Heat-shielding film and method of forming the same
AssigneeToyota Jidosha Kabushiki Kaisha
InventorsTakayasu Sato, Yoshinori Takeuchi, Takeshi Utsunomiya
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Abstract
A heat-shielding film formed on the wall surface of a metal base material contains a plurality of ceramic hollow particles (1) and metal phases (2) to which the plurality of ceramic hollow particles (1) are joined at points. Each of the plurality of ceramic particles (1) is joined at a point, through the metal phase (2), to another ceramic particle among the plurality of ceramic particles (1) so that the plurality of ceramic particles (1) are joined to each other. The plurality of ceramic hollow particles (1) of the heat-shielding film (10) and the wall surface are joined at points to the metal phases (2) so that the plurality of ceramic hollow particles (1) are joined to the wall surface.
Claims13
A heat-shielding film formed on a wall surface of a metal base material, comprising:
- a plurality of ceramic hollow particles;
- and
- metal phases to which the plurality of ceramic hollow particles are joined at points, wherein
- each of the plurality of ceramic hollow particles is joined at a point, through the metal phase, to another ceramic hollow particle among the plurality of ceramic hollow particles so that the plurality of ceramic hollow particles are joined to each other, and
- the plurality of ceramic hollow particles of the heat-shielding film and the wall surface are joined at points to the metal phases so that the plurality of ceramic hollow particles are joined to the wall surface, wherein
- the plurality of ceramic hollow particles consist of ceramic hollow particles having two different average particle sizes,
- a first layer of the ceramic hollow particles having a larger average particle size among the two different average particle sizes is joined to the wall surface through the metal phases, and
- a second layer of the ceramic hollow particles having a smaller average particle size among the two different average particle sizes is disposed above the first layer, and joined to the first layer.
A heat-shielding film formed on a wall surface of a metal base material, comprising:
- a plurality of ceramic hollow particles;
- and
- metal phases to which the plurality of ceramic hollow particles are joined at points, wherein
- each of the plurality of ceramic hollow particles is joined at a point, through the metal phase, to another ceramic hollow particle among the plurality of ceramic hollow particles so that the plurality of ceramic hollow particles are joined to each other, and
- the plurality of ceramic hollow particles of the heat-shielding film and the wall surface are joined at points to the metal phases so that the plurality of ceramic hollow particles are joined to the wall surface, wherein
- the plurality of ceramic hollow particles consist of ceramic hollow particles having two different average particle sizes,
- a first layer of the ceramic hollow particles having a smaller average particle size among the two different average particle sizes is joined to the wall surface through the metal phases, and
- a second layer of the ceramic hollow particles having a larger average particle size among the two different average particle sizes is disposed above the first layer, and joined to the first layer.
A method of forming a heat-shielding film in which a plurality of ceramic hollow particles are joined at points to metal phases, and each of the plurality of ceramic hollow particles is joined at a point, through the metal phase, to another ceramic hollow particle among the plurality of ceramic hollow particles so that the plurality of ceramic hollow particles are joined to each other, wherein the plurality of ceramic hollow particles of the heat-shielding film are joined to a wall surface of a metal base material at points through the metal phases, the forming method comprising:
- mixing the plurality of ceramic hollow particles with metal particle paste made of at least metal particles and a solvent to generate a slurry;
- applying the slurry to the wall surface of the metal base material;
- carrying out heating at a temperature that is a boiling point of the solvent or higher to volatilize the solvent;
- and
- further carrying out heating at a temperature that is a melting temperature of the metal particles or higher to melt the metal particles and to sinter molten metal between the plurality of ceramic hollow particles so that the metal phases are formed, wherein
- the plurality of ceramic hollow particles consist of ceramic hollow particles having two different average particle sizes,
- a first layer of the ceramic hollow particles having a larger average particle size among the two different average particle sizes is joined to the wall surface through the metal phases, and
- a second layer of the ceramic hollow particles having a smaller average particle size among the two different average particle sizes is disposed above the first layer, and joined to the first layer.
A method of forming a heat-shielding film in which a plurality of ceramic hollow particles are joined at points to metal phases, and each of the plurality of ceramic hollow particles is joined at a point, through the metal phase, to another ceramic hollow particle among the plurality of ceramic hollow particles so that the plurality of ceramic hollow particles are joined to each other, wherein the plurality of ceramic hollow particles of the heat-shielding film are joined to a wall surface of a metal base material at points through the metal phases, the forming method comprising:
- mixing the plurality of ceramic hollow particles with metal particle paste made of at least metal particles and a solvent to generate a slurry;
- applying the slurry to the wall surface of the metal base material;
- carrying out heating at a temperature that is a boiling point of the solvent or higher to volatilize the solvent;
- and
- further carrying out heating at a temperature that is a melting temperature of the metal particles or higher to melt the metal particles and to sinter molten metal between the plurality of ceramic hollow particles so that the metal phases are formed, wherein
- the plurality of ceramic hollow particles consist of ceramic hollow particles having two different average particle sizes,
- a first layer of the ceramic hollow particles having a smaller average particle size among the two different average particle sizes is joined to the wall surface through the metal phases, and a second layer of the ceramic hollow particles having a larger average particle size among the two different average particle sizes is disposed above the first layer, and joined to the first layer.
Dependencies are inferred from the claim text.