JPS6270537A - Manufacture of composite material - Google Patents

Abstract

PURPOSE:To easily and inexpensively obtain a composite material in which various physical properties are arbitrarily varying in a molding, by carrying out molding with changing, with the passage of time, the mixing ratio between plural constituents different from each other in physical properties and by treating and fixing the above. CONSTITUTION:The composite material in which constituents are varying in the direction of thickness is prepared by use of, for example, grain-dispersed solution as in the following: A dispersed solution 1' in which grains 1 are agitated 3 and uniformly dispersed in a vessel 4 is fed into a dispersed solution 2' in which grains 2 other than the grains 1 are dispersed in a vessel 5, which is agitated 3' to form a mixed dispersed solution; then said mixed dispersed solution is introduced via a supply route 7 and spouted 9 into a molding apparatus 10, which is piled up on a filter 13 to form a sedimentary layer, that is, a molding 12. During the above procedure the mixing proportion of the grains 1 in the vessel 5 is raised as the total outflow rate of the mixed dispersed solution is increased. Accordingly, in the molding 12, the mixing proportion of the grains 1 is increased in the direction of the thickness from the base toward the tip. In this way, the molding 12, that is, the desired composite material can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for producing a composite material, and particularly aims to provide a composite material with a novel structure that is useful in various industrial fields.

(Prior art) Conventionally, molded products made of a single material only exhibit properties specific to the material used, and therefore, in order to make these molded products have other functions, they have been combined with other components. Composite materials are widely used.

Typical examples include composite organic materials such as various colored plastic moldings, various conductive plastic moldings, various filler-containing plastic moldings, various special glasses, various ceramics, and various alloy materials. The types of composite inorganic materials such as various catalysts, etc. are almost limitless.

Various techniques have been devised to ensure that the constituent components of these conventional composite materials are evenly blended with each other, and when the two are layered, molded products made from each material are Composites are achieved by laminating, welding, adhering, etc.

(Problems to be Solved by the Invention) The various conventional composite materials as described above can be broadly classified into homogeneous composite materials in which the constituent components are uniformly present (for example, conductive particles are uniformly dispersed in a plastic base material). They are broadly classified into two types: laminates (for example, vapor-deposited moldings in which metal is vapor-deposited) and laminates in which constituent components are joined in layers (for example, vapor-deposited moldings in which metal is vapor-deposited).

For these conventionally known composite materials, for example, in a specific magnetic material, the magnetic strength is higher than at least one part of the molded material.
composite materials whose conductivity changes in at least one direction of the molded material; composite materials whose conductivity changes in at least one direction of the molded material; composite materials whose thermal conductivity changes in at least one direction of the molded material Composite materials in which the photoconductivity of photoconductors varies in at least one direction, or materials in which these properties are further combined, are also widely desired in various industrial fields.

However, there is no method for manufacturing these composite materials easily and with high quality, and the reality is that there are almost no known composite materials that are high-performance and inexpensive enough to be used industrially.

Therefore, an object of the present invention is to provide a composite material in which various physical properties as described above are arbitrarily changed in a molded product.

(Disclosure of the Invention) As a result of intensive research in order to solve the problems of the prior art as described above and to obtain a composite material whose physical properties change arbitrarily, the present inventor has discovered that a plurality of constituent components having different physical properties can be synthesized over time. By varying the mixing ratio and processing and fixing the distribution of the relative abundance ratio reflected from the mixing ratio of the constituent components, the above-mentioned problems of the conventional technology can be solved, and a crowded composite material can be easily and inexpensively produced. The present invention was completed after discovering that the present invention can be obtained.

That is, the present invention provides a method for manufacturing a composite material using a plurality of components, which comprises a step of molding by changing the mixing ratio of the components and a step of treating the molded product. It's a method.

Next, to explain the present invention in more detail, the structure of the composite material provided by the method of the present invention is such that at least one of the composite materials forming the composite material is
It is characterized in that the components of the seeds are varied arbitrarily in the composite material.

For example, as schematically shown in FIGS. 1a and 1b, in a composite material molded article C consisting of component A and matrix B, the concentration of component A may vary, for example, in the thickness direction, length direction, center direction, or outside of the molded material. Component A occupies 100% at one edge or outside of molding C, is absent at one edge or center, and in the intermediate region increases in proportion to the distance from the edge or center. It is characterized by an increase or decrease in the concentration of component A.

The above examples are typical examples for ease of understanding.
The composite material provided by the method of the present invention may be a planar molded product such as a plate, sheet, or film, or a three-dimensional molded product such as a cylinder, a cylinder, a disk, a prism, or a pyramid. The shape of the object does not matter, and the form of the constituent components such as particulate matter and molecular matter does not matter either.

Furthermore, although the illustrated example is an example in which a component A different from the matrix is dispersed in a specific matrix, the components constituting the molded product are components that can ultimately take some shape. As long as it is, it is not limited to the above example, it may be two or more components dispersed or dissolved in a specific matrix, or it may be two or more different components fixed in powder. etc., the form, number and type of components constituting the composite material are not limited.

