# US 7,407,146 B2 · Composite material and resin mold

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- Number: US 7,407,146 B2
- Document ID: US7407146B2
- Status: Granted
- Kind: B2
- Application number: 11/024,484
- Filed: 2004-12-30
- Published: 2005-07-14
- Granted: 2008-08-05
- Earliest claimed: 2004-01-09
- Assignees: Towa Corporation; Japan Fine Ceramics Center
- Inventors: Takaki Kuno; Keiji Maeda; Yosinori Noguchi; Satoshi Kitaoka; Naoki Kawashima
- Web page: https://patentgrep.com/patent/US7407146B2

## CPC

- C08J 5/00: Manufacture of articles or shaped materials containing macromolecular substances (manufacture of semi-permeable membranes B01D67/00 - B01D71/00)
- B29C 33/40: Plastics, e.g. foam or rubber
- B29C 33/56: Coatings {, e.g. enameled or galvanised}; Releasing, lubricating or separating agents {(in-mould coating B29C37/0028; using or applying separating agents B29C37/0067)}
- B29C 45/37: Mould cavity walls {, i.e. the inner surface forming the mould cavity, e.g. linings}
- B29C 45/02: Transfer moulding, i.e. transferring the required volume of moulding material by a plunger from a "shot" cavity into a mould cavity
- B29C 45/14639: {for obtaining an insulating effect, e.g. for electrical components}
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)

## Abstract

A composite material used for a resin mold for forming hardened resin by hardening fluid resin is provided. The composite material comprises a first material having excellent wear resistance against the fluid resin and a second material having excellent unwettability against the fluid resin. The resin mold comprises a substrate of the first material, a large number of pores each provided to form an opening on a surface of the substrate opposite to the fluid resin and a film of the second material formed along the inner wall surface of each pore at least around the opening. Each of the large number of pores is a communicating hole connecting the surface opposite to the fluid resin and the remaining surface with each other. Therefore, releasability between a mold surface and the hardened resin and wear resistance of the composite material against the fluid resin can be improved.

## Claims

### Claim 1

A composite material used for a portion coming into contact with fluid resin, comprising:
a first material consisting of an inorganic material and having excellent wear resistance against said fluid resin; and
a second material consisting of an organic material and having excellent unwettability against said fluid resin, wherein
said first material and said second material are hybridized with each other, such that said inorganic material and said organic material are fused with each other over an entire portion of the composite material at a molecular level.

### Claim 2

A composite material used for a portion coming into contact with fluid resin, comprising:
a substrate containing a first material consisting of an inorganic material and having excellent wear resistance against said fluid resin;
a plurality of pores each provided to form an opening on a surface of said substrate opposing said fluid resin; and
a film, formed along the inner wall surface of each of said plurality of pores at least around said opening without obstructing said each of said plurality of pores, containing a second material consisting of an organic material and having excellent unwettability against said fluid resin,
wherein, said first material and said second material are hybridized with each other, such that said inorganic material and said organic material are fused with each other over an entire portion of said film at a molecular level.

### Claim 3 (depends on 2)

The composite material according to claim 2, wherein
each of said plurality of pores is a communicating hole connecting said surface opposing said fluid resin and the remaining surface with each other.

### Claim 4

A resin mold, having a cavity charged with fluid resin, used for manufacturing a molding containing hardened resin obtained by hardening said fluid resin and prepared from a composite material, wherein
said composite material comprises:
a first material consisting of an inorganic material and having excellent wear resistance against said fluid resin; and
a second material consisting of an organic material and having excellent unwettability against said fluid resin, and
said first material and said second material are hybridized with each other, such that said inorganic material and said organic material are fused with each other over an entire portion of said composite material at a molecular level.

### Claim 5

A resin mold, having a cavity charged with fluid resin, used for manufacturing a molding containing hardened resin obtained by hardening said fluid resin and prepared from a composite material, comprising:
a substrate containing a first material consisting of an inorganic material and having excellent wear resistance against said fluid resin;
a plurality of pores each provided to form an opening on a surface of said substrate opposing said fluid resin; and
a film, formed along the inner wall surface of each of said plurality of pores at least around said opening without obstructing said each of said plurality of pores, containing a second material consisting of an organic material and having excellent unwettability against said fluid resin,
wherein, said first material and said second material are hybridized with each other, such that said inorganic material and said organic material are fused with each other over an entire portion of said film at a molecular level.

### Claim 6 (depends on 5)

The resin mold according to claim 5, wherein
each of said plurality of pores is a communicating hole connecting said surface opposing said fluid resin and the remaining surface with each other.

### Claim 7 (depends on 2)

The composite material according to claim 2, wherein
each of said plurality of pores is a one-dimensional communicating hole that extends substantially linearly.

### Claim 8 (depends on 5)

The composite material according to claim 5, wherein
each of the plurality of pores is a one-dimensional communicating hole that extends substantially linearly.