GLASSLIKE CARBON COMPOSITE MATERIAL AND METHOD OF PREPARING THE SAME

Abstract: The present invention provides a glasslike carbon composite material which is less frictional against and causes less damages and scars to members to be con­ tacted with, and is in itself excellent in wear resistance and durability because of the addition of specific ultra­ fine ceramic particles as a reinforcing material to the main component glasslike carbon. The present invention further provides a method for preparing such a glasslike carbon composite material, as well as a similar method for preparing a glasslike carbon material.

Description: The present invention relates to a method for preparing a glasslike carbon composite material. Various recording/reproduction devices are currently available on the market which use sheets and films having a magnetic layer, or paper as the recording medium. These recording/reproduction devices include a number of elements which either constantly or temporarily come into a sliding contact with the recording medium, such as a head slider of a flexible disk, floating slide of a hard disk, a thermal printing head, and a magnetic head. These elements are required to have excellent durability and properties which would not damage the recording medium coming in sliding contact therewith. Moreover, these elements, the magnetic head in particular, are subject to super precision processings in the order of several micrometres to several tens of micrometres. The materials in turn are required to have high performance in precision processing. Silicon dioxides, alumina (aluminium dioxides), silicon carbides, hard glasses, alumina ceramics, ferrites, calcium titanates and barium titanates are commonly used as the material for such elements. Although these materials are suited for precision parts, their hardness and inferior slidability are likely to cause damages on the recording medium. Graphites are known as a material having high slidability. However, they are highly susceptible to wear and are not stable in maintaining their shape over a long period of time. Because of the constituent particles, they are insufficient in density and thus are not suited for use in precision parts. Various studies were conducted to overcome these defects and it was found out that glasslike carbon is effective in solving the defects. Patent applications have been filed for the findings and laid open as Jap. Pat. Appln. Laid-open Nos. Sho 59-84325 and Sho 59-144019. Glasslike carbon has an appropriate degree of wearability which, when slid against another material, becomes worn before the other material is damaged. Applications concerning a method of preparing glasslike carbon having excellent wear resistance are laid open under the Nos. Sho. 60-171209, Sho 60-131816, Sho 60-171208, Sho 60-171209, Sho 60-171210 and Sho 60-171211. Upon further experiments, it was found that glasslike carbon may sometimes fail to give sufficient wear resistance when used alone depending on the surface hardness or coarseness of the materials to be contacted with. From US-A-4 466 932 a method for preparing a glasslike carbon composite material is known which uses a granular or powdery starting material comprising a heat moldable resin and an inorganic filler from which a pre cursor article is molded. This article is then carbonized in an inert atmosphere at a temperature between 500°C and 2500°C. However, the filler does not scatter homogeneously in the granular or powdery starting material which effects the quality of the composite material. The present invention aims to provide a method for preparing a glasslike carbon composite material for sliding elements that can be used without coating the material with a lubricant or protective film and which (1) has small friction resistance against the material to be contacted with, (2) would not damage the material to be contacted with, and (3) is excellent in its wear resistance and durability. Therefore, the invention concerns a method for preparing a glasslike carbon composite material comprising the steps of hardening a material containing a thermosetting resin as the main component as liquid and carbonizing the material thus treated by heating, wherein said carbonization process further includes a pretreatment by heating at a temperature between 800°C and 1200°C and a heat treatment under high pressure by heating in an inert atmosphere at a pressure of 101.3 MPa (1000 atm) or higher and at a temperature between 1200°C and 1600°C. It is preferred that the material containing a thermosetting resin as its main component is added as its unhardened precursor with one or more types of whiskers selected from silicon carbide, silicon nitride and graphite and said heat treatment under high pressure is conducted at a temperature between 1200°C and 1500°C. Furthermore, it is preferred that the method comprises the steps of mixing an unhardened precursor of a thermosetting resin with ultrafine particles having the average particle size of 1 µm or less and containing one or more types selected from metal oxides, metal nitrides, metal cabides and metal borides; hardening the resin; and pretreating the resin by heating at a temperature between 800°C and 1200°C and carbonizing the resin under high pressure by heating in an inert atmosphere at a pressure of 101.3 MPa (1000 atm) or higher and at a temperature between 1200°C and 1500°C. Ultrafine particles of alumina, silicon carbides, titanium carbides, silicon oxides, silicon nitrides, and titanium borides are particularly suitable for the present invention. Glasslike carbon to be used as the main component of the composite material may include those obtained by carbonizing thermosetting resins such