In addition, physical properties of the material include, for example, electrical conductivity, magnetic force,
Magnetism, thermal conductivity, photoconductivity, hardness, light absorption, reflectivity, heat absorption, sound absorption, gas absorption, hue, thermal softening, refractive index,
Any physical property that is industrially useful, such as specific gravity, mechanical strength, heat resistance, corrosion resistance, and chemical resistance, may be used.

Further, changes in the positions and relative abundance ratios of the components constituting the composite material provided by the method of the present invention with respect to distance do not necessarily have to be linear, and as long as there is a change in abundance ratio, for example, a specific component The concentration is high in the middle of the mold, and the concentration decreases toward the periphery, or vice versa, and the specific component moves from one side of the molded object to the other in any curved shape, such as a parabolic shape, a quadratic curve shape, or a wave shape. Any such change in the abundance ratio can be easily achieved by the present invention, as explained below.

Next, the method of the present invention for providing the composite material as described above will be explained in more detail with reference to Figures 2 to IG, which schematically illustrate preferred embodiments of the method of the present invention.

(Example 1) Preparation of a composite material in which the constituent components change in the thickness direction using a particle dispersion For convenience of explanation, as an example that is easiest to understand, two types of particles that are different from each other are placed in an arbitrary liquid medium. An example will be explained in which two kinds of dispersion liquids are used, and a siphon method using gravity is adopted as the simplest feeding method.

FIG. 2 shows a preferred method for mixing dispersions each containing two types of particles while changing the mixing ratio and supplying the mixture to a molding machine. ,
2 represents a certain particle present in the container 4, 2 represents another particle present in the container 5 and different from the particles 1, and 3.3' represents the stirring means.

The stirring means 3 in the container 4 is provided to ensure uniform dispersion of the particles 1, but is not necessary if the dispersion state is stable.

Further, 6 is a means for supplying the dispersion liquid 1' containing the particles 1 into the container 5, and 7 is a supply path for supplying the mixed dispersion liquid to the molding machine 10 illustrated in FIG. Yes, 8
9 is a means for adjusting the opening/closing of the supply channel 7 and the supply speed of the mixed dispersion liquid, and 9 is a cock for controlling the opening/closing of the supply channel 7 and the feeding speed of the mixed dispersion liquid.
This is a means for uniformly supplying O.

filling the supply channels 6 and 7 with dispersions 1' and 2';
With no air inside, open the cock 8 to obtain an appropriate flow rate.

A jetting device 9 using a nozzle or the like is provided at the tip of the supply path 7 to jet the mixed dispersion liquid flowing out.

As the dispersion liquid 2' first spouts out, an amount of the dispersion liquid 1' corresponding to the amount that flows out flows through the supply path 6 into the container 5, and is mixed with the dispersion liquid 1' in the container 5 by the stirring means β'. The dispersion liquid 2' is uniformly mixed.

In this way, as the total flow rate of the mixed dispersion liquid increases, the mixing ratio of particles 1 in the container 5 increases as shown by the solid line a, for example, as shown in FIG. On the other hand, particle 2
The mixing ratio decreases as shown by the broken line. In addition, the horizontal axis of FIG. 4 shows the cumulative release amount of the mixture, and the vertical axis shows the abundance ratio of the components in the particle mixture.

The mixed dispersion liquid ejected from the ejection device 9 passes through a filter 13 in a cylindrical molding device 10, for example, as shown in FIG.
The liquid 16 which is a dispersion medium deposited on the filter 1
3 and accumulates in tank 15 below the filter. The mixed particles remaining on the filter 13 form a deposited layer or molded article 12. Subsequently, the mixed dispersion liquid ejected from the ejection device 9 falls on the deposited layer 12 and first forms the mixed dispersion liquid layer 11, but the mixed dispersion liquid is supplied so that this layer is not formed or is as thin as possible. Preferably, the amount and filtration rate are adjusted.

The molded product 12 thus produced is a molded product 1 in which the mixing ratio of particles l increases from the bottom surface to the top surface in the thickness direction.
It becomes 2. The abundance ratio of particles 1 and 2 in this molded product 12 changes as shown in FIG. In FIG. 5, the vertical axis represents the distance from the filter 13, and the horizontal axis represents the particle l.
shows the abundance ratio of particle 2, and the broken line C shows the abundance ratio of particle 2, and the solid line d shows the abundance ratio of particle 1.

In the above method, one method of preferable mixing of the particles to be used is exemplified, but other methods can be used at any time as long as the mixing ratio of two or more types of particles can be changed. The method is not limited to the illustrated method.

