JPS6046242A - Cloth-like composite material - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention is characterized in that a cloth foil mainly made of organic fibers and an inorganic molded article are integrated by bonding force at the interface between the cloth foil and the molded article. This paper relates to a novel cloth foil-like composite material.

Many composite materials of organic fiber materials and inorganic materials have been known. However, most of them have adhesives at the material interface or are made by mixing inorganic substances inside the fibers. At present, it is not fully demonstrating its performance due to the limitations of the properties of the fibrous material present on the outside of the adhesive layer or the inorganic material.

On the other hand, plating and vapor deposition are known methods for producing composite materials in which organic fiber materials and metal are in direct contact, but the metal films produced by these methods are generally extremely thin and have little protective effect on organic fiber materials. . Furthermore, the strength and durability of the metal film in this case is not great.

The feature of the composite material of the present invention is that the organic fiber material and the inorganic molded product are integrated by the bonding force generated by the surface bonding force of the organic fibers and the intertwining with the inorganic molded product due to the surface morphology of the cloth fabric mainly made of organic fibers. The reason is that it is becoming more and more popular. Such a structure can be formed even under conditions where there are kana-shi discontinuities in the inorganic molded product, and the existence of such discontinuities makes it possible to create highly flexible and durable fabrics. Forms a cylindrical composite material.

The cloth foil-like composite material of the present invention is produced by thermally spraying an inorganic material onto a cloth foil mainly made of organic fibers to form a solidified molded article. Here, the inorganic material is formed into hybrid fine particles that can be melted or sintered in plasma or flame generated by electric discharge, etc., and then carried on a plasma stream or high-temperature air stream and collided with the cloth foil. The cloth foil is removed from the plasma stream or high-temperature air stream and immediately cooled down before it deteriorates due to heat. This operation is repeated until the spray amount reaches the desired value, and the inorganic material is formed into a film, sponge, or scale shape on the cloth foil. Here, the inorganic particles riding on the plasma flow or high-temperature air flow are
The whole or the surface layer of the particle or its binder component is melted, accelerated to a speed close to the speed of sound, and collides with the fabric foil.

The particles are pressed against the fiber surface by their own momentum and form a film, and some of them penetrate into the fabric through the gaps between the fibers and fuse with subsequent particles to form a network structure. . Particles pressed onto the surface of organic fibers soften and melt the surface area of the organic fibers due to their heat, but by cooling them at a sufficient rate, it is possible to mold inorganic materials without softening the core of the fibers. We have discovered that it is possible to do so, and have arrived at the present invention. - The mobile particles are formed into a continuous film, an intermittent film, or a layered film by selecting thermal spraying conditions. Furthermore, by incorporating particles that do not melt during thermal spraying, a sintered body-like molded product or a sponge-like molded product can be obtained.

Thermal spray processing has been widely known as a surface treatment technology for metal materials, but for materials with low thermal conductivity such as organic fiber materials, heat transfer is difficult to occur during processing, which can lead to fiber deterioration. It has been said that this occurs and the bond does not bond properly. In an attempt to avoid this, for example, by lowering the temperature of the spray fluid or spraying from a distance, it has been said that the spray particles will no longer be integrated. Therefore, it is a well-established theory that thermal spray particles cannot be processed unless they have a melting point that is lower than the softening point of the fiber material.

As an example of thermal spraying processing for organic fibers, it is known that lead is thermally sprayed onto cotton cloth to produce radiation shielding work clothes. Furthermore, JP-A-52-66798 discloses an example in which epoxy resin, polyethylene, polypropylene, and nylon 11 are thermally sprayed as thermal spray powder onto vinylon cloth and cotton cloth by thermal spraying using a plasma jet. All of the above examples are examples in which the melting point of the organic fiber is higher than the melting point of the thermal spray particles, and it has been thought that the actual thermal spray processing temperature is slightly lower than the melting point or thermal decomposition temperature of the organic fiber. The present inventor accidentally found out that this established theory was wrong while researching thermal spraying technology, and arrived at the present invention.

That is, the present inventor conducted an experiment in which aluminum was thermally sprayed onto vinylon cloth. According to the conventional theory,
It is said that aluminum cannot be thermally sprayed onto vinylon cloth, so the inventor decided to first thermally spray a tin alloy (melting point: approximately 200°C) onto vinylon cloth, and then thermally spray aluminum on top of that. . Tin alloy has a much higher thermal conductivity than vinylon fiber, and it absorbs the heat of fusion at a lower temperature than vinylon's melting point (approximately 220°C).
The present inventor predicted that it would be a strong protective material for vinylon fibers. There were samples with large variations in the peel strength of the sprayed aluminum film, so when we tried to find out the reason for this, we found that due to an error in the experiment, there were some areas where the sprayed tin alloy film was not formed, and those areas were covered with vinylon cloth. It was found that aluminum could be directly sprayed and solidified.
From this, I learned that the conventional theory is wrong.

As a result of various studies, the inventor of the present invention found that by shortening the contact time per thermal spray jet and cooling as rapidly as possible after contact, the present inventors could coat the organic fiber cloth with a temperature lower than the melting point of the organic fiber. It has been found that a composite material in the form of cloth can be obtained by thermal spraying inorganic materials such as metals and ceramics with much higher melting points. If the thickness of the molded product produced by thermal spraying is insufficient, this operation may be repeated. The contact time with the thermal spray jet is 91 seconds or less per time, preferably around 1/100 second, and the cooling device is made of a material with high thermal conductivity, such as a complete set of cloth strips that are mainly made of organic fibers to be thermally sprayed. Place the back sides together and cool. It is preferable to blow a cooling air stream immediately after leaving the thermal spray jet to cool the surface as well. The cooling device from the back side of the cloth foil must be maintained under conditions that do not allow thermal spray particles to adhere, and the surface must be smoothed to a certain level of gloss, and the surface temperature must be kept below 200°C, preferably below 100°C. The cooling device from the back side of the cloth foil may have any shape as long as the cloth foil can come into close contact with it, but it is generally preferable to have a roller shape.

