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US4601956A
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Composite material made from matrix metal reinforced with mixed amorphous alumina-silica fibers and mineral fibers
Assignee: Toyota Motor Corp
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Filing: 1985-05-16
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Granted: 1986-07-22
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Expires: 2005-05-16
Abstract
Abstract This composite material includes reinforcing hybrid fiber mixture material in a matrix of metal which is aluminum, magnesium, copper, zinc, lead, tin, or an alloy having these as principal components. The hybrid fiber mixture is a mixture of amorphous alumina-silica fiber material and mineral fiber material. The amorphous alumina-silica fiber material has as principal components 35% to 80% by weight of Al 2 O 3 and 65% to 20% by weight of SiO 2 , with a content of other substances of less than or equal to 10% by weight, with the percentage of non fibrous particles included therein being less than or equal to about 17% by weight, and with the percentage of non fibrous particles with diameters greater than 150 microns being less than or equal to 7% by weight. And the mineral fiber material has as principal components SiO 2 , CaO, and Al 2 O 3 , the content of MgO being less than or equal to 10% by weight, the content of Fe 2 O 3 being less than or equal to 5% by weight, and the content of other inorganic substances being less than or equal to 10% by weight, with the percentage of non fibrous particles being less than or equal to 20% by weight, and with the percentage of non fibrous particles with diameters greater than 150 microns being less than or equal to 7% by weight. The volume proportion of the reinforcing hybrid fiber material is at least 1%. The qualities of this composite material with regard to wear and bending strength are good.
Inventors
- 👤 Tadashi Dohnomoto
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 17:52
CPC Classifications
C; C22; C22C; C22C47/00; C22C47/08; C22C49/00; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12444; Y10T428/12458; Y10T428/12486
Claims Analysis
Total Claims: 17
Claim 1
Independent Claim
287 words
A composite material, consisting essentially of: (a) a reinforcing material which is a hybrid fiber mixture material consisting essentially of: (a1) an effective amount of a reinforcing amorphous alumina-silica fiber material with the principle components being about 35% to about 80% by weight of Al 2 A 3 and about 65% to about 20% by weight of SiO 2 , and with a content of other substances of less than or equal to about 10% by weight, with the percentage of non-fibrous particles included therein being less than or equal to about 17% by weight, and with the percentage of non-fibrous particles with diameters greater than about 150 microns included therein being less than or equal to about 7% by weight; and (a2) an effective amount of a reinforcing mineral fiber material having as the principle components SiO 2 , CaO, and Al 2 O 3 , the content of included MgO therein being less than or equal to about 10% by weight, the content of included Fe 2 O 3 therein being less than or equal to about 5% by weight, and the content of other inorganic substances included therein being less than or equal to about 10% by weight, with the percentage of non-fibrous particles included therein being less than or equal to about 20% by weight, and with the percentage of non-fibrous particles with diameters greater than about 150 microns included therein being less than or equal to about 7% by weight; and (b) a matrix metal selected from the group consisting of aluminum, magnesium, copper, zinc, lead, tin and alloys having these metals as principle components; wherein the volume of said hybrid fiber mixture material in said composite material is at least 1%.
Claim 2
Dependent Claim
287 words
A composite material, consisting essentially of: (a) a reinforcing material which is a hybrid fiber mixture material consisting essentially of: (a1) an effective amount of a reinforcing amorphous alumina-silica fiber material with the principle components being about 35% to about 80% by weight of Al 2 A 3 and about 65% to about 20% by weight of SiO 2 , and with a content of other substances of less than or equal to about 10% by weight, with the percentage of non-fibrous particles included therein being less than or equal to about 17% by weight, and with the percentage of non-fibrous particles with diameters greater than about 150 microns included therein being less than or equal to about 7% by weight; and (a2) an effective amount of a reinforcing mineral fiber material having as the principle components SiO 2 , CaO, and Al 2 O 3 , the content of included MgO therein being less than or equal to about 10% by weight, the content of included Fe 2 O 3 therein being less than or equal to about 5% by weight, and the content of other inorganic substances included therein being less than or equal to about 10% by weight, with the percentage of non-fibrous particles included therein being less than or equal to about 20% by weight, and with the percentage of non-fibrous particles with diameters greater than about 150 microns included therein being less than or equal to about 7% by weight; and (b) a matrix metal selected from the group consisting of aluminum, magnesium, copper, zinc, lead, tin and alloys having these metals as principle components; wherein the volume of said hybrid fiber mixture material in said composite material is at least 1%.