For example, in the method shown in FIG. 2, it is preferable to make the volumes of the supply channels 6 and 7 as small as possible. Therefore, instead of the supply channel 7, the supply channel 7 is installed at the bottom of the container 5 as shown in FIG. is also valid. Furthermore, although the containers 4 and 5 in FIG. 2 have the same capacity and the same shape in the above example, if the cross-sectional area of one of the containers is different, the amount of flow from the container 5 and the container 4 can be changed. It is possible to change the relationship between the amount of water supplied from the container 5 to the container 5, and by changing the shape of the container in this way, it is also possible to freely change the mixing ratio. Therefore, the mixing ratio of materials in the molded article and the distribution of constituent components in the composite material can be freely changed. Also,
As shown in FIG. 7, a closed mixing chamber 18 may be provided and the mixed dispersion liquid may be flowed out from there. In this case, an amount of the dispersion liquid corresponding to the flow rate is supplied from the containers 4 and 5. Ru. In this process, the mixing ratio and outflow amount of the mixed dispersion liquid can be adjusted using the valves 19 and/or 20 provided in the supply channels 6 and 7. Note that the mixing chamber 18 may not be a closed system depending on the purpose, and may not be necessary in some cases.

The example shown in FIG. 8 is a method in which the flow rate of the dispersion liquid is adjusted using pumps 21 and 22, and the mixing ratio of the mixed dispersion liquid in the mixing chamber 18 is changed. Even in this example, the mixing chamber 18 may not be provided depending on the case, and may not be a closed system.

Alternatively, as in the example shown in FIG. 9, a method may be used in which a mixing chamber is not provided, the outlet ports of each dispersion liquid are brought close to each other, and the dispersion liquids are ejected and mixed using ejection means 9 such as a nozzle.

Furthermore, as shown in Figures 1θ to 11, Figures 3, 6, and 7
It is also possible to combine the methods shown in FIG. 8, FIG. 9, and the mixing method is not limited to the above-mentioned method.

Further, as a method for molding the mixed dispersion obtained as described above, one example is shown in FIG. 3, but the method of the present invention is not limited to such an illustrative method. For example, in the exemplary molding device 10, by rotating the exemplary molding device, it is possible to produce an effect of eliminating uneven deposition of ejected particles. In this case, the same effect can be achieved by rotating the ejection device 9. Also, by evacuating the lower part of the exemplary filter through the exhaust port 17 to reduce the pressure, the dispersion medium can quickly pass through the filter 13 and one dispersion layer 11 can be eliminated or made very thin.

The example shown in FIG. 10 is an example in which three ejection devices 9 are provided. In this method, the filter 13 is
Depressurize the bottom of the. By this method, a large-area molded article 12 can be made in a short time. In addition, as mentioned above, the supply path 7. By rotating the portion including the ejection device 9, the molded product 12 can also be made into a disk shape.

The example shown in FIG. 11 is a method in which a compressor 24 is used to apply high pressure to the upper part of the filter 13 for forced filtration. In this case as well, by rotating the molding machine 10 without breaking the closed system, a large-area, disc-shaped molded product 12 can be obtained.

There are many ways to obtain a molded product having a distribution of the mixing ratio of the constituent components in the thickness direction as described above.
It is also possible to combine the methods shown in FIGS.

In the manner described above, a molded product in which the abundance ratio of two or more components varies in a layered manner in the thickness direction can be obtained. Moreover, if the molded product is made into a columnar shape, the abundance ratio of the components will change in the length direction.

(Example 2) Preparation of a composite material in which the constituent components change from the center to the outside or vice versa in Example 1 In the same manner as in Example 1, a mixed dispersion in which the mixing ratio was changed over time was prepared in 12a. When the particles are fed from the supply port to a rotor-type molding machine 10 of an arbitrary shape rotating at an appropriate speed as shown in the figure, the centrifugal force generated by the rotation of the molding machine 10 causes particles to be pushed onto the side wall surface of the molding machine IO. The liquid medium is separated by sedimentation on top. The molded article 12 is formed by removing this separated liquid medium by suitable means.

This molding machine IO as shown in Fig. 8123 is suitable when the particles in the dispersion are extremely fine and difficult to separate from the liquid medium using a general filter medium. That is, in such cases, a relatively volatile medium is used as the dispersion medium and the liquid medium is removed by evaporation during or after molding, or if a non-volatile liquid medium is used, the particles are removed after molding. The separated liquid medium may be removed by other means.

Furthermore, instead of the molding device shown in FIG. 12a, a filter type molding device as shown in FIG. 12b may be used.

In this case, the mixed dispersion liquid flowing out from the tip of the supply path 7 is deposited by centrifugal force on the filter 13 in the rotating molding device 10 in the shape of a rotor, as shown in FIG. 12b. The liquid 16, which is a dispersion medium, passes through the filter 13, passes through the outlet 14, and accumulates in a tank 15 outside the system.

The mixed particles remaining on the filter 13 form a sediment layer, that is, a molded product 12. Subsequently, the mixed dispersion liquid flowing out from the supply channel 7 moves onto the deposited layer 12, and first the mixed dispersion liquid layer 1
However, it is preferable to adjust the supply amount of the mixed dispersion liquid and the filtration rate so that this layer is not formed or is as thin as possible.

