JP5566608B2 - 二相ナノポーラスガラス状炭素材料およびその製造方法 - Google Patents
二相ナノポーラスガラス状炭素材料およびその製造方法 Download PDFInfo
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Description
米国特許法第120条の規定に基づき、2006年1月27日に出願された米国仮特許出願第60/762,588号明細書の優先権の利益が本明細書により主張される。米国仮特許出願第60/762,588号明細書の開示全体が、本明細書に援用される。
本発明は、特にトライボロジー用途において有用な、二相ナノポーラスガラス状炭素材料、およびその製造方法に関する。
ガラス状炭素は優れたトライボロジー特性を有することが十分に実証されている(R.A. Burton and R.G. Burton “Vitreous Carbon Matrix for Low-Wear Carbon/Metal Collectors” IEEE Transactions June 1989, Vol. 12 No. 2)。純粋なガラス状炭素の使用における限定要因は、厚さが最大で約0.2インチに制限されることである。米国特許第5,182,166号明細書および第6,506,482号明細書に開示されているようにガラス状炭素マトリックス中に銅繊維マトリックスを混入することによって、R. A. BurtonおよびR. G. Burtonは厚さの制限を克服することができた。厚さの制限を克服できたにもかかわらず、ガラス状炭素に亀裂が生じやすいこと、ならびに適切な構造的完全性および商業的有用性を有する大型のガラス状炭素物品を形成することができないことによって、商業的に有用な金属強化炭素複合材料を実現しようとする試みでは断続的に問題が発生している。
本発明は、二相ナノポーラスガラス状炭素材料およびその製造方法に関する。
本発明は、二相ナノポーラス形態を特徴としトライボロジー用途に有用である新規なガラス状炭素材料に関する。
Claims (34)
- 硬化および熱分解によりガラス状炭素を形成することができる前駆体樹脂を含有する組成物中の粒子状ガラス化炭素を不活性雰囲気下で焼成するステップによって製造され、
0.2インチよりも大きな厚さを有する、
二相ナノポーラスガラス状炭素材料。 - 硬化および熱分解によりガラス状炭素を形成することができる前駆体樹脂を含有する組成物中の粒子状ガラス化炭素を不活性雰囲気下で焼成するステップによって製造され、
0.2インチよりも大きな厚さを有し、
前記組成物が、(a)固体潤滑剤、および(b)トライボロジー特性、電気的性質、または機械的性質を変化させる添加剤からなる群から選択される少なくとも1種類の添加剤をさらに含有する、
請求項1に記載の二相ナノポーラスガラス状炭素材料。 - 固体潤滑剤と、黒鉛、窒化ホウ素、および二硫化モリブデンからなる群から選択される少なくとも1種類の材料とを含む添加剤を含む、請求項2に記載の二相ナノポーラスガラス状炭素材料。
- 前記固体潤滑剤が二硫化モリブデンを含む、請求項2に記載の二相ナノポーラスガラス状炭素材料。
- 1.2〜1.5g/ccの範囲内の密度を有し、亀裂が存在しない、請求項1または2に記載の二相ナノポーラスガラス状炭素材料。
- 金属繊維強化材を内部に有さない、請求項1または2に記載の二相ナノポーラスガラス状炭素材料。
- 請求項1または2に記載の二相ナノポーラスガラス状炭素材料を含み、金属、セラミック、または炭素の強化繊維を内部に含有する、複合材料。
- 銅、青銅、鋼、合金鉄、黒鉛、アルミナ、シリカ、および炭化ケイ素からなる群から選択される材料から形成された繊維を含む金属強化繊維を含む、請求項7に記載の複合材料。
- 硬化および熱分解によりガラス状炭素を形成することができる前駆体樹脂を含有する組成物中の粒子状ガラス化炭素を不活性雰囲気下で焼成するステップを含み、
前記ガラス状炭素が、0.2インチよりも大きい厚さを有する、
ガラス状炭素複合材料の製造方法。 - 前記組成物中の前記前駆体樹脂を硬化させるステップを含み、前記硬化中に熱が除去される、請求項9に記載の方法。
- 前記粒子状ガラス化炭素が、#40メッシュからサブミクロンサイズの範囲内の平均粒度を有する、請求項9に記載の方法。
- 前記粒子状ガラス化炭素が、#200メッシュからサブミクロンサイズの範囲内の平均粒度を有する、請求項9に記載の方法。
- 前記組成物が、繊維状強化材を含有する、請求項9に記載の方法。
- 前記繊維状強化材が、銅、青銅、鉄合金、黒鉛、アルミナ、シリカ、および炭化ケイ素からなる群から選択される材料から形成された繊維を含む、請求項13に記載の方法。
