Copper-carbon composite material with graded function and method for manufacturing the same

• US 5,580,658 A
• Filed: 07/12/1994
• Issued: 12/03/1996
• Est. Priority Date: 07/14/1993
• Status: Expired due to Fees

• Current Assignee: Japan Nuclear Cycle Development Institute
• Original Assignee: Doryokuro Kakunenryo Kaihatsu Jigyodan, TOYO Tanso Company Limited
• Inventors: Okada, Masaki, Nagaoka, Katuhide, Maruyama, Tadashi
• Primary Examiner(s): Robinson, Ellis
• Assistant Examiner(s): JONES III, LEON
• Application Number:
  US08/273,769
• Time in Patent Office: 875 Days
• Field of Search: 428/408, 428/688, 428/689, 428/698, 428/704, 428/304.4, 428/306.6, 428/307.3, 428/307.7, 428/312.2, 428/312.8, 428/218, 428/244, 428/367, 428/368, 164/97, 164/91, 419/27, 427/226, 427/227, 427/228, 427/237, 427/249, 264/291, 264/292, 264/294, 376/287, 376/288, 423/447.1, 423/447.5, 423/448, 250/515.1
• US Class Current: 428/408
• CPC Class Codes: B22F 2207/01 Composition gradients
• CPC Class Codes: B22F 2207/03 of the metallic binder phase in cermets
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/002 Manufacture of articles essentially made from metallic fibres
• CPC Class Codes: B22F 3/26 Impregnating making ferrous alloys by impregnation C22C33/0242
• CPC Class Codes: C04B 2111/00405 Materials with a gradually increasing or decreasing concentration of ingredients or property from one layer to another
• CPC Class Codes: C04B 35/52 based on carbon, e.g. graphite
• CPC Class Codes: C04B 35/83 Carbon fibres in a carbon matrix
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4531 by C.V.D.
• CPC Class Codes: C04B 41/4556 coating or impregnating with a product reacting with the substrate, e.g. generating a metal coating by surface reduction of a ceramic substrate
• CPC Class Codes: C04B 41/5059 Silicon carbide
• CPC Class Codes: C04B 41/5127 Cu, e.g. Cu-CuO eutectic
• CPC Class Codes: C04B 41/52 Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
• CPC Class Codes: C04B 41/88 Metals
• CPC Class Codes: C04B 41/89 for obtaining at least two superposed coatings having different compositions
• CPC Class Codes: C22C 32/0089 with other, not previously mentioned inorganic compounds as the main non-metallic constituent, e.g. sulfides, glass
• CPC Class Codes: C22C 47/06 by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element
• CPC Class Codes: C22C 47/08 by contacting the fibres or filaments with molten metal, e.g. by infiltrating the fibres or filaments placed in a mould C22C47/16 takes precedence
• CPC Class Codes: C22C 49/14 : characterised by the fibres or filaments
• CPC Class Codes: C23C 16/045 : Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
• CPC Class Codes: C23C 16/26 : Deposition of carbon only
• CPC Class Codes: Y02E 30/10 : Nuclear fusion reactors
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/249956 : Void-containing component is inorganic
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

A function ally gradient composite material containing copper and carbon as main components and having a predetermined shape, in which the composition ratio of the copper to the carbon in the material continuously varies in at least one predetermined direction. The material is manufactured, for example, by impregnating carbon felt with a resin and thermo-compressively molding the impregnated felt (step S101), carbonizing the resin by baking (step S102) to provide a preformed carbon material (step S104). Pyrolytic carbon is thereafter deposited in the preformed carbon material by the CVI method (step S105) to provide a carbon material having the bulk density varying in a predetermined direction (step S107). After the wettability of the carbon material against copper is improved by siliconization (step S108), pores of the carbon material are impregnated with copper (step S109) to obtain a functionally gradient composite material of copper and carbon.

Claims

1. A functionally gradient composite material containing copper and carbon as main components and having a predetermined shape, wherein the compositional ratio of the copper to the carbon in said material varies in at least one predetermined direction, wherein said variation of the compositional ratio is continuous, and wherein the carbon material is formed by depositing pyrolytic carbon in a carbon fiber-reinforced carbon composite material.

2. A functionally gradient composite material containing copper and carbon as main components according to claim 1, wherein the compositional ratio of the copper to the carbon successively increases or decreases in at least one predetermined direction.

3. A functionally gradient composite material containing copper and carbon as main components according to claim 1, wherein the compositional ratio of the copper to the carbon varies in the thickness direction of a composite material having a plate shape.

4. A functionally gradient composite material containing copper and carbon as main components according to claim 1, wherein said composite material is formed by impregnating pores of a carbon material of which bulk density varies in at least one predetermined direction with copper.

5. A functionally gradient composite material containing copper and carbon as main components according to claim 4, wherein the carbon material is graphite.

6. A functionally gradient composite material containing copper and carbon as main components according to claim 1, wherein said carbon fiber-reinforced carbon composite material is formed by impregnating carbon fiber felt with a resin and carbonizing the resin.

7. A functionally gradient composite material containing copper and carbon as main components according to claim 1, wherein the bulk density of said carbon fiber-reinforced carbon composite material as a whole is in the range of from 0.1 to 0.8 Mg/m³, and the bulk density varies in said carbon material while having the upper and lower limits which are in the range of from 0.1 Mg/m³ to 2.2 Mg/m³.

8. A functionally gradient composite material containing copper and carbon as main components according to claim 1, wherein the periphery of the pores in the carbon material is siliconized.