The molded article 12 formed as described above becomes a molded article 12 in which the mixing ratio of particles 1 increases in the radial direction from the outer periphery toward the center. The abundance ratio of particles 1 and 2 in this molded product 12 changes as shown in FIG.

(Example 3) An example of preparing a composite material in which the constituent components change in the thickness direction using powder particles.

FIG. 13 shows a preferred method for mixing two types of particles while changing the mixing ratio and supplying the same to a molding machine. 25 in FIG. 26 represents another powder material present in the container 28 and different from the powder material described above, and 29 and 3o represent powder materials 25 and 26 by adjusting the discharge amount of the powder materials 25 and 26. This is a poppet that adjusts the mixing ratio of 26. Poppets 29 and 30 are.

This is an example of a preferred means for supplying powdered materials 25 and 26 from containers 27 and 28.

Reference numeral 31 indicates a powder material transport pipe, and 32 indicates a blower fan for moving the powder material therein. 33 is a mixing fan for mixing the powder materials 25 and 26, and 34 is a powder material mixture consisting of the powder materials 25 and 26.

Different powders 25 and 26 are placed in containers 27 and 28.
Put in. The blower fan 32 and the mixing fan 33 are rotated, the poppets 29 and 30 are activated, and the powder material 25 is
and 26 are released into the transport tube 31 at the desired rate. The powdered materials 25 and 26 are directed to the mixing fan 33 on the downstream side by the blowing fan 32, thereby creating a mixed state 34.
It is then transported.

The mixing ratio of the powder materials 25 and 26 in this mixed state 34 can be arbitrarily controlled by the poppets 29 and 30.

For example, keeping the total amount of powder material 25 and 26 discharged from poppets 29 and 30 constant, first powder material 2
5 is released, then the powder material 26 is gradually released, and finally only the powder material 26 is released. By controlling the amount of powder materials 25 and 26 released in this way, the mixing ratio of powder materials 25 and 26 changes with the cumulative amount of material released. For example, as shown in FIG. 4, the mixing ratio of the powder material 26 increases continuously as shown by the solid line a. On the other hand, the mixing ratio of the powder material 25 decreases continuously as shown by the broken line.

Next, the powder mixture 34 is transported and supplied from an inlet 35 to a cylindrical molding device 36 as shown in FIG. 14, for example. The distance between the inlet 35 and the filter 38 is long to some extent, and the mixed powder material 34 falls onto the filter 38 by gravity and is deposited uniformly to form a mixed powder layer (molded product) 37.
form. A suction chamber 39 is provided at the bottom of the filter 38.

Suction through the exhaust pipe 41 from the exhaust port 40 can accelerate the rate of deposition of the mixed powder material 34 in the molding machine. If the mixing ratio of the powder mixture is changed as described above, the molded article 37 thus produced will have a mixture ratio of the powder material 26 increasing from the bottom to the top in the thickness direction. The abundance ratio of powder material 25 and powder material 26 in this molded article 37 changes as shown in FIG.

By the method described above, the powder material 25 and the powder material 26 used, regardless of their types, can be very easily formed into a molded product in which the amount of components is arbitrarily changed in the thickness direction.

(Example 4) Preparation of a composite material in which the constituent components change from the center to the outside or vice versa in Example 3 A preferred example of a mixed powder material 34 mixed as in Example 3 is schematically shown in FIG. Rotor-shaped molding machine 3
The space outside the molding machine 36 is fed to the suction pump 4
5 is suctioned from the exhaust pipe 41.

A filter 38 is provided on the side of the molding device 36, and when the molding device 36 is rotated, the mixed powder material 34 is pressed against the filter 38 by centrifugal force and flow. The mixed powder material 34 is deposited on the filter 38 and the molded article 37
is formed. This molded product 37 has a mixing ratio distribution adjusted by the poppets 29 and 30 illustrated in FIG. Therefore, poppets 29 and 30
By adjusting , the mixing ratio of powder materials 25 and 26 can be freely changed.

By the method described above, the powder material 25 and the powder material 26 used can have their component amounts arbitrarily changed from the center to the outside or from the outside to the center, regardless of their type, particle size, specific gravity, etc. A molded article 37 is obtained.

In addition, in the method of the present invention as described above, when a filter-type molding machine is used and suction and exhaust is carried out from the bottom of the filter, the pressure difference between the inside and outside of the molding machine is large, so the filter should be made of highly rigid stainless steel. It is preferable to use something like a solid body or to support it with a highly rigid support.

In addition, in the method using a dispersion liquid as described above, for example, a binder such as various polymers or inorganic colloids or a temporary coagulant may be dissolved in any or all of the dispersion liquids, or a powder material may be used. In this case, the strength of the molded product can be improved by adding the binder, temporary coagulant, etc. 42 from the injection device 44 through the supply pipe 43 during or after molding. These temporary coagulants may be unnecessary depending on the type of particles.