Claim 3
Dependent Claim
38 words
The composite material according to claim 1, wherein the ratio of the volume proportion of said amorphous alumina-silica fiber material to the total volume proportion of said hybrid fiber mixture material is between about 5% and about 80%.
Claim 4
Dependent Claim
56 words
The composite material according to claim 2, wherein the ratio of the volume proportion of said amorphous alumina-silica fiber material to the total volume proportion of said hybrid fiber mixture material is between about 5% and about 40%, and the total volume proportion of said hybrid fiber mixture material is between about 2% and about 40%.
Claim 5
Dependent Claim
28 words
The composite material according to claim 1, wherein the volume proportion of said mineral fiber material in said composite material is less than or equal to about 25%.
Claim 6
Dependent Claim
63 words
The composite material according to claim 1, wherein the total proportion of non fibrous particles included in said amorphous alumina-silica fiber material is less than or equal to about 6% by weight, and the proportion of non fibrous particles with diameters greater than about 150 microns included in said amorphous alumina-silica fiber material is less than or equal to about 1% by weight.
Claim 7
Dependent Claim
61 words
The composite material according to claim 1, wherein the total proportion of non fibrous particles included in said mineral fiber material is less than or equal to about 10% by weight, and the proportion of non fibrous particles with diameters greater than about 150 microns included in said mineral fiber material is less than or equal to about 2% by weight.
Claim 8
Dependent Claim
30 words
The composite material according to claim 1, wherein, in said hybrid fiber mixture material, said amorphous alumina-silica fiber material and said mineral fiber material are mutually substantially evenly mixed together.
Claim 9
Dependent Claim
14 words
The composite material according to claim 1, wherein said matrix metal is aluminum alloy.
Claim 10
Dependent Claim
14 words
A composite material according to claim 1, wherein said matrix metal is magnesium alloy.
Claim 11
Dependent Claim
14 words
A composite material according to claim 1, wherein said matrix metal is zinc alloy.
Claim 12
Dependent Claim
13 words
A composite material according to claim 1, wherein said matrix metal is lead.
Claim 13
Dependent Claim
14 words
A composite material according to claim 1, wherein said matrix metal is tin alloy.
Claim 14
Dependent Claim
85 words
The composite material according to claim 1, wherein said other substances added to said amorphous alumina-silica fiber material or said mineral fiber material is selected from the group of metal oxides of CaO, MgO, Na 2 O, Fe 2 O 3 , Cr 2 O 3 , ZrO 2 , TiO 2 , PbO, SnO 2 , ZnO, MoO 3 , NiO, K 2 O, MnO 2 , B 2 O 3 , V 2 O 5 , CuO and Co 3 O 4 .
Claim 15
Dependent Claim
36 words
The composite material according to claim 1, wherein said amorphous alumina-silica fibers are short fibers having an average fiber diameter of approximately 1.5 to 5.0 microns and a fiber length of 20 microns to 3 millimeters.
Claim 16
Dependent Claim
26 words
The composite material according to claim 1, wherein said amorphous alumina-silica fibers are long fibers having an average fiber diameter of approximately 3 to 30 microns.
Claim 17
Dependent Claim
37 words
The composite material according to claim 1, wherein said mineral fibers are short fibers with a fiber diameter of about 1 to 10 microns and with a fiber length of about 10 microns to about 10 cm.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1989-07-21 | 1990-01-20 | 1990-07-22 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-07-21 | 1994-01-20 | 1994-07-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-07-21 | 1998-01-20 | 1998-07-22 | $7700.00 | Window Closed / Lapsed |