JP6610070B2 - Composite material and manufacturing method thereof - Google Patents

Description

  The present invention relates to a composite material in which a carbon sheet and a metal sheet are laminated and a method for producing the same.

  Various methods for laminating a carbon sheet with a high thermal conductivity and a metal sheet have been proposed as a method for increasing the thermal conductivity of a metal material (see, for example, Patent Documents 1 to 6). The carbon sheet and the metal sheet do not naturally adhere to each other, and in many cases, the carbon sheet and the metal sheet are adhered using an adhesive.

  However, since the carbon sheet has releasability, even if the metal sheet and the carbon sheet are bonded to each other, the carbon sheet itself is peeled off, and mechanical strength such as bending cannot be secured. Therefore, as in Patent Documents 2 to 4, the anchor effect is used together for adhesion between the metal sheet and the carbon sheet, or through the through holes formed in the carbon sheet between the metal sheets sandwiching the carbon sheet as in Patent Document 6. There has been proposed a method for securing the strength by joining them through.

Japanese Patent Laid-Open No. 10-247708 JP-A-11-240706 Japanese Patent Laid-Open No. 11-286070 JP 2002-329987 A JP 2006-1232 A JP 2011-35645 A

  However, the methods described in Patent Documents 2 to 4 and 6 currently do not provide the desired structure unless a complicated shape is prepared or a complicated process is performed.

  In view of the above points, an object of the present invention is to ensure mechanical strength in a composite material in which a metal sheet and a carbon sheet are laminated.

In order to achieve the above object, according to the first aspect of the present invention, in the composite material used in a state where the metal sheets (10) are laminated on both surfaces of the plurality of carbon sheets (20), the metal sheet (10). A plurality of the carbon sheets (20) are periodically arranged between the adjacent carbon sheets (20), and a predetermined gap (21) is provided between the adjacent carbon sheets (20). The metal sheets (10) laminated on both sides of each other are joined to each other through the gap (21), and adjacent carbon sheets (20) are characterized in that corners are connected to each other .

  Thereby, since the circumference | surroundings of a carbon sheet (20) will be covered with a metal sheet (10), it can prevent that a metal sheet (10) and a carbon sheet (20) peel without using an adhesive agent etc. The mechanical strength such as bending can be ensured.

  In addition, the code | symbol in the bracket | parenthesis of each said means shows the correspondence with the specific means as described in embodiment mentioned later.

It is a top view of a composite material. It is II-II sectional drawing of FIG. It is a top view of the carbon sheet before forming a composite material. It is a figure which shows the manufacturing process of the composite material by the hot press of 1st Embodiment. It is a X-ray CT image of the composite material manufactured by the manufacturing process of FIG. It is a figure which shows the manufacturing process of the composite material by the roll rolling of 2nd Embodiment. It is an ultrasonic flaw detection image of the composite material manufactured by the manufacturing process of FIG.

(First embodiment)
Hereinafter, a first embodiment of the present invention will be described with reference to FIGS.

  As shown in FIG. 1, the composite material 1 of the present embodiment has a sheet shape, and a metal sheet 10 and a carbon sheet 20 are laminated. The carbon sheet 20 is in a state of being built in the metal sheet 10. In the present embodiment, plate-like aluminum is used as the metal sheet 10. In order to improve the thermal conductivity of the composite material 1, it is desirable that the carbon sheet 20 has a thermal conductivity that is twice or more that of the metal sheet 10. The carbon sheet 20 of the present embodiment has a thermal conductivity of 800 W / mK or more.

  A plurality of carbon sheets 20 are provided, and a plurality of carbon sheets 20 are periodically arranged. Between adjacent carbon sheets 20, cuts 21 with a predetermined interval are provided. In the example shown in FIG. 1, a plurality of carbon sheets 20 formed in a rectangular plate shape are arranged in a matrix form with five vertical and horizontal portions.

  In the composite material 1 of the present embodiment, two metal sheets 10 are formed by sandwiching one carbon sheet 20 therebetween. The two metal sheets 10 are joined to each other so as to surround the carbon sheet 20. In the example shown in FIG. 1, two metal sheets 10 are joined to each other on four sides of a rectangular carbon sheet 20. That is, the two metal sheets 10 are joined by the cut 21 provided between the adjacent carbon sheets 20.

  As shown in FIG. 3, the carbon sheet 20 before forming the composite material 1 is in a state in which cuts 21 are formed in a perforated shape and a plurality of carbon sheets 20 are connected. In this embodiment, the length A of the cut line 21 is 2.70 mm, the width B of the cut line 21 is 0.20 mm, and the interval C between the adjacent cut lines 21 is 0.95 mm.

  In the present embodiment, a carbon foil (manufactured by Kaneka) having a thickness of about 50 to 70 μm is used as the carbon sheet 20, and the cut line 21 is formed in a perforated pattern using an Olfa perforation cutter. In addition, the intersecting cut line 21 intersects with the connected portions of the perforations so that the individual carbon sheets 20 are not separated. Thereby, the carbon sheet 20 is in a state where corners are connected to the adjacent carbon sheet 20.