Cloth foils made mainly of organic fibers, which are a component of the cloth foil composite material of the present invention, are woven fabrics*, knitted fabrics, non-woven fabrics, braided fabrics, paper, etc. made of natural and man-made organic fibers. The fabric foil-shaped composite material of the present invention can contain some inorganic fibers, adhesive resins, fillers, adhesives, and various finishing agents. A molded product made by solidifying and molding at least one component of a melt of an inorganic material is an inorganic material that can be thermally sprayed and has a melting point higher than the melting point or thermal decomposition temperature of the other component, organic fibers. It is.

Here, inorganic substances include metals, carbon, boron, silicon, oxides, carbides, nitrides, borides, and other so-called ceramics, and mixtures of ceramic particles and metals, where the metal acts as a binder for the ceramic particles. The one that does is used.

As for the thermal spraying method, any of the conventionally known methods can be applied, but there are two methods: introducing the thermal spraying material in powder form into a plasma jet, and spraying the thermal spraying material in the form of a rod into a flame or arc discharge. The method of introducing a thermal spray material in powder form into a flame and thermal spraying by crushing and melting is preferable for the end of the fabric foil-shaped composite material of the present invention. Although only one type of thermal spraying material may be used, it is also possible to use 21 or more.

It is also possible to thermally spray two or more types of thermal spraying materials in a superimposed manner to bring out the characteristics of each material. In addition, each material is arranged in the upward direction where the pattern is created,
It is also possible to provide decorative effects.

Next, the present invention will be demonstrated by examples.

Example 1 Alumina-titania-based ceramics thermal spray powder was applied to vinylon spun yarn cloth (fabric weight 205 f/♂, plain weave, density 42 threads/inch x 40 threads/inch) using a plasma spray system 7M device manufactured by Metco, Inc. in the United States. (Meteco 1308F, melting point 1,840°C) was sprayed to a thickness of about 30 am. Thermal spraying conditions were: power supply 50 volts, current 16077 pairs, argon 80 normal cubic feet/hour, fabric feed speed 130.
m/min (one contact time with the thermal spray fluid: 0.014 seconds), and the number of thermal sprays was 6 times.

The surface condition of the fabric thus obtained was good, and the flexibility was not much different from that of the vinylon fabric used as the raw material. There was little decrease in air permeability, and the wear resistance and peeling resistance of the ceramic layer were also good.

Example 2 The same vinylon cloth as in Example 1 was thermally sprayed with a 3/16 inch aluminum wire using a frame spray gun 12F4 manufactured by Metco, USA. The spraying conditions are:
Oxygen flow rate 88 normal cubic feet/hour, acetylene flow rate 40 normal cubic feet/hour, wire feed rate 7.3
The coating speed was 130 m/min, and the number of thermal sprays was 8 times.

The average thickness of the aluminum film on the fabric thus obtained was approximately 40 μm.1 The surface had the appearance of a satin-finished metal material, and the fabric was made of vinylon fabric, which was the raw material, and although it was slightly stiffer, it was quite flexible. was maintained. An adhesive tape was attached to the aluminum film and peeled off and repeated 10 times, but no change was observed either macroscopically or microscopically.

Example 3 As a substitute for the vinylon cloth in Example 1, cotton of approximately the same weight,
When fabrics made of wool, polyester, nylon, and acrylic yarns were treated under the same conditions as in Example 1, thermal spray coatings could be formed on all of them, and the flexibility was within a range that could be used as fabric foil. It had good air permeability, abrasion resistance, and peeling resistance.

Example 4 Instead of the vinylon cloth in Example 2, fabrics made of cotton, wool, polyester, nylon, and acrylic spun yarns with the same weight were used and treated under the same conditions as in Example 2, resulting in a thermal spray coating. It had a flexibility that could be used as a cloth foil, and its air permeability, abrasion resistance, and peeling resistance were all good.

Example 5 Alumina (Meteco 105SF), chromium oxide (Meteco 106F), zirconia (Meteco 201NS), molybdenum (Methicolo 3), and 17% cobalt-tungsten caramel were used instead of the alumina-based ceramic powder of Example 1. Bite type cermet (Meticore 3F N5-1)
When thermal spraying was carried out, a uniform and good thermal sprayed coating was formed in all cases.

Example 6 Zinc, copper, nickel, carbon steel (Meteco's Suprasteel #io), and stainless steel (SUS304.) were thermally sprayed on the aluminum wire of Example 2, and good results were obtained in all cases. A sprayed coating was formed.

Patent applicant: Rishi Co., Ltd. Representative Patent Attorney Ken Honda

Claims (1)

[Scope of Claims] 1) A cloth foil consisting mainly of organic fibers, and
A fabric foil-like composite material characterized by being formed by integrally laminating a melt-solidified product of an inorganic substance having a melting point higher than the melting point or thermal decomposition temperature of fiber. 2) The fabric foil-like composite material as set forth in the preceding item, wherein the inorganic substance is one or more metals. 3) A fabric foil-like composite material according to item 1, wherein the inorganic substance is selected from the group of carbon, boron, silicon, oxide, carbide, nitride, and boride. 4) Item 1, characterized in that the inorganic substance is selected from the group of metal 2 and carbon, boron, silicon, oxides, carbides, nitrides, and borides having a higher melting point than the metal. Cloth foil composite material.