US5230138A
Expired / Lapsed
US
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Method of manufacturing a metal-contained composite material and a metal-contained composite material produced thereby
Assignee: Furukawa Electric Co Ltd
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Filing: 1990-07-26
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Granted: 1993-07-27
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Expires: 2010-07-26
Abstract
Abstract This invention relates to a method of producing a metal-contained composite material from a metal and a sinterable material such as a ceramic material, and to a metal-contained composite material produced by the method. Conventional composite materials consisting of metal and ceramic material do not have sufficient mechanical and electrical properties, under some conditions in use, and are too expensive to be applied extensively. To solve this problem, the invention provides a manufacturing method comprising a process of fabricating a roll of a laminate consisting of a metal strip and a sinterable material, by winding up the laminate, and a process of subjecting the roll to plastic working; a manufacturing method including a heat treatment process carried out at a predetermined temperature, in addition to the above processes; and metal-contained composite materials produced by these methods. The metal-contained composite materials produced by the methods of the invention can be suitably used for machine parts, electrical sliding contact materials, electrical and thermal conductors, electromagnetic shielding materials, and the like.
Inventors
- 👤 Shoji Shiga
- 👤 Minoru Suzuki
- 👤 Masanori Ozaki
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 22:39
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/622; C04B35/64; C04B35/645; C04B35/6455; B; B22; B22F; B22F7/00; B22F7/06; B22F7/08; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49544; Y10T29/4956; Y10T29/49636; Y10T29/49705; Y10T29/4998; Y10T29/49982
Claims Analysis
Total Claims: 35
Claim 1
Independent Claim
62 words
A method of manufacturing a metal-contained composite material, comprising the steps of; fabricating a roll of a laminate by laminating at least one sinterable material on one surface of a metal strip to form a laminate, and thereafter winding up the laminate with or without a core to form the roll of the laminate; and thereafter subjecting the roll to plastic working.
Claim 2
Independent Claim
62 words
A method of manufacturing a metal-contained composite material, comprising the steps of; fabricating a roll of a laminate by laminating at least one sinterable material on one surface of a metal strip to form a laminate, and thereafter winding up the laminate with or without a core to form the roll of the laminate; and thereafter subjecting the roll to plastic working.
Claim 3
Dependent Claim
30 words
The method according to claim 1, wherein a core is used and said core is made of a metal identical to or different from the metal of the metal strip.
Claim 4
Dependent Claim
39 words
The method according to claim 1, wherein said step of fabricating a roll comprises the operation of winding the metal strip simultaneously with the step of laminating at least one sinterable material on one surface of the metal strip.
Claim 5
Dependent Claim
38 words
A method according to claim 1, wherein the step of laminating the sinterable material comprises applying the sinterable material to the metal strip by plasma spraying, PVD, CVD spray pyrolysis, printing, dip coating, slurry application, and electrophoretic deposition.
Claim 6
Dependent Claim
14 words
The method according to claim 1, wherein said plastic working is rolling or drawing.
Claim 7
Dependent Claim
21 words
The method according to claim 1, which further comprises a compression step to be carried out after said plastic working step.
Claim 8
Dependent Claim
19 words
The method according to claim 2, wherein the core is made of said identical metal to the metal strip.
Claim 9
Dependent Claim
16 words
The method according to claim 1, wherein said plastic working is hot pressing or cold pressing.
Claim 10
Dependent Claim
18 words
The method according to claim 8, wherein said plastic working is hot isotactic pressing or cold isotactic pressing.
Claim 11
Dependent Claim
93 words
The method according to claim 1, wherein the metal strip is an alloy of Ag-Pd, Cu-Zn, Cu-Sn, Cu-Ni, Fe-Ni, Fe-Ni-Co, or Mo-Cr-Fe, and the ceramic is Al 2 O 3 . SiC, ZrO 2 , MgO, BaTiO 3 , Fe 2 O 3 , MoS 2 , WC, TiC, TiB 2 , TiN, AlN, soda-lime glass, lead glass, MoSi, ZnN, ZrC, ZrB 2 , PbTiO 3 , NaTaO 3 , KNSO 3 , NaNbO 3 , K 2 O.6TiO 2 , 9Al 2 O 3 .B 2 O 3 and KTaO 3 .
Claim 12
Dependent Claim
87 words
The method according to claim 1, wherein the metal strip is an alloy of stainless steel and the ceramic is Al 2 O 3 . SiC, ZrO 2 , MgO, BaTiO 3 , Fe 2 O 3 , MoS 2 , WC, TiC, TiB 2 , TiN, AlN, soda-lime glass, lead glass, MoSi, ZnN, ZrC, ZrB 2 , PbTiO 3 , NaTaO 3 , KNSO 3 , NaNbO 3 , K 2 O.6TiO 2 , 9Al 2 O 3 .B 2 O 3 and KTaO 3 .
Claim 13
Independent Claim
83 words
A method of manufacturing a metal-contained composite material, comprising the steps of: fabricating a roll of a laminate prepared by laminating at least one sinterable material on one surface of a metal strip, and thereafter winding up the laminate with or without a core to form the roll; drawing the roll; and thereafter heat treating the drawn roll at a temperature higher than a sintering temperature of the sinterable material and lower than a melting point of the metal constituting the metal strip.
Claim 14
Independent Claim
83 words
A method of manufacturing a metal-contained composite material, comprising the steps of: fabricating a roll of a laminate prepared by laminating at least one sinterable material on one surface of a metal strip, and thereafter winding up the laminate with or without a core to form the roll; drawing the roll; and thereafter heat treating the drawn roll at a temperature higher than a sintering temperature of the sinterable material and lower than a melting point of the metal constituting the metal strip.