  Next, the manufacturing process of the composite material 1 of this embodiment is demonstrated based on FIG. First, a cut forming process for forming a perforated cut 21 in the carbon sheet 20 is performed. The cut forming process corresponds to the gap forming process of the present invention.

  Next, lamination is performed such that the brazing material is applied to the metal sheet 10 and the carbon sheet 20 is sandwiched between the two metal sheets 10 so that the surface of the metal sheet 10 on which the brazing material is applied contacts the carbon sheet 20. Perform the process.

  Next, the press process which pressurizes the laminated body which pinched | interposed the carbon sheet 20 with the metal sheet 10 from both sides is performed. In the press process of this embodiment, it pressurizes for 30 minutes with the pressure of 50 kN with the uniaxial press. The brazing material applied to the metal sheet 10 is pushed outward by the pressing process. At this time, the carbon sheet 20 is pulled by the flow of the brazing material, so that the opening of the cut 21 is enlarged. As a result, the brazing material enters the cut line 21, the perforated cut line 21 is opened, and the adjacent carbon sheets 20 are separated. Note that the pressing step corresponds to the separation step of the present invention.

  Next, a hot press process is performed in which the metal sheet 10 sandwiching the carbon sheet 20 is heated while being pressed from both sides. In this embodiment, using a discharge plasma sintering apparatus SPS-515 (manufactured by Sumitomo Coal Mining Co., Ltd.), the metal sheet 10 sandwiched with the carbon sheet 20 was heated at 525 ° C. while applying a pressure of 20 kN, and held for 20 minutes. Cooling to room temperature with post-pressure applied. The hot press process corresponds to the bonding process of the present invention.

  The composite material 1 of this embodiment can be obtained by the above manufacturing process. When the manufactured composite material 1 was observed by X-ray CT, all the cut lines 21 appeared bright as shown in FIG. Thereby, it was confirmed that the two metal sheets 10 sandwiching the carbon sheet 20 were joined together, and the periphery of the carbon sheet 20 was covered with the metal sheet 10 or the brazing material at at least four places. In addition, the plurality of carbon sheets 20 has a structure in which they are periodically arranged.

  In the composite material 1 of the present embodiment, since the periphery of the carbon sheet 20 is covered with the metal sheet 10 or the brazing material, the metal sheet 10 and the carbon sheet 20 can be prevented from peeling without using an adhesive or the like. The mechanical strength such as bending can be ensured.

  Moreover, the thermal conductivity in the plate thickness direction of the manufactured composite material 1 was about four times the thermal conductivity of the metal sheet 10. That is, high thermal conductivity could be achieved by sandwiching the carbon sheet 20 between the metal sheets 10.

(Second Embodiment)
Next, a second embodiment of the present invention will be described. Description of the same parts as those in the first embodiment will be omitted, and only different parts will be described.

  In the first embodiment, the brazing material is applied to the metal sheet 10 and the composite material 1 is manufactured by hot pressing. However, in the second embodiment, the brazing material is not applied to the metal sheet 10 and the composite material is rolled and rolled. The material 1 is manufactured.

  The manufacturing process of the composite material 1 of the second embodiment will be described with reference to FIG. First, a cut forming process for forming a perforated cut 21 in the carbon sheet 20 is performed. Next, a lamination process is performed in which the carbon sheet 20 is sandwiched between the two metal sheets 10.

  Next, the rolling process which rolls 50% of the laminated body of the metal sheet 10 and the carbon sheet 20 by roll rolling is performed. When the carbon sheet 20 is pulled in the rolling direction by the rolling process, the opening of the cut line 21 orthogonal to the rolling direction becomes large. Thereby, while brazing material enters into the cut line 21, the cut line 21 is cut open, and the carbon sheets 20 adjacent in the rolling direction are separated. The rolling process corresponds to the separation process and the joining process of the present invention.

  The composite material 1 of the second embodiment can be obtained by the above manufacturing process. When the manufactured composite material 1 is observed by ultrasonic flaw detection, as shown in FIG. 6, two metal sheets 10 sandwiching the carbon sheet 20 are bonded to each other, and the periphery of the carbon sheet 20 is at least two places. It was confirmed that the metal sheet 10 or the brazing material was covered. In addition, the plurality of carbon sheets 20 has a structure in which they are periodically arranged.

  Even in the composite material 1 of the second embodiment, since the periphery of the carbon sheet 20 is covered with the metal sheet 10 or the brazing material, it is possible to prevent the metal sheet 10 and the carbon sheet 20 from being peeled off without using an adhesive or the like. The mechanical strength such as bending can be ensured.

(Third embodiment)
Next, a third embodiment of the present invention will be described. A description of the same parts as those in the above embodiments will be omitted, and only different parts will be described.

  In the third embodiment, a copper foil is used as the metal sheet 10 and a copper brazing material is used as the brazing material. The manufacturing process is the same as that of the first embodiment shown in FIG. 4 except that the heating temperature in the hot pressing process is 800 ° C.

