1混合物が支持層を構成し、かつ前記第2混合物が前記支持層の2側面の少なくとも1つの上に少なくとも1つの表面層を構成するような手法で設置すること、
d)前記第1混合物および前記第2混合物を前記型内で造型し、半完成品を得ること、
e)前記半完成品を前記化学バインダの炭化または熱分解を本質的にもたらすような温度での第1焼成に供すること、
f)前記焼成半完成品をシリコンの存在で前記シリコンを溶融し、前記半完成品に浸潤させることをもたらすような温度の第2焼成に供し、本質的にある期間にわたって一定のままである高、中または低の摩擦係数を持つ前記造型複合材料を得ること
を含む方法。 - 工程b)において、前記混合物は5〜60重量%、好ましくは6〜40重量%の実質的にカーボンからなるフィラメントを含む請求項1記載の方法。
- 工程b)において、前記混合物は1〜30重量%、好ましくは2〜25重量%のSiCを含む請求項1または2記載の方法。
- 工程b)において、前記混合物は40〜80重量%、好ましくは50〜75重量%の樹脂を含む請求項1から3いずれか記載の方法。
- 工程b)において、前記混合物は0.1〜8mm、好ましくは0.2〜7mmの長さを持つ実質的にカーボンからなるフィラメントを含む請求項1から4いずれか記載の方法。
- 工程b)において、前記混合物は0.01〜2mm、好ましくは0.02〜1.7mmの粒子寸法を持つSiCを含む請求項1から5いずれか記載の方法。
- 工程b)において、前記混合物は高摩擦係数を得るために25〜60重量%の、5〜8mmの長さを持つ実質的にカーボンからなるフィラメント、1〜10重量%の、1〜2mmの粒子寸法を持つSiCおよび40〜75重量%の樹脂を含む請求項1から6いずれか記載の方法。
- 工程b)において、前記混合物は中間摩擦係数を得るために10〜25重量%の、1〜5mmの長さを持つ実質的にカーボンからなるフィラメント、10〜15重量%の、0.1〜1mmの粒子寸法を持つSiCおよび60〜80重量%の樹脂を含む請求項1から7いずれか記載の方法。
- 工程b)において、前記混合物は低摩擦係数を得るために5〜10重量%の、0.1〜1mmの長さを持つ実質的にカーボンからなるフィラメント、15〜30重量%の、0.01〜0.1mmの粒子寸法を持つSiCおよび40〜70重量%の樹脂を含む請求項1から8いずれか記載の方法。
- 工程b)において、前記混合物は高摩擦係数を得るために30〜40重量%の、6〜7mmの長さを持つ実質的にカーボンからなるフィラメント、2〜7重量%の、1.2〜1.7mmの粒子寸法を持つSiCおよび50〜65重量%の樹脂を含む請求項1から6いずれか記載の方法。
- 工程b)において、前記混合物は中間摩擦係数を得るために10〜20重量%の、2〜4mmの長さを持つ実質的にカーボンからなるフィラメント、11〜13重量%の、0.1〜1mmの粒子寸法を持つSiCおよび65〜75重量%の樹脂を含む請求項1から10いずれか記載の方法。
- 工程b)において、前記混合物は低摩擦係数を得るために6〜8重量%の、0.2〜0.8mmの長さを持つ実質的にカーボンからなるフィラメント、18〜25重量%の、0.02〜0.09mmの粒子寸法を持つSiCおよび50〜65重量%の樹脂を含む請求項1から11いずれか記載の方法。
- 前記樹脂がポリウレタン樹脂である請求項1から12いずれか記載の方法。
- 前記第1混合物は、強化繊維および/または添加剤をさらに含む請求項1から13いずれか記載の方法。
- 工程a)において、前記混合物は30mm以下、好ましくは7〜10mm、より好ましくは約8mmの長さを持つ実質的にカーボンからなるフィラメントを含む請求項1から14いずれか記載の方法。
- 工程a)において、前記混合物は実質的にカーボンからなるフィラメント40〜70体積%、好ましくは50〜60体積%を含む請求項1から15いずれか記載の方法。
- 工程a)において、化学バインダ5〜30体積%、好ましくは15〜25体積%を含む請求項1から16いずれか記載の方法。
- 工程a)において、前記混合物は添加剤0.5〜20体積%、好ましくは1〜15体積%を含む請求項1から17いずれか記載の方法。
- 工程a)において、前記混合物は複数の強化繊維を含む請求項1から18いずれか記載の方法。
- 前記強化繊維は0〜30体積%量である請求項19記載の方法。
- 前記工程d)は、80〜180℃、好ましくは100〜120℃の温度でなされる請求項1から20いずれか記載の方法。
- 前記工程d)は、0.1N/cm2〜5N/cm2、好ましくは0.5〜1N/cm2の圧力でなされる請求項1から21いずれか記載の方法。
- 前記工程e)は、炉内にて900〜1200℃の温度でなされる請求項1から22いずれか記載の方法。
- 前記工程e)は、不活性ガスの流れの存在にて、10〜100ミリバール、好ましくは20〜30ミリバールの圧力でなされる請求項1から23いずれか記載の方法。
- 工程e)からの半完成品は、表面仕上げ工程に供する請求項1から24いずれか記載の方法。
- 前記工程f)において、用いられるシリコンが純粋シリコンおよび/またはシリコンとアルミニウムまたは銅の合金である請求項1から25いずれか記載の方法。
- 前記工程f)は炉内にて1400〜1700℃でなされる請求項1から26いずれか記載の方法。
- 前記工程f)は約1ミリバール、好ましくは約1.5ミリバールの圧力でなされる請求項1から27いずれか記載の方法。
- 前記第2混合物b)は50〜90℃、好ましくは60〜75℃の温度で熱予備成型される(工程b1)請求項1から28いずれか記載の方法。
- 前記予備成型混合物は多孔質フェルトを得るために予備熱分解に供され、それから工程c)〜e)に従って処理される請求項29記載の方法。
