JPH0447932A - Production of thermal spraying member based on synthetic resin material - Google Patents

Abstract

PURPOSE:To reduce qualitative irregularity, to enhance working efficiency, to reduce cost and to perform atmospheric pressure thermal spraying by applying a metal material having a low m.p. and rich in ductility to a synthetic resin material by thermal spraying and further applying a desired to the metal layer by thermal spraying. CONSTITUTION:First, bond coat 8 is applied to a material to be subjected to thermal spraying composed of a synthetic resin 9. In many cases, copper is thermally sprayed but a material composed of silver, alminum or an alloy is also thermally sprayed. Thereafter, a desired material is thermally sprayed. When an electrical material is simply subjected to thermal spraying, for example, a powder of ceramics such as alumina or alumina titanic is used and thermal spraying is carried out under reduced pressure or atmospheric pressure. When abrasion resistance is imparted, for example, the thermal spraying of a tungsten carbide cermet is performed.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to electrically insulating materials and wear-resistant materials based on synthetic resin materials or carphone-carbon composite materials (hereinafter referred to as synthetic resin materials, etc.). The present invention relates to a method of manufacturing a thermal sprayed member such as the following.

[Prior Art] Generally, synthetic resins such as hakelite, glass epoxy resin, and polyester are used for insulating substrates carrying electrical circuits.

However, in recent years, there has been a remarkable trend toward higher density electrical circuits, and as a result, heat generation from local circuits has become more intense, causing problems in terms of service life, which is currently a major issue. There is.

That is, for example, alloy resins such as the above-mentioned glass epoxy resins start to yellow at about 200 to 300°C, and at about 300 to 300°C.
It turns black (carbonized) at about 60°C. If the surface of the board becomes carbonized, the circuit will short out and its life will end.

Therefore, it is possible to thermally spray ceramics directly onto the synthetic resin plate, but in this case, sublimation (gasification) occurs from the surface of the synthetic resin due to the high temperature heat of the plasma. It is difficult or impossible to form a film using normal thermal spraying methods.

In order to overcome such problems, for example,
11353 (Figure 5), a method has also been proposed in which a material mixed with ceramic powder and resin adhesive is applied, an adhesive layer (intermediate layer) is provided, and then thermal spraying is performed on top of the adhesive layer (intermediate layer). .

[Problems to be Solved by the Invention] However, there is no method of coating a synthetic resin plate with a material containing ceramic powder and resin adhesive, providing an adhesive layer (intermediate layer), and then thermally spraying the adhesive layer. This material, which is a mixture of ceramic powder and resin adhesive, has a very high viscosity and is difficult to apply evenly and thinly. In other words, it is not viable in terms of cost. Therefore,
In many cases, the application process must be done manually,
It largely depends on the skill of the worker, there is large variation in the product, and the work efficiency is not good.

Furthermore, when performing low-pressure thermal spraying, the plasma flame may extend several times longer than in atmospheric thermal spraying, and the material to be thermally sprayed is exposed to much higher temperatures. Since the resin component of the mixed material sublimates, it is virtually impossible to form a sprayed film of the desired material.

In addition, taking advantage of its lightness, wear-resistant materials can be thermally sprayed onto the surface of synthetic resin materials to be used as mechanical parts, or to manufacture insulating substrates using dense films that require high insulation properties. It was not practical because low-pressure thermal spraying could not be used.

Therefore, the present invention provides a method that does not use the current problematic resin adhesives mentioned above and does not require any equipment investment.
Regarding the thermal spraying method of electrically insulating materials and wear-resistant materials, it actually has high adhesion strength, little variation in quality, good work efficiency, and is applicable not only to atmospheric thermal spraying but also to low-pressure thermal spraying, which has many characteristics. The purpose is to provide thermal spraying technology that solves the problems of conventional technology.

[Means for Solving the Problems] In order to achieve the above object, the method for thermal spraying onto synthetic resin materials of the present invention provides a method for thermal spraying onto synthetic resin materials, which is a base material, such as a material having a low melting point and high ductility. First, a material made of metal, copper, silver, aluminum or an alloy thereof is thermally sprayed,
This is used as a bond coat, and a desired material is thermally sprayed onto it.