- 前記前駆体樹脂が、フルフリルアルコールから誘導されるポリマーまたはオリゴマーを含む、請求項9に記載の方法。
- 前記組成物が、前記樹脂を硬化させるための触媒を含有する、請求項9に記載の方法。
- 前記前駆体樹脂を硬化させた後に、前記組成物を不活性雰囲気下で熱分解させて、前記硬化した樹脂をガラス様炭素マトリックスに変換するステップを含む、請求項9に記載の方法。
- 前記熱分解プロセスが、前記硬化した材料を、不活性雰囲気下で、少なくとも750℃の温度まで40〜60時間かけて加熱し、前記温度を少なくとも1時間維持するステップを含む、請求項17に記載の方法。
- 硬化および熱分解によりガラス状炭素を形成することができる前駆体樹脂を含有する組成物中の粒子状ガラス化炭素を不活性雰囲気下で焼成するステップを含み、
前記ガラス状炭素が、0.2インチよりも大きい厚さを有し、
前記組成物が、(a)固体潤滑剤、および(b)トライボロジー特性、電気的性質、または機械的性質を変化させる添加剤からなる群から選択される少なくとも1種類の添加剤をさらに含有する、
ガラス状炭素複合材料の製造方法。 - 前記組成物中の前記前駆体樹脂を硬化させるステップを含み、前記硬化中に熱が除去される、請求項19に記載の方法。
- 前記粒子状ガラス化炭素が、#40メッシュからサブミクロンサイズの範囲内の平均粒度を有する、請求項19に記載の方法。
- 前記粒子状ガラス化炭素が、#200メッシュからサブミクロンサイズの範囲内の平均粒度を有する、請求項19に記載の方法。
- 前記組成物が、繊維状強化材を含有する、請求項19に記載の方法。
- 前記繊維状強化材が、銅、青銅、鉄合金、黒鉛、アルミナ、シリカ、および炭化ケイ素からなる群から選択される材料から形成された繊維を含む、請求項23に記載の方法。
- 前記前駆体樹脂が、フルフリルアルコールから誘導されるポリマーまたはオリゴマーを含む、請求項19に記載の方法。
- 前記組成物が、前記樹脂を硬化させるための触媒を含有する、請求項19に記載の方法。
- 前記前駆体樹脂を硬化させた後に、前記組成物を不活性雰囲気下で熱分解させて、前記硬化した樹脂をガラス様炭素マトリックスに変換するステップを含む、請求項19に記載の方法。
- 前記熱分解プロセスが、前記硬化した材料を、不活性雰囲気下で、少なくとも750℃の温度まで40〜60時間かけて加熱し、前記温度を少なくとも1時間維持するステップを含む、請求項27に記載の方法。
- 所定の大きさのガラス状炭素体を製造する方法であって、
前記所定の大きさよりも小さい大きさの複数のガラス状炭素前駆粒子を形成するステップであって、前記前駆粒子のそれぞれが、硬化した前駆体樹脂から形成されているステップと、
前記前駆体樹脂を含む接合媒体を使用して前記複数のガラス状炭素前駆粒子を互いに接合させて凝集体を形成するステップと、
前記硬化した接合媒体を含む前記凝集体を熱分解させて、前記所定の大きさの前記ガラス状炭素体を得るステップと、
を含み、
前記ガラス状炭素体が、0.2インチよりも大きい厚さを有する、
方法。 - 前記所定の大きさよりも小さい大きさの前記ガラス状炭素前駆粒子自体が、前駆体樹脂を硬化させることによって、前記小さい大きさよりもさらに小さい大きさの複数のガラス状炭素粒子を形成するステップと、前記前駆体樹脂を含む接合媒体を使用して、前記さらに小さい大きさの複数のガラス状炭素粒子を互いに接合させるステップと、前記前駆体樹脂を硬化させるステップと、前記凝集体を熱分解させて前記所定の大きさよりも小さい大きさの前記ガラス状炭素粒子を得るステップとの対応する方法の生成物である、請求項29に記載の方法。
- 所定の大きさの前記凝集体を得るために、前記形成ステップ、接合ステップ、および硬化ステップのサイクルの繰り返しを含む、請求項29に記載の方法。
- 前記ガラス状炭素体が、二相ナノポーラスガラス状炭素を含む材料から形成されている、請求項29に記載の方法。
- 所定の大きさのガラス状炭素体を製造する方法であって、
前記所定の大きさよりも小さい大きさの複数のガラス状炭素前駆粒子を形成するステップであって、前記前駆粒子のそれぞれが、粒子状ガラス化炭素を含有する硬化した前駆体樹脂から形成されているステップと、
前記前駆体樹脂を含む接合媒体を使用して前記複数の硬化したガラス状炭素前駆粒子を互いに接合させて凝集体を形成するステップと、
前記硬化した接合媒体を含む前記凝集体を熱分解させて、前記所定の大きさの前記ガラス状炭素体を得るステップと、
を含み、
前記ガラス状炭素体が、0.2インチよりも大きい厚さを有する、
方法。 - 前記接合媒体が、前記前駆体樹脂中に分散した粒子状ガラス化炭素を含む、請求項33に記載の方法。
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