Although typical methods for obtaining the composite material according to the present invention have been illustrated above, the composite material according to the present invention is not limited to those produced by these exemplified methods. For example, when using powder materials, The composite material according to the present invention can also be obtained using an injection molding machine, an extrusion molding machine, etc. that have been conventionally used for molding synthetic resins. When using such molders, the hopper of those molders should be
The structure may be as shown in the figure, or even if there is a single hopper, the mixing ratio of the constituent components may be varied within the hopper.

In addition, in Examples 2 and 4 above, examples of composite materials in which the constituent components change from the center to the outside or in the opposite direction were explained using a single-rotation molding machine. If an object is formed into a donut shape and the donut-shaped molded product is cut into an appropriate width, the change in the constituent components of the cut product can also be said to be a change in the thickness direction1.For example, a molding machine with a large diameter is used. However, if you make a molded product that is thin compared to its diameter and cut it, you will end up with a molded product that is almost like a flat plate, and the changes in the constituent components of the molded material will occur in the radial direction (from the center to the outside, from the center to the outside). It is appropriate to say that it is in the thickness direction.

There are two or more types of components used in the method of the present invention, and any material can be used as long as they have different physical properties and can be finally solidified. Alternatively, it may be a dispersion, and may also be an inorganic substance, an organic substance, or a mixture thereof.

Further, the components constituting the composite material as described above may be mutually reactive components, and even when such reactive components are used, by changing the mixing ratio of these reactive components, 1, for example, component A. The abundance ratio of the components can also be varied by different reaction products, such as when component B is reacted in arbitrary proportions to produce the product AnBm.

In addition, the components used are not limited to solids, but may be those that can be finally solidified. For example, in the case of a gas, the gas may react or decompose to produce a solid; for example, in the case of a liquid, the component may be one that produces a solid. Any material that can be solidified by reaction, cooling, or the like may be used.

Examples of typical inorganic particles include particles of various metals or alloys commonly used in powder metallurgy and sintered steel technology, particles of refractory metals such as tungsten, molybdenum, rhenium, tantalum, titanium, etc. cemented carbide powder,
Electromagnetic material particles, nuclear material particles, abrasive material particles, pigment particles, rubber and plastic filler particles, papermaking powders,
Pharmaceutical powder, agricultural powder, conventionally known composite material powder,
Examples include particles of catalysts, catalyst carrier material particles, adsorbent particles, ceramic powders, glass powders, metal carbides, nitrides, borides, oxides, and the like.

Other typical examples of inorganic materials include silica, titania,
Examples include aqueous sols of zirconia, alumina, and other metal oxides and hydroxides. These sols can be used as a mixture with each other or with particles of the f# and organic materials described above.

It is also a preferred material that can also serve as a dispersion medium for particles of these inorganic materials.

Further, the gaseous inorganic substance may be any substance that can be finally solidified by cooling, reaction, decomposition, association, or other changes in state, such as SiH4,5i2H8, SiC, etc. SfC sentence 3゜S i B2 (112, GeH4,
ASH3, PH3, B2 He, B2 Se, AsC
l3, PCl3, PCJ15, POCl3.5bCi
5, Sn(, fL4, etc.) or metal vapor generated by heating.

Examples of typical organic materials include particles, melts, solutions and dispersions of conventionally known natural or synthetic materials, and precursors (monomers, prepolymers, oligomers) for forming synthetic materials.

For example, particles and short fibers of acrylic resin, polyester resin, polyamide resin, polyimide resin, polycarbonate resin, polystyrene resin, other thermoplastic synthetic resins, phenolic resin, urea resin, melamine resin, alkyd resin and other thermosetting resins, Furthermore, particles and solutions of cellulose, chitin, chitosan, starch, proteins, enzymes, nucleic acids, and other natural products can be used in the same manner as the above-mentioned inorganic materials. When these particles or solutions are used, they can be easily fixed by heating or removing the solvent, and the melts, solutions, precursors, etc. of the organic substances can be easily fixed by cooling, removing the solvent, polymerizing or crosslinking the precursor. It may be solidified after molding by a conventional method such as curing.

In addition, organic substances are not limited to the above-mentioned polymers, but also organic metal compounds, various pigments such as dyes and pigments, surfactants,
Organic substances such as pharmaceuticals, nucleic acids, enzymes, hormones, vitamins, proteins, and biological substances such as amino acids, as well as the above-mentioned inorganic gases, can eventually solidify through cooling, reaction, decomposition, association, or other changes in state, or Gaseous organic substances that can be fixed by being dissolved or absorbed in other components can also be used.

Further, in the method of the present invention, the above-mentioned inorganic materials and organic materials can be used in combination.

For example, by using a mixture of the two, it is possible to easily mold a composite material consisting of components having significantly different physical properties. These composite materials provided by the method of the present invention are different from conventional composite materials, such as metal-deposited plastic moldings, filled plastic moldings, or alloys, in which the constituent components are either homogeneous as a whole or separated into layers. It is characterized in that the abundance ratio of the constituent components changes in at least one direction of the molded article.

