JP2010500268A - 多孔性物品を高密度化する方法 - Google Patents
多孔性物品を高密度化する方法 Download PDFInfo
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Abstract
Description
本件は、米国仮出願第60/821,596(2006年8月7日出願)による優先権を主張し、その全内容を参照により本明細書に組み入れる。
本発明は、望ましく高い製造率で多孔性物品を高密度化する方法および装置に関し、特に、これのみには限らないが摩擦ブレーキ物品,例えば航空機ブレーキの分野に関する。
摩擦材料の分野において、摩擦部材(摩擦ブレーキ盤等)を製造するために多孔性材料を用いることは一般的に公知である。
このような摩擦部材の製造は、一般的に、多孔性プレフォームの構成から始まる。例えば、多くの摩擦ブレーキ用途において輪状(annular)プレフォームが用いられている。
また、ニアネットシェイププレフォームを、例えば、炭素繊維を織ることによって、または炭素繊維を所望の形状に編むことによって形成できる。特定の炭素繊維布帛は、螺旋形状の布帛の構築を容易にする織り方を有することが公知である。本明細書において「ニアネット(near-net)」は、最終物品の所望の形、例えば輪状ブレーキ盤に近い形状を有する形成構造を意味する。
いずれの場合も、所望の摩擦特性および機械的特性を得るために、得られる多孔性プレフォーム(特に、限定するものではないが炭素質材料によるもの)をさらに高密度化することが望ましい。
本発明は、液体プレカーサーを用いて多孔性基材を高密度化(densify)する方法に関し、ここで、使用する「新しい」または「未使用の」液体プレカーサーの体積は、高密度化に使用する液体プレカーサーを、純粋であるよりは低いが、高密度化プロセスに対してはなお化学的に好適な純度レベルに維持することにより有用に低減される。実際には、本発明は、人工的に「エージングした(aged)」(その中に存在する不純物の観点で)液体プレカーサーを用いる。
本発明は、添付の図面を参照してさらにより明瞭に理解されよう。
添付の図面を参照し、本発明の方法および装置の特徴および詳細は例示としてであって発明の限定としてではなく示される。
単に例および/または例示として、以下に多孔性プレフォーム(摩擦ブレーキディスク製造用のプレフォーム等)の言及がなされる。しかし、説明される様式で本発明は他の種類の多孔性基材の高密度化に対してより一般的に適用可能であることが明白に留意される。
施設の種々の部分を相互接続するために用いるパイプ系(ポンプ等が挙げられる)は従来のものであり、そして用いる液体プレカーサー、特に、これのみに限らないが液体炭化水素を輸送するのに適切な任意の構成および配置であることができる。流体移送系は、好ましくは、これである必要はないがコンピュータ制御される。市販で入手可能なコンピュータ制御された系(例えば、これらに限定されないが、OPTO 22社から市販で入手可能なもの)を、この型の流体移送系(外部供給元からの新しい液体プレカーサーの充填等)の監視および制御のために使用できる。
さらに、分析は、全化学成分の濃度が幾つかの実施の後で実質的に定常で維持されることを示す。
Claims (17)
- 反応チャンバー内で液体プレカーサー中に多孔性基材を浸漬することによって液体プレカーサーを多孔性基材中の孔隙に浸透させること;および
多孔性基材を高密度化するために、浸漬された多孔性基材を、液体プレカーサーを熱分解させて分解生成物を該基材の孔隙内に堆積させるのに十分な温度に誘導的に加熱すること;
を含み、
液体プレカーサーの化学的純度レベルを、化学的に純粋であるよりは低く、そして所望の物理的特性を有する分解生成物を得るには十分に化学的に純粋であるように制御する、
多孔性基材の高密度化方法。 - 液体プレカーサーが炭化水素を含む、請求項1に記載の方法。
- 分解生成物が炭素を含む、請求項1に記載の方法。
