JPH04211455A - Formed article of metal powder - Google Patents

Abstract

PURPOSE:To provide the subject material having excellent heat-resistance and fire resistance without deteriorating the processability, rigidity, thermal dimensional stability, vibration-damping property, sound-shielding property, mechanical property and economic merits. CONSTITUTION:The objective material can be produced by forming a mixture of stainless steel powder 2, aluminum powder 3, melamine resin 4 and ceramic powder 5 to a desired form and buffing the surface of the formed material to effect the deformation and mutual-bonding of the stainless steel powder 2 and aluminum powder 3 positioned at the surface layer to form a metallic layer 1a covering the surface part.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal powder molded body used for, for example, elevator landing doors, building interiors, exterior products, heating equipment panels, and the like.

0002

2. Description of the Related Art Hitherto, as a molded article of this type, a metal powder-containing sheet is known, for example, as disclosed in Japanese Unexamined Patent Publication No. 57-135861. This is a sheet formed from a blended composition of thermoplastic resin and metal oxide powder.

0003

[Problems to be Solved by the Invention] Conventional metal powder-containing sheets as described above have poor moldability, rigidity, thermal dimensional stability, vibration damping properties, sound insulation properties, mechanical properties, economic efficiency, etc. Although it is excellent, it has problems with heat resistance and fire resistance, so it cannot be used in places that require heat resistance and fire resistance, such as elevators. On the other hand, metal plate press forming or metal fusion forming improves heat resistance and fire resistance, but metal plate press forming has the problem of being limited in shape and impairing workability. However, in metal melt forming, it is difficult to form thin walls, reduce weight, etc., making it unsuitable for mass production and having poor economic efficiency.

[0004] This invention was made with the aim of solving the above-mentioned problems, and has improved workability, rigidity, thermal dimensional stability, vibration damping properties, sound insulation properties, mechanical properties, economic efficiency, etc. The object of the present invention is to obtain a metal powder molded body having excellent heat resistance and fire resistance without impairing the properties.

[0005]

[Means for Solving the Problems] A metal powder molded body according to the present invention is molded from a mixed material containing a nonflammable metal powder and a synthetic resin, and the nonflammable metal powder located on the surface of the body is mutually bonded by processing deformation. A metal film is formed by bonding to the metal film, and the surface portion is covered with this metal film.

[0006]

[Operation] In this invention, heat resistance and fire resistance are improved by covering the surface portion with a nonflammable metal film.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to figures showing embodiments thereof. FIG. 1 is a perspective view showing a metal powder compact according to a first embodiment of the present invention, FIG. 2 is a partially sectional view of FIG. 1, and FIG. 3 is an enlarged sectional view of a part of FIG. 2. In the figure, a metal powder molded body 1 is made of stainless steel powder 2 and aluminum powder 3, which are nonflammable metal powders, melamine resin 4, which is a synthetic resin such as a thermosetting resin, and ceramic powder 5. Among these, the stainless steel powder 2 and the aluminum powder 3 are in the same proportion, the ceramic powder 5 is in a smaller amount than these metal powders 2 and 3, and the melamine resin 4 is in the amount of 10 to 10% of the total.
The allocation is approximately 20%.

[0008] Furthermore, the entire surface of the metal powder molded body 1 is buffed, so that the metal powders 2 and 3 located on the surface are deformed and elongated, and the adjacent metal powders 2 and 3 are deformed and extended.
3 and are joined by overlapping each other. As a result, a metal film 1a is formed, and the surface portion of the metal powder compact 1 is covered with this metal film 1a.

Next, an example of a method for manufacturing the metal powder compact 1 described above will be explained. First, stainless steel powder 2, aluminum powder 3, melamine resin 4, and ceramic powder 5 are placed in a container 6 as shown in FIG. 4 and mixed in the above-mentioned distribution to prepare a mixed material 7. An enlarged cross section of this mixed material 7 is shown in FIG. 5, and in this state, the melamine resin 4 is also powder. Next, as shown in FIG. 6, this powdered mixed material 7 is placed between upper and lower molds 8 and 9, and is pressurized and heat-molded. As a result, a molded product 10 having a predetermined shape is completed.

After that, as shown in FIG.
The entire surface of the sheet 0 is brushed under pressure using a metallic rotating brush 11, so-called buffing. By such buffing, molded product 1 of each metal powder 2 and 3
Those located on the surface of the metal powder compact 1 are deformed, stretched, and bonded to each other to form the metal film 1a, so that the surface of the metal powder compact 1 is covered with the metal film 1a. Finally, an alumite finish or the like is appropriately applied as a rust-preventing cosmetic finish.