The components used in the method of the present invention as described above must be used as a mixture of two or more types with different physical properties. As explained in the above principle, the mixing ratio of the blue component and the blue component may be continuously changed, or if there are three components, one of the components is always kept at a constant mixing ratio while the other two components are mixed at a constant mixing ratio. Any method such as changing the mixing ratio may be used.

As described above, a molded article is obtained in which components having different physical properties are present in proportions that vary in at least one direction of the molded article.In the present invention, in order to improve the strength of the molded article, a solidification process is performed. For example, if the material used is inorganic particles, such as metal powder or ceramic material powder, the molded product should be heated to 500 to 2.5
It is preferable to sinter the particles and solidify them as a whole by heat treatment at an appropriate temperature of about 00°C, and in the case of organic particles, the temperature is such that at least one of the constituent components is fused, for example 50 to 250°C. It can be heat treated to a certain degree. Of course, these temperatures vary depending on the types of constituent components.

In addition, when the material used is a sol, solution, melt, polymer precursor, etc., conventional solidification treatments such as 1 reaction, gelation, evaporation of the liquid medium, cooling, polymerization, crosslinking, and heat treatment are performed. Just give it.

According to the method of the present invention as described above, in a conventionally unknown composite material, that is, a composite material molded product consisting of two or more different components, the constituent components change in at least one direction of the molded material. These molded products have unique functions previously unknown, such as magnetic materials, conductive materials, semiconductive materials, insulating materials, thermally conductive materials, heat-resistant materials, and hard materials. It is useful as materials, polishing materials, optical materials, luminescent materials, various sensors, bonding materials, ceramic materials, catalyst materials, medical materials, display materials, recording materials, etc.

Next, the method of the present invention will be explained in more detail with reference to Examples. In the text, parts or % are based on weight unless otherwise specified.

Example 1 The raw materials are thermoplastic resin particles and additive particles.

A 10% butanol suspension of thermoplastic resin fine particles is placed in the larger vessel of the mixing apparatus shown in Figure 2, which has two vessels with a volume ratio of 10:9, and a 10% butanol suspension of the additive fine particles is placed in the other vessel.
Add 0% butanol suspension in proportion to the volume of each container.

Following the previously described procedure using a siphon, the two vessels are connected with the feed lines and the outlet tube is attached to the vessel containing the butanol suspension of the thermoplastic resin to drain the mixture.

The above liquid mixture is introduced into the molding machine shown in FIG.

Match the flow rate of the mixture to the filtration rate of the solvent.

In this way, a disc-shaped molded product is obtained in the molding machine. This means that the abundance ratio of the thermoplastic resin increases successively toward the bottom, and the abundance ratio of the additive increases successively toward the top.

This molded product was pressure-fused while degassing at a temperature near the softening point of the thermoplastic resin used to obtain a composite material by the method of the present invention. These composite materials according to the present invention are materials in which the concentration of additives changes continuously in the thickness direction according to the additives used.

The crude synthesis of the thermoplastic resin and additives used is as follows.

(1) Polybutylene terephthalate and conductive carbon black (2) Polyacrylate and photoconductive organic pigment (3) Polysulfone and alumina-based abrasive (4) Polyethylene terephthalate and CrO2-based magnetic particles (5) Polyethylene and endothermic pigment .

(6) The composite material produced by the method of the present invention, such as silicone rubber and highly conductive metal particles, differs from conventional painted or laminated composite materials in that the thermoplastic resin and additives are integrated in all parts. Moreover, unlike conventional mixed wire type composite materials, the presence ratio of additives is high only in the areas where functionality is required, so each performance and strength of the molded product were significantly improved. In particular, the composite material in the case (6) above has higher conductivity than a material in which these metal particles are uniformly dispersed in silicone rubber, and can also withstand high voltage and high current. It is useful as a conductive rubber for input switches, cords, and mat-like switches in precision equipment, and as a material for connections or peripheral parts of LSI wiring boards.

Example 2 The following powders A and B were used as raw materials, and methanol was used as the dispersion medium. The mixed solution is flowed out in the same manner as in Example 1 while controlling the flow rate.

No. 12a: Use a molding machine as shown in the figure at a speed of 4,500 to 6.00 per minute.
It is rotated at a speed of 0 rotations, and the above-mentioned liquid mixture is introduced from the center. The molding machine is heated to 70-80° C. to promote evaporation of the solvent, and the inflow rate of the liquid mixture is adjusted to the evaporation rate of the solvent.

In this way, a disc-shaped molded product is obtained in the molding machine.

In the above method, when a 3=2 mixture of polyamide powder and ferrite magnet powder is used as raw material A, and a 3:1 mixture of polyamide powder and thin short carbon fibers is used as raw material B, the molded product obtained is as follows: Polyamide outer periphery:
Ferrite magnet powder: carbon short li! 1 fiber ratio is 3:2
:1, and the center part is 3:O:1. This molded product was pressure-fused while degassing at a temperature of the softening point of polyamide to obtain a composite material according to the present invention.

