Composite product, preform for making the composite product and process of making the preform
AssigneeMazda Motor Corporation
InventorMakoto Fujita
Life of this patent
Estimating the term…
Abstract
A preform used as a reinforcement of a composite product is formed by heating a homogeneous slurry mixture of oxide type ceramic particles and/or oxide type ceramic whiskers which are reactive with magnesium (Mg) and a metal oxide having standard energy of formation equal to or less than a magnesium oxide (MgO) or an inorganic compound formed by decomposing the metal oxide to sinter the oxide type ceramic particles and/or oxide type ceramic whiskers.
Claims39
A preform for producing a composite product, said preform comprising:
- at least one of oxide type ceramic particles and oxide type ceramic whiskers chemically reactive with magnesium (Mg) which are sintered to form a predetermined skeletal structure of a composite product;
- and
- a metal oxide having standard energy of formation equal to or less than a magnesium oxide (MgO) and existing as a chemical compound formed resulting from a chemical reaction with said at least one of oxide type ceramic particles and oxide type ceramic whiskers.
A preform for producing a composite product, said preform comprising:
- at least one of titanium oxide (TiO2) particles, silicon oxide (SiO2) particles, aluminum borate (9Al2O3.2B2O3) whiskers and potassium titanium (K2O.6TiO2) whiskers which are sintered to form a predetermined skeletal structure of the composite product;
- at least one of a calcium oxide (CaO), a magnesium oxide (MgO) and an aluminum oxide (Al2O3) having standard energy of formation equal to or less than a magnesium oxide (MgO) and existing as a chemical compound formed resulting from a chemical reaction with said at least one of titanium oxide (TiO2) particles, silicon oxide (SiO2) particles, aluminum borate (9Al2O3.2B2O3) whiskers and potassium titanium (K2O.6TiO2) whiskers;
- and
- chopped fibers.
A composite product comprising:
- a porous preform comprising at least one of oxide type ceramic particles and oxide type ceramic whiskers chemically reactive with magnesium (Mg) which are sintered to form a predetermined skeletal structure of the composite product and a metal oxide having standard energy of formation equal to or less than a magnesium oxide (MgO) and existing as a chemical compound formed resulting from a chemical reaction with said at least one of oxide type ceramic particles and oxide type ceramic whiskers;
- and
- a light metal alloy containing magnesium (Mg) filled in pores of said porous preform.
A process of forming a preform for a composite product, said preform forming process comprising the steps of:
- preparing a homogeneous mixture of at least one of oxide type ceramic particles and oxide type ceramic whiskers chemically reactive with magnesium (Mg) and at least one of a metal oxide having standard energy of formation equal to or less than a magnesium oxide (MgO) and an inorganic chemical compound formed resulting from a chemical reaction with said metal oxide;
- and
- heating said homogeneous mixture to sinter said at least one of oxide type ceramic particles and oxide type ceramic whiskers with an effect of causing said metal oxide to chemically react with said at least one of oxide type ceramic particles and oxide type ceramic whiskers.
A process of forming a preform for a composite product, said preform forming process comprising the steps of:
- preparing a homogeneous mixture of at least one of oxide type ceramics, chemically reactive with magnesium (Mg), which include titanium oxide (TiO2) particles, silicon oxide (SiO2) particles, aluminum borate (9Al2O3.2B2O3) whiskers and potassium titanium (K2O.6TiO2) whiskers, at least one of metal oxides having standard energy of formation equal to or less than a magnesium oxide (MgO) which include a calcium oxide (CaO), a magnesium oxide (MgO) and an aluminum oxide (Al2O3), calcium carbonate (CaCO3) as an inorganic chemical compound formed resulting from a chemical reaction with said metal oxide flammable particles and chopped fibers;
- and
- heating said homogeneous mixture to sinter said oxide type ceramic particles with an effect of causing said metal oxide to chemically react with said oxide type ceramic particles.
Dependencies are inferred from the claim text.