[Operations and Examples] As shown in FIG. 2, a bond coat 8 is first applied to a thermally sprayed material of synthetic resin 9 to be manufactured. Often sprayed with copper. In addition, a material made of aluminum or an alloy thereof may be thermally sprayed. Thereafter, the desired material is thermally sprayed. To simply spray an electrically insulating material, for example, ceramic powder such as alumina or alumina/titania is used and sprayed under reduced pressure or atmospheric pressure. In addition, in order to impart wear resistance, thermal spraying of a cermet such as WC (tungsten carbide) is performed, for example.

The inventor has found that if copper or aluminum is thermally sprayed as the bond coat 8, the melting point of each material will be 1080°C.
℃, 640℃, and the specific heat is also low, so the plasma input power can be kept low, and the synthetic resin 9
It was found that sublimation etc. did not occur. Furthermore, since the materials of the above series have high ductility, even if the particles are in a semi-molten state and are bombarded with the synthetic resin 9, they will stick by plastic processing and it is possible to stack them in many layers. It is also possible to keep the plasma input power low.

Further, as shown in FIG. 3, the particles of copper 11 and the like that collided first can sink into the synthetic resin 9 and adhere strongly to it. The first layer can serve as a heat shield for the plasma flame of the next second bus, so multiple layers of copper 11 or aluminum, etc. are sprayed in this way to create the bond coat 8. .

Thereafter, the supply system of the thermal spray powder is continuously switched, and a top coat 7 of ceramic or WC-based cermet 12 or the like is thermally sprayed depending on the purpose. At this time, since the bond coat 8 made of copper 11 or aluminum has a heat shielding effect on the synthetic resin 9, sublimation of the synthetic resin 9 does not occur, and several layers of thermally sprayed ceramics or WC-based cermet 12 are applied. It is also possible to laminate layers to provide desired electrical insulation properties, abrasion resistance, etc.

When imparting electrical insulation, low-pressure thermal spraying provides a dense film, improves voltage resistance, and improves insulation.

This is particularly good for membranes used in vacuum environments. On the other hand, for intermediate to low grade materials, atmospheric pressure spraying is used. Furthermore, in order to improve the heat insulation properties, it is also possible to intentionally improve the porosity.

By setting the thermal spraying powder supply speed and the six-motion speed of the plasma gun 5 appropriately in advance and knowing how many micrometers will be formed per thermal spraying bath, it is easy to obtain the film thickness as designed. It's easy. Usually, according to this method, 10 to several 100μ
It is possible freely between m.

Of course, for special applications, it is also possible to obtain a film with a thickness of about lff1 m or more.

In this way, a heat-resistant electrically insulating member and a lightweight wear-resistant member using the synthetic resin 9 as a base material can be easily obtained.

Hereinafter, the present invention will be explained in more detail by way of examples with reference to the accompanying drawings. Fig. 1 is a side cross-sectional view showing the state of thermal spraying on a base material according to the present invention, Fig. 2 is a cross-sectional view of a general product film after thermal spraying, and Fig. 3 is a synthetic resin of bond coat 8. FIG. 4 is a side cross-sectional view showing the state of biting into the groove 9, and FIG. 4 is a perspective view of the synthetic resin wear-resistant roll of the example.

A method of manufacturing the wear-resistant synthetic resin roll 14 will be described when a glass epoxy resin 13 is used as the synthetic resin 9 and a wC-based cermet 12 is used as the top coat 7.

As shown in FIG. 1, a cylindrical glass epoxy resin 13 is used as a base material and set in a vacuum chamber 20. The stiffener is attached to a rotating jig called a sting (not shown) and is rotatable. vacuum pump 22
Rotate the filter 2 to remove the air inside the vacuum chamber 20.
1 and then discharged from the system.

After lowering the vacuum to an appropriate level, the plasma is ignited. Normally, it is operated at about 50 Torr.

Thereafter, the powder feeder 23 is activated to feed the powder of copper 11 into the plasma gun 5 through the tube 24. By thermally spraying the copper 11 over multiple baths, a thermally sprayed film of the copper 11 with a thickness of 20 to several tens of micrometers can be obtained, and the bond coat 8 is applied.

Thereafter, the paratar feeder 23 is switched to another powder feeder 25, and the powder of the WC-based cermet 12 is fed into the plasma gun 5 through a tube 26.