This composite material is entirely reinforced with short carbon fibers, and has the function of a plastic magnet near its outer periphery, making it suitable for cameras,
It is useful as a component for precision instruments such as watches and electrical products.

In addition, as A and B above, molded products obtained by combining ABS powder and copper powder and combinations of ABS powder and aluminum powder are useful as advanced electromagnetic shielding materials and antistatic materials.

Further, by using the combination of materials illustrated in Example 1 and molding and solidifying in the same manner as described above, a composite material according to the present invention having a concentration distribution in the radial direction can be obtained.

Example 3 The raw materials are T i C and B4C in powder form. The device shown in Figure 13 contains TiC powder in one container and B4 in the other.
Add powder C. While flowing carrier gas through the transport pipe, turn the blower fan and mixing fan, and activate the poppet installed in the container.

TiC powder and B4C powder are each discharged into a transport tube.

At this time, the total amount of discharge from the two containers that control the poppet is kept constant, and only TiC is discharged at first. After a while, B4C powder is released. Gradually change the amount of discharge from the two containers until only 84C powder is discharged at the end of molding. During this time,
A planar disc-shaped molded product is obtained by using a cylindrical molding machine shown in FIG. 14, which draws suction from the exhaust port of the molding machine with a vacuum pump to speed up the deposition of the mixed powder material on the filter. This means that the abundance ratio of T i C is higher in order towards the bottom.
This is a molded product in which the abundance ratio of B4C increases in the upward direction.

The abundance ratio of B4C is 0 to 10 from the bottom to the top.
It is 0%.

500kg/crfte2 of this molded product, OO0℃
The composite material according to the present invention was obtained by sintering for 2 hours and slowly cooling.

The composite material obtained by the method of the present invention obtained through the above steps has the superhardness and wear resistance of T i C at one end, the chemical resistance of B4C at the other end, and the edge in the middle. It has properties intermediate between these depending on the distance from the surface, and is useful as a composite material for plants that requires corrosion resistance.

Further, in the above method, the following combinations of materials were used to obtain molded products of each combination, and the molded products were sintered at an appropriate temperature to obtain a composite material according to the method of the present invention.

(1) W2 B5 (ITFt fever) and B4 G
(High electrical resistance, chemical resistance) (2) ZrC (oxidation resistance) and ZrB2 (high conductivity) (3) S fc (semiconductivity) and WC (hardness and wear resistance) (4) SiC (heat resistance) Example 4 The materials were iron powder, high carbon ferromanganese powder (C: 6.67
%, Si: 0.1%, Mn near 3.65%, P: 0.1
4%, S: 0.008%, Iron: 19.43%), graphite powder and zinc stearate powder.

A mixed powder (A) consisting of 77.4% iron powder, 21.7% high carbon ferromanganese powder, 0.12% graphite powder and 0.8% zinc stearate powder is placed in one container.

A mixed powder (B) consisting of 88.9% iron powder, 9.5% high carbon ferromanganese powder, 0.81% graphite powder and 0.8% zinc stearate powder is placed in one container.

As in Example 3, while mixing mixed powders A and B, the first
The material is fed to the molding machine shown in Fig. 5, and the molding machine is rotated. Then, the outside of the molding machine is depressurized using a suction pump, and the amount of powder discharged is adjusted by controlling the poppet.At first, only B is
Finally, only A is emitted. Thereafter, acetone is sprayed as a temporary coagulant to complete the molding. In this way, a disc-shaped molded product is obtained. This means that the abundance ratio of B increases sequentially toward the outer circumference, and the abundance ratio of A increases sequentially toward the center. The manganese concentration increases from 7% to 16% from the outer periphery to the center.

This molded product was fired by a sintering forge method in a desired heating furnace with the heating program shown below to obtain a composite material according to the present invention.

(1) The molded product is molded again at 390 MPa.

(2) The molded product is inserted into an argon atmosphere furnace heated to 1,200°C.

(3) Hold for 1 hour and transfer to the mold surface.

(4) Forging at 800 MPa(r) pressure.

(5) Pour water into room temperature water from 1.050°K.

When the mechanical strength of the center portion and the outer peripheral portion of the composite material according to the present invention obtained through the above steps was measured, the results were as follows.

Ichimushioi 1- UJLiL Tensile strength 800MPa 500MPa Impact value 1, 814J/go 0.5MJ/go This is a composite material with different mechanical strengths in the center and outer periphery, and considering ease of processing, etc. Since it has mechanical properties similar to cast materials and heat-treated materials, it is useful as sintered forged materials and structural materials.

Further, in the above method, the following combinations of materials were used, and composite materials according to the present invention were obtained in the same manner.