as furan and phenol, and those obtained by carbonizing resins modified by co-polymerization or co-polycondensation to give thermosetting property such as phenol resins. Non-porous glasslike carbons obtained from the starting material of thermosetting resins which may contain more than 20% of water in the state of initial condensate are particularly preferable as disclosed in the Jap. Pat. Appln. Laid-open Nos. Sho 60-171208, Sho 60-171209, Sho 60-171210 and Sho 60-171211. The glasslike carbons are amorphous and have adequate degree of wearability so that when slid against a recording medium, they would become worn before damaging the surface layer of the recording medium. Ultrafine particles can be prepared by gas phase reactions such as evaporation in an inert gas, plasma evaporation and chemical vapor deposition; or liquid phase reaction such as precipitation, and thermal decomposition of sprayed molten material. Any of these methods can be used in the present invention. The particle size of the ultrafine particles varies depending on the use of the glasslike carbon composite material, but the size is preferably less than 0.1 µm in view of homogeneous property of the glasslike carbons, homogeneous and stable mixing and dispersion with liquid and unhardened precursor. Ultrafine particles to be used in the present invention may include silica particles manufactured by Nippon Aerogel Co., Ltd. (Aerogel 130; primary particle size of ca. 16 nm), ultrafine particles of aluminium oxides (Aluminum oxide C; primary particle size of ca. 20 nm), and of titanium oxides (Titanium oxide P25; primary particle size of ca. 21 nm). Particle size can be measured by a microscope, a coal tar counter, centrifugal precipitation method, electromagnetic wave scattering, and specific surface area measurement. The particle size of ultrafine particles of ceramics according to the present invention were measured using scanning electron microscope. The content of ultrafine particles is preferred to be in the range of 0.005 and 0.2 in volume ratio of the glasslike carbon, and more preferably between 0.005 and 0.1. Excellent precision processability, wear resistance and coefficient of friction can be obtained within the above range. If the content of ultrafine particles is below said range, effects of addition cannot be obtained. If the content exceeds the range, precision processability deteriorates and the coefficient of friction becomes too high. Thermosetting resins alone or unhardened precursors mixed with whiskers as a filler may be used as the resin material containing thermosetting resin as the main component. When the filler is used, the heat treatment under high pressure is preferably conducted at a temperature between 1200°C and 1500°C. As for the ultrafine particles, those mentioned above are used. One or more kinds of whiskers are selected from among the whiskers of silicon carbides, silicon nitrides and graphites and are mixed with the thermosetting resin. Ultrafine particles or whiskers are preferably dispersed in the initial condensate of the resin. Whiskers as used herein are needle-like crystals obtained by natural growth from the solid, condensation of vapor, chemical reactions, one directional freezing of eutectic mixture, electrodeposition, etc. The thickness ranges from less than 0.05 µm to ca. 10µm. The greatest advantage of whiskers is that dislocations and defects are hardly, or never in some cases, observed inside the crystals, giving the crystals almost an ideal strength. The aspect ratio (ratio of thickness and the length) of whiskers is not specifically defined. Generally, however, the greater the aspect ratio, the greater the composite material containing the whiskers becomes in its strength. Use of whiskers having the aspect ratio of more than 10, or more preferably more than 50 demonstrated excellent effect in the glasslike carbon composite material of the present invention. The whisker content is preferably in the range of 0.005 to 0.2 in volume ratio of the glasslike carbon material, and more preferably between 0.005 and 0.1. Excellent precision processability, wear resistance and coefficient of friction can be obtained within the above range. If the whisker content is small, effects of addition can not be obtained. If the content exceeds the above range, precision processability decreases and the coefficient of friction becomes too high. External mechanical force such as hydraulic pressure can be applied to a sealed vessel to directly or indirectly pressurize the material under processing. The pressure inside the sealed vessel can be raised to 1000 atm or more, pressurizing the sample inside the vessel isometrically. The HIP (hot isostatic pressing) treatment is particularly advisable for this method. The HIP treatment applies the pressure of inert gas to the object to be treated at a high temperature. Heat treatment under high pressure achieves the following effects; (1) prevents formation of voids during carbonization; (2) reduces the micropores present in the glasslike carbon material, enabling production of highly dense composite material with improved wear resistance. Heat treatment under high pressure is also effective in enhancing the bonding strength of the filler with the matrix when ultrafine particles and or whiskers are used as the filler. The pretreatment temperature must be raised to 800°C to 1200°C and is preferably between 1000°C and 1200°C. If it exceeds 1200°C, effect of the subsequent heat treatment under high pressure can not be obtained. At a temperature below 800°C, the carbonization under pressure will not exhibit the desired effects. The heat treatment under high pressure is carried out at a temperature between 1200°C and 1