Metal powder compact 1 produced in this way
The entire surface is covered with a metal film 1a made of a nonflammable metal, and the inside is also made of a nonflammable material as a base material, so it has excellent heat resistance and fire resistance. In addition, since it uses melamine resin 4 as a matrix, it has good moldability.
Moreover, since each of the metal powders 2 and 3 is a powder, it has good thermal dimensional stability. Furthermore, by containing a large amount of each metal powder 2 and 3,
It also has excellent rigidity, vibration damping properties, mechanical properties, and sound insulation properties. In addition, since all the materials to be mixed are powder, there is no waste, and waste products can be used, so it is economically advantageous. Furthermore, since the metal film 1a is formed on the entire surface of the metal powder molded body 1, it is also possible to perform plating such as anodization (for example, anodization) for decoration or protection. In addition, in the above example, since ceramic powder 5 was mixed,
Heat resistance and fire resistance can be further improved, and the overall weight can be reduced.

FIG. 8 is a sectional view showing an example in which the metal powder compact 1 is used for the wall of an elevator car. In the figure, a surface plate 21 is made of a metal powder compact 1. A corrugated reinforcing plate 22 is bonded to the back side of the surface plate 21 with an adhesive. Corrugated reinforcing plate 22
Even if it is composed of the metal powder molded body 1 similar to the surface plate 21,
Alternatively, it may be constructed from a metal plate such as an aluminum plate or a thin copper plate. Elevator cab walls like this require not only workability, rigidity, thermal dimensional stability, vibration damping, sound insulation, mechanical properties, and economy, but also fire resistance and heat resistance. , it is optimal to use the metal powder compact 1 according to this example.

Further, FIG. 9 is a sectional view showing a state in which two cage walls similar to those shown in FIG. 8 are connected for actual use. In the figure, two surface plates 21 are connected to each other by bolts 23, reinforcing seats 24, washers, spring washers, nuts 25, and the like. In this way, the surface plate 21 with a large area,
That is, if a metal molded body 1 is required, a plurality of surface plates 2 are required.
1 may be connected, thereby making it possible to make the molding apparatus etc. compact and simple.

Next, second to fourth embodiments of the present invention are shown in the table below. Note that the manufacturing process is the same as in the first embodiment.

[0015]

[Table 1]

Although a plurality of nonflammable metal powders were used in each of the above embodiments, only one type of nonflammable metal powder may be used. However, by using a plurality of noncombustible metal powders, additional effects such as improving the aesthetic appearance by changing the color tone of the surface can be obtained. Further, in the above embodiment, ceramic powder 5 was mixed in addition to the nonflammable metal powder and synthetic resin, but this does not have to be mixed. Further, when the ceramic powder 5 is mixed, it is preferable to use bead-shaped powder with rounded corners as much as possible so as not to interfere with the formation of the metal film 1a.

Furthermore, the nonflammable metal powder and synthetic resin may be other than those in the above embodiments, and various changes can be made in their combination. However, the distribution amount of synthetic resin (
The volume ratio) is preferably 20% or less of the total from the viewpoint of heat resistance and fire resistance, and conversely, if it is too small, molding becomes difficult.
Approximately 10% is optimal. Furthermore, in the above embodiment, the entire surface of the metal powder compact 1 was buffed, but it is also possible to buff only the surface that requires fire protection. The metal powder on the surface may be stretched by means such that the metal powder overlaps with each other. In addition, synthetic resins are not limited to thermosetting resins,
Thermoplastic resins may be used as long as they have a high temperature at which they become fluidized.

[0018]

[Effects of the Invention] As explained above, the metal powder molded body of the present invention is molded from a mixed material containing nonflammable metal powder and synthetic resin, and the nonflammable metal powder on the surface is processed and deformed. By joining them together, a non-combustible metal film is formed that covers the surface, so it is possible to achieve The heat resistance and fire resistance can be improved, and the range of application can be expanded to places where heat resistance and fire resistance are required. Furthermore, since a metal film is formed on the surface portion, decorative plating can be applied thereon.

[Brief explanation of the drawing]

FIG. 1 is a perspective view showing a metal powder compact according to a first embodiment of the present invention.

FIG. 2 is a partial cross-sectional view of FIG. 1;

FIG. 3 is an enlarged cross-sectional view of a part of FIG. 2;

FIG. 4 is a cross-sectional view showing one manufacturing process of the metal powder compact of FIG. 1.

FIG. 5 is an enlarged cross-sectional view of FIG. 4;

FIG. 6 is a sectional view showing a manufacturing process subsequent to FIG. 4;

FIG. 7 is a sectional view showing a manufacturing process subsequent to FIG. 6;

8 is a cross-sectional view of a wall of an elevator cab using the metal powder molded body of FIG. 1. FIG.

9 is a sectional view showing a state in which the cage walls of FIG. 8 are connected; FIG.

[Explanation of symbols]

1 Metal powder compact 1a Metal film 2 Stainless steel powder (nonflammable metal powder) 3
Aluminum powder (nonflammable metal powder) 4 Melamine resin (synthetic resin) 7 Mixed material

Claims (1)

[Claims] Claim 1: Molded from a mixed material containing non-combustible metal powder and synthetic resin, and made of a metal film formed by processing and deforming the non-combustible metal powder located on the surface and joining each other. , a metal powder molded body characterized in that the surface portion is covered.