  Also according to the third embodiment, a composite material 1 having the same structure as the composite material 1 of the first embodiment was obtained. That is, the periphery of the carbon sheet 20 is covered with the metal sheet 10 or the brazing material, and the metal sheet 10 and the carbon sheet 20 can be prevented from being peeled off without using an adhesive or the like, and mechanical strength such as bending can be improved. Can be secured.

  Further, the thermal conductivity in the plate thickness direction of the composite material 1 manufactured in the third embodiment was about twice the thermal conductivity of the metal sheet 10. That is, high thermal conductivity could be achieved by sandwiching the carbon sheet 20 between the metal sheets 10.

(First comparative example)
Next, a first comparative example of the present invention will be described. In the first comparative example, a composite material composed of the metal sheet 10 and the carbon sheet 20 was manufactured by hot pressing in the same manufacturing process as that of the first embodiment except that the cut line 21 was not formed in the carbon sheet 20. .

  In the composite material obtained in the first comparative example, the metal sheet 10 and the carbon sheet 20 could be easily peeled off by hand.

(Second comparative example)
Next, a second comparative example of the present invention will be described. In the second comparative example, a composite material composed of the metal sheet 10 and the carbon sheet 20 was manufactured by roll rolling in the same manufacturing process as that of the second embodiment except that the cut line 21 was not formed in the carbon sheet 20. .

  In the composite material obtained in the second comparative example, the metal sheet 10 and the carbon sheet 20 could be easily peeled off by hand.

(Other embodiments)
As mentioned above, although the Example of this invention was described, this invention is not limited to this, Unless it deviates from the range described in each claim, it is not limited to the description word of each claim, and those skilled in the art Improvements based on the knowledge that a person skilled in the art normally has can also be added as appropriate to the extent that they can be easily replaced.

  For example, in the first and second embodiments, aluminum is used as the metal sheet 10, and in the third embodiment, copper is used as the metal sheet 10. Various types of metals can be used. Further, it may be an alloy containing the metal in consideration of linear expansion coefficient, strength, workability, and the like.

  In the configurations of the first and third embodiments, the composite material 1 may be brought to room temperature and then pressurized again after the hot pressing step. Thereby, the contact state of the metal sheet 10 of the composite material 1 and the carbon sheet 20 can be improved, and the thermal contact between the metal sheet 10 and the carbon sheet 20 can be improved.

  In the second embodiment, the laminate of the metal sheet 10 and the carbon sheet 20 is roll-rolled in one direction in the rolling process. However, the present invention is not limited to this, and the laminate of the metal sheet 10 and the carbon sheet 20 in two directions. You may make it roll-roll. Thereby, the contact state of the metal sheet 10 of the composite material 1 and the carbon sheet 20 can be improved, and the metal sheet 10 and the carbon sheet 20 can be made more difficult to peel off.

  Moreover, in each said embodiment, although the one carbon sheet 20 and the two metal sheets 20 were laminated | stacked alternately, and it comprised the composite material 1, it is not restricted to this, Two or more carbon sheets 20 are comprised. Alternatively, the composite material 1 may be configured by alternately stacking three or more metal sheets 20.

1 Composite material 10 Metal sheet 20 Carbon sheet 21 Cut (gap)

Claims (6)

In the composite material used in a state where the metal sheets (10) are laminated on both surfaces of the plurality of carbon sheets (20),
A plurality of the carbon sheets (20) are periodically arranged between the metal sheets (10),
A predetermined gap (21) is provided between the adjacent carbon sheets (20),
The metal sheets (10) laminated on both sides of the carbon sheet (20) are joined to each other via the gap (21) ,
The adjacent carbon sheet (20) is a composite material in which corners are connected to each other .   The composite material according to claim 1, wherein the carbon sheet (20) has a thermal conductivity of 800 W / mK or more.   The composite material according to claim 1 or 2, wherein the metal sheet (10) is made of aluminum, copper, titanium, or an alloy containing them. A gap forming step of forming a gap (21) between the adjacent carbon sheets (20) in a state where the adjacent carbon sheets (20) are partially connected to each other;
A laminating step of laminating a metal sheet (10) on both sides of the carbon sheet (20);
Separating the adjacent carbon sheets (20) from each other, and a plurality of the carbon sheets (20) are periodically arranged; and
And a joining step of joining the metal sheets (10) laminated on both surfaces of the carbon sheet (20) to each other through the gap (21). In the laminating step, the metal sheet (10) coated with a brazing material on the surface in contact with the carbon sheet (20) is laminated on both surfaces of the carbon sheet (20),
In the separation step, the metal sheets (10) laminated on both surfaces of the carbon sheet (20) are pressurized from the outside to flow the brazing material and separate the adjacent carbon sheets (20). The method for producing a composite material according to claim 4.   In the separation step and the joining step, a laminate in which the metal sheet (10) is laminated on both surfaces of the carbon sheet (20) is rolled to separate the adjacent carbon sheet (20), and the carbon The method for producing a composite material according to claim 4, wherein the metal sheets (10) laminated on both surfaces of the sheet (20) are joined to each other through the gap (21).