Claim 15
Dependent Claim
25 words
The method according to claim 12, wherein said core is made of a metal identical to or different from the metal of the metal strip.
Claim 16
Dependent Claim
41 words
The method according to claim 12, wherein said process of fabricating a roll, comprises the operation of winding the metal strip with or without the core while simultaneously laminating at least one sinterable material on one surface of the metal strip.
Claim 17
Dependent Claim
37 words
The method according to claim 12, wherein the laminating of the sinterable material comprises applying the sinterable material to the metal strip by plasma spraying, PVD, CVD, spray pyrolysis, printing, dip coating, slurry application, and electrophoretic deposition.
Claim 18
Dependent Claim
32 words
The method according to claim 12, wherein said sinterable material is one or more substances selected from the group consisting of ceramic materials, metals, and a mixture of ceramic materials and metals.
Claim 19
Dependent Claim
18 words
The method according to claim 12, wherein said plastic working is rolling, drawing, hot pressing or cold pressing.
Claim 20
Dependent Claim
21 words
The method according to claim 12, which further comprises a compression step to be carried out after said plastic working step.
Claim 21
Dependent Claim
27 words
The method according to claim 12, wherein said heating process is effected by using an HIP, an electric furnace, a burner, a lamp, a laser, or self-reaction.
Claim 22
Dependent Claim
18 words
The method according to claim 12, wherein said plastic working is cold isotactic pressing or hot isotactic pressing.
Claim 23
Dependent Claim
103 words
The method according to claim 12, wherein the metal strip is Cu, Al, Ag, Au, Fe, Ni, Co, W, Mo, Nb, Ta, Ti, Zr, or an alloy of two or more thereof, and the ceramic is Al 2 O 3 . SiC, ZrO 2 , MgO, BaTiO 3 , Fe 2 O 3 , MoS 2 , WC, TiC, TiB 2 , TiN, AlN, soda-lime glass, lead glass, MoSi, ZnN, ZrC, ZrB 2 , PbTiO 3 , NaTaO 3 , KNSO 3 , NaNbO 3 , K 2 O.6TiO 2 , 9Al 2 O 3 .B 2 O 3 and KTaO 3 .
Claim 24
Dependent Claim
17 words
The method according to claim 21, wherein the metal strip is Cu and the ceramic is TiN.
Claim 25
Independent Claim
75 words
A method of manufacturing a metal-contained composite material, comprising the steps of; fabricating a roll of a laminate by laminating at least one sinterable material on one surface of a metal strip to form a laminate, and thereafter winding up the laminate with or without a core to form the roll of the laminate; and thereafter subjecting the roll to plastic working, and wherein said sinterable material contains a mixture of ceramic materials and metals.
Claim 26
Independent Claim
75 words
A method of manufacturing a metal-contained composite material, comprising the steps of; fabricating a roll of a laminate by laminating at least one sinterable material on one surface of a metal strip to form a laminate, and thereafter winding up the laminate with or without a core to form the roll of the laminate; and thereafter subjecting the roll to plastic working, and wherein said sinterable material contains a mixture of ceramic materials and metals.
Claim 27
Independent Claim
74 words
A method of manufacturing a metal-contained composite material, comprising the steps of; fabricating a roll of a laminate by laminating at least one sinterable material on one surface of a metal strip to form a laminate, and thereafter winding up the laminate with or without a core to form the roll of the laminate; and thereafter subjecting the roll to plastic working, and wherein said sinterable material contains ceramic materials, electrochemical polymers, or metals.
Claim 28
Independent Claim
74 words
A method of manufacturing a metal-contained composite material, comprising the steps of; fabricating a roll of a laminate by laminating at least one sinterable material on one surface of a metal strip to form a laminate, and thereafter winding up the laminate with or without a core to form the roll of the laminate; and thereafter subjecting the roll to plastic working, and wherein said sinterable material contains ceramic materials, electrochemical polymers, or metals.
Claim 29
Dependent Claim
13 words
The method according to claim 24, wherein said sinterable material contains electroconductive polymers.
Claim 30
Dependent Claim
12 words
The method according to claim 25, wherein said sinterable material contains metals.
Claim 31
Dependent Claim
42 words
A metal-contained composite material, comprising an innards thereof made of a lamination of a metal layer and a layer of sinterable material, which is spirally wound to form a roll, and a metallic pipe surrounding said spirally wound roll of the lamination.
Claim 32
Dependent Claim
42 words
A metal-contained composite material, comprising an innards thereof made of a lamination of a metal layer and a layer of sinterable material, which is spirally wound to form a roll, and a metallic pipe surrounding said spirally wound roll of the lamination.
Claim 33
Dependent Claim
71 words
A metal-contained composite material, comprising a lamination of a metal layer and a layer of sinterable material, which is spirally wound to form a roll, said spirally wound roll having an end portion of the lamination on the outermost thereof, at which said sinterable material layer is not formed on an inner surface of said metal layer, and said inner surface of said metal layer abuts on an outer surface thereof.
Claim 34
Dependent Claim
71 words
A metal-contained composite material, comprising a lamination of a metal layer and a layer of sinterable material, which is spirally wound to form a roll, said spirally wound roll having an end portion of the lamination on the outermost thereof, at which said sinterable material layer is not formed on an inner surface of said metal layer, and said inner surface of said metal layer abuts on an outer surface thereof.
Claim 35
Dependent Claim
13 words
The method according to claim 24, wherein said sinterable material contains ceramic materials.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1996-07-26 | 1997-01-25 | 1997-07-27 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2000-07-26 | 2001-01-25 | 2001-07-27 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2004-07-26 | 2005-01-25 | 2005-07-27 | $7700.00 | Window Closed / Lapsed |