The product is thermally sprayed as many times as necessary to obtain the desired film thickness.

Although it is rice, if the required film thickness is large enough to exceed several hundred μm, care must be taken to prevent the temperature of the base material from rising too high.
If the plasma gun 5 is moved away from time to time and the thermal spraying is performed slowly, or the thermal spraying is performed without spraying Ar gas, the thermal spraying can be carried out without any problems.

Of course, since the normal abrasion resistance is 200 to 300 μm or less, thermal spraying can be carried out as usual without any problem.

In order to obtain an appropriate film thickness, it is convenient to vary the number of thermal spraying baths and to collect data in advance for obtaining an appropriate film thickness.

Further, FIG. 3 shows a situation where the copper 11 of the bond coat 8 is deeply and reliably dug into. Adhesion is greater and more reliable than with adhesive.

In this way, it is possible to obtain a roll 14 that is lightweight and has excellent abrasion resistance, taking advantage of the lightness of the synthetic resin 9 as described above.

According to this method, it is of course possible to use metals, alloys, etc. other than the cermet 12 of the [system], and it is also possible to use ceramics with a high melting point and low thermal conductivity. For example, in addition to alumina, there are alumina/titania, titania, zirconia, chromia...
..., etc., can be obtained using exactly the same method for most ceramics.

On the other hand, as the synthetic resin 9, it can be applied to almost all materials such as polyethylene, polypropylene, polyamide, acrylic, melamine, vinyl acetate, etc., in addition to epoxy and polyester, regardless of whether they are thermoplastic or thermosetting. It is. What is also noteworthy is its light weight, dimensional stability, specific strength, etc.
This makes it possible to thermally spray carbon-carbon composites, which have excellent heat resistance.

Furthermore, since it is possible to apply the thin film to an appropriate minimum required level, machining such as drilling and cutting can be performed extremely easily using ordinary tools.

Furthermore, since the film of the top coat 7 according to the present invention is basically formed by a thermal spraying method, the porosity can be adjusted by controlling the thermal spraying conditions (parameters), such as the current value and the pressure of the reduced atmosphere. can be controlled,
Therefore, its thermal conductivity can be easily controlled. Therefore, the heat shielding effect of the ceramic/sprayed film can be sufficiently obtained, and the desired film can be firmly coated on the synthetic resin 9.

[Effects of the Invention] As explained above, according to the present invention, compared to a method in which a material containing ceramic powder and a resin adhesive is applied, an adhesive layer (intermediate layer) is provided, and thermal spraying is performed on the adhesive layer, Since automation is possible with a simple investment in equipment, it is possible to perform thermal spraying with less variation in quality and high work efficiency, which not only greatly reduces costs, but also allows for atmospheric thermal spraying.
The effects of the present invention are remarkable, such as making it possible to apply reduced-pressure thermal spraying, which has a number of features.

[Brief explanation of the drawing]

Figure 1 is a side sectional view showing the situation of thermal spraying on a base material according to the present invention, Figure 2 is a sectional view of a general product after thermal spraying, and Figure 3 is a sectional view of a general product after thermal spraying.
The figure is a side sectional view showing how the bond coat bites into the synthetic resin, and FIG. 4 is a perspective view of the synthetic resin wear-resistant roll of the example. FIG. 5 shows a member thermally sprayed onto synthetic resin by a conventional method. 1...Synthetic resin plate, 2...Sintered ceramic plate, 3
...adhesive, 5--plasma gun, 6--plasma flame, 7-1-bulb coat, 8--bond coat, 9--synthetic resin, 11--copper, 12- WC cermet, 13.-Glass epoxy resin, 14...
Wear-resistant synthetic resin roll, 20...decompression chamber 2
1... Filter 22... Vacuum pump, 23... Balata feeder A, 24-... Tube A, 25-...
・Balata feeder B, 26...Tube B, 27
...ceramics or metal, 28...resin, 29-
... Thermal spray base material, 30... Ceramic or metal spray coating.

Claims (1)

[Claims] 1. First, a low melting point and highly ductile material such as metal, copper, silver, aluminum, or an alloy thereof is sprayed onto the synthetic resin material or carbon-carbon composite material that is the base material. As a bond coat,
A method for producing a thermal sprayed member using a synthetic resin material as a base material, which comprises thermally spraying a desired material thereon.