(1) Copper-carbon alloy powder and iron powder (2) Chromium-carbon alloy powder and iron powder Example 5 An iron melt is divided into two containers, and one melt contains 6% titanium and 1.5% carbon. mix. As shown in FIG. 7, valves are used to control the flow rate of the melt from the two vessels to lWgi. The above melt is introduced into a rotomolder having the same principle as in FIG. 12a. During the inflow, the rate of solidification of the molten liquid in the molding machine is matched with the inflow rate of the molten liquid.

Initially, only the iron melt is allowed to flow in, and the amount of the melt containing titanium and carbon is gradually increased.

In this way, a composite material according to the present invention was obtained.

Within this composite material, titanium and carbon are present as eutectic high melting point carbides (Tic) in a solidified alloy.

The deformation resistance value (kg-m) of the outside and center of the molded product is 1
,000°C, the deformation resistance values were 14 kg-m and 27 kg-m, and the deformation resistance values were continuously changing. This composite material was useful as a heat-resistant material for heat exchangers.

Further, in the above method, the following combinations of materials were used to obtain a composite material according to the present invention in the same manner.

(1) Fe-Ni-Cr alloy and Ti-C alloy (2)
Ni-Cr-W alloy and Nb-C alloy (3) Aluminum alloy and A text 203 (4) Aluminum alloy and SiC In particular, AJI-Mg-3t alloy is used as the aluminum alloy in (3) and (4) above. Composite materials (3) and (0) showed wear resistance more than five times that of conventional aluminum alloys at high abundance ratios of AJ1203 and SiC.

Further, in addition to the above-mentioned examples, conventionally known methods such as die casting can also be used for molding.

Example 6 Co304, La203 and Pr8 in ZnO powder
011 powder at 0.5%, 2% and 1.8% respectively.
Add it to make mixed powder A.

On the other hand, Co304, La203 and Pr8011 powders were added to 5i02 powder at 0.5%, 2% and 1%, respectively.
．． 8% was added to obtain mixed powder B. The above powders A and B
After mixing each with a Raikai machine, 70% of A
Calcinate B at 0°C and 1,000°C.

Thereafter, it is pulverized to a fine powder. W1 Powdered mixed powders of A and B are put into hoppers as shown in Fig. 13, and the mixing ratio is changed by controlling the poppet.The rotary molding machine shown in Fig. 15 is used as the molding machine. It is molded using methanol as a temporary coagulant.

A molded product was obtained in which the abundance ratio of ZnO was zero at the outer periphery and the abundance ratio of 5i02 was zero near the center.

The relationship between the relative abundance ratio of 5f02 and ZnO and the distance from the center of the molded article was as shown in FIG. In FIG. 16, the solid line e indicates the abundance ratio of ZnO, and the broken line f indicates the abundance ratio of 5i02.

This molded product was fired using the following thermal program.

(1) Heating to 200°C at a heating rate of 2°C/min.

Continue degassing during this time.

(2) Maintain in a degassed state at 200°C for 10 hours.

(3) Heat to 1,400°C at a temperature increase rate of 2°C/min.

During this time, continue the degassing operation.

(4) 1. Maintain in a degassed state for 2 hours at 400°C and 300 kg/c.

(5) Stop applying pressure and lower the temperature to 90°C at a rate of 2°C/min.
Cool to 0°C while degassing.

(6) Cool from 900°C to 700°C while degassing at a temperature drop rate of 0.2°C/min.

(7) Stop the degassing operation using the pump and let it cool naturally in the furnace.

The composite material according to the present invention obtained through the above process is useful as a ZnO varistor, and there is no need to cover or coat the peripheral part with an insulating material, and it can be used in electrical products, semiconductor power conversion devices, etc. It is useful as a component of industrial equipment.

[Brief explanation of drawings]

1 to 16 are diagrams for explaining the method of the present invention. A: Component B; Matrix C; Molded product 1; Particle 2; Particle 1'; Dispersion liquid, 2'; Dispersion liquid 3.3', 3''
; Stirring means 4.5; Container 6.7: Supply path 8
; Cock 9; Ejection device 1O; Molding device 11, dispersion liquid layer 12: Molded product (sediment layer) 13;
Filter 14; Outlet 15: Drainage tank 16: Solvent (dispersion medium) 17; Exhaust port 18; Mixing chamber I9.20: Valve 21.22.23; Pump 24; Compressor 25; Powder 26; Powder 27.28: Container 29 .30: Boppet 31; Transport pipe 32: Blower fan 33; Mixing fan 34; Mixed state of powders 25 and 26 35; Inlet 36; Molding device 37; Molded product 38; Filter 39; Suction chamber 40; Exhaust port 41; Exhaust pipe 42; Temporary coagulant 43; Supply path
44; Ejection device 45; Suction pump agent Patent attorney Kichi 1) Katsuhirocho 1.1'1, 7th. Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 12b Figure 13 Figure 14 Figure 15 Figure 16 (%)

Claims (1)

[Claims] (1) A method for producing a composite material using a plurality of constituent components, which comprises a step of molding by changing the mixing ratio of the constituent components and a step of treating the molded product.