- 前記第2混合物は予備熱分解化され、それから工程c)〜e)に従って処理される請求項29または30記載の方法。
- 請求項1から31のいずれかに従って得ることが可能な造型複合材料。
- ディスクブレーキ用ディスクである請求項32記載の材料。
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Cited By (5)
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JP2015523948A (ja) * | 2012-05-16 | 2015-08-20 | ペトロチェラミクス ソシエタ ペル アチオニ | 成形複合材料 |
JP2018083755A (ja) * | 2018-01-09 | 2018-05-31 | ペトロチェラミクス ソシエタ ペル アチオニ | 成形複合材料 |
JP2018188323A (ja) * | 2017-04-28 | 2018-11-29 | クアーズテック株式会社 | 炭素短繊維強化複合材料およびその製造方法 |
JP2018188322A (ja) * | 2017-04-28 | 2018-11-29 | クアーズテック株式会社 | 炭素短繊維強化複合材料およびその製造方法 |
JP2019156682A (ja) * | 2018-03-13 | 2019-09-19 | イビデン株式会社 | シリコン含浸セラミック複合材の製造方法、摩擦板の製造方法、及びブレーキディスクの製造方法 |
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EP1124074B2 (en) * | 2000-02-09 | 2010-09-22 | Freni Brembo S.p.A. | A shaped composite material for breaking applications and a method for the preparation thereof |
DE102006026550A1 (de) * | 2006-06-08 | 2007-12-13 | Audi Ag | Keramische Werkstoffe enthaltend Kohlenstoff-Teilchen mit kugelförmiger Gestalt |
WO2013166275A1 (en) * | 2012-05-02 | 2013-11-07 | Intellectual Property Holdings, Llc | Ceramic preform and method |
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US20170015592A1 (en) * | 2014-03-14 | 2017-01-19 | General Electric Company | Process of producing ceramic matrix composites and ceramic matrix composites formed thereby |
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JP2015523948A (ja) * | 2012-05-16 | 2015-08-20 | ペトロチェラミクス ソシエタ ペル アチオニ | 成形複合材料 |
US10710341B2 (en) | 2012-05-16 | 2020-07-14 | Petroceramics S.P.A. | Shaped composite material |
JP2018188323A (ja) * | 2017-04-28 | 2018-11-29 | クアーズテック株式会社 | 炭素短繊維強化複合材料およびその製造方法 |
JP2018188322A (ja) * | 2017-04-28 | 2018-11-29 | クアーズテック株式会社 | 炭素短繊維強化複合材料およびその製造方法 |
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JP2018083755A (ja) * | 2018-01-09 | 2018-05-31 | ペトロチェラミクス ソシエタ ペル アチオニ | 成形複合材料 |
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WO2019176896A1 (ja) * | 2018-03-13 | 2019-09-19 | イビデン株式会社 | シリコン含浸セラミック複合材の製造方法、摩擦板の製造方法、及びブレーキディスクの製造方法 |
JP7049869B2 (ja) | 2018-03-13 | 2022-04-07 | イビデン株式会社 | シリコン含浸セラミック複合材の製造方法、摩擦板の製造方法、及びブレーキディスクの製造方法 |
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EP1831129B1 (en) | 2010-11-03 |
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ATE486827T1 (de) | 2010-11-15 |
US8349231B2 (en) | 2013-01-08 |
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US20070284772A1 (en) | 2007-12-13 |
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