- 炭化水素が、シクロペンタン、シクロヘキセン、1−ヘキセン、ガソリン、トルエン、メチルシクロヘキサン、n−ヘキサン、灯油、水素脱硫灯油、ベンゼン、およびこれらの組合せからなる群から選択される、請求項2に記載の方法。
- 液体プレカーサーの化学的純度レベルを、約80〜約99.9%の間に制御する、請求項1に記載の方法。
- 液体プレカーサー中に不純物が存在し、不純物が、シクロペンタジエン、ヘキサン、メチルシクロペンタン、ベンゼン、シクロヘキセン、ヘプタン、メチルシクロヘキサン、トルエン、エチルベンゼン、フェニルアセチレン、スチレン、ノナン、インデン、ナフタレン、メチルナフタレン、アセナフタレン、およびフッ素のうち1種以上を含む、請求項5に記載の方法。
- 液体プレカーサーの化学的純度を、インライン蒸留プロセスを用いて制御する、請求項1〜6のいずれかに記載の方法。
- 液体プレカーサーの化学的純度を、約95%±5%の範囲内に制御する、請求項7に記載の方法。
- 化学的に純粋な液体プレカーサーの量を、1つ以上の前高密度化サイクルにおける使用を示す1種以上の不純物を含むエージングした液体プレカーサーの量と混合することによって、液体プレカーサーの化学的純度を約90%±5%の範囲内に制御する、請求項7に記載の方法。
- 液体プレカーサーがオルガノシランを含む、請求項1に記載の方法。
- オルガノシランが、メチルトリクロロシラン、ジメチルジクロロシラン、メチルジクロロシラン、およびトリス−n−メチルアミノシランからなる群から選択される、請求項10に記載の方法。
- 分解生成物が、炭化珪素および窒化珪素を含む、請求項10に記載の方法。
- 液体プレカーサーが、オルガノシランと炭化水素との混合物である、請求項1に記載の方法。
- 分解生成物が、炭素/炭化珪素または炭素/窒化珪素のいずれかである、請求項12に記載の方法。
- 反応チャンバー;
反応チャンバー内に配置される少なくとも1つの誘導コイル加熱アセンブリ;
液体プレカーサー消費を監視するための流体レベル表示器;
高密度化プロセスの間に液体プレカーサーを添加するための手段;
反応チャンバーを不活性ガスでパージするための手段;
反応チャンバーに接続され、そして反応チャンバー内のプレカーサー蒸気を凝縮させ、そして凝縮されたプレカーサーを反応容器に戻すように構成および配列された蒸気回収系;
蒸気回収系および熱酸化器にパージするための手段に接続する排出系;ならびに
高密度化の間、反応器圧力を約760Torr〜約780Torrの間に維持するための加圧手段;
を含む、液体マトリクスプレカーサーを用いて多孔性プレフォームを高密度化するための反応器。 - 浸漬された多孔性基材を誘導的に加熱することが、
誘導加熱のための初期周波数およびパワーレベルを設定し、初期周波数およびパワーレベルが、多孔性基材の幾何学的中心領域に位置する孔隙内で優先的に液体プレカーサー蒸気を熱分解させるように多孔性基材の幾何学的中心領域で十分な熱を蓄積するのに効果的であるようにすること;
多孔性基材の他の部分を同時に高密度化することなく多孔性基材の幾何学的中心領域を高密度化するのに十分な初期周波数で誘導加熱するための初期パワーレベルを供給すること;
多孔性基材の幾何学的中心領域を後高密度化し、さらに、多孔性基材の内側領域を半径方向にて多孔性基材の幾何学的中心領域から外側に向かって徐々に高密度化するように、供給されるパワーレベルおよび周波数を調整すること;ならびに
高密度化プロセスの終了時にパワーレベルをゼロに下降させること
を含む、請求項1に記載の方法。 - 高密度化後に行なう熱処理をさらに含み、該熱処理が:
液体プレカーサーを完全に反応チャンバーから排水すること;
反応チャンバーを不活性ガスでパージすること;
約760Torr〜約780Torrの圧力を維持しながら、高密度化された多孔性基材を、不活性ガス雰囲気中、温度約1600〜約2400℃の間で誘導的に加熱すること;および
誘導加熱をゼロに下降させて熱処理を完了させること
を含む、請求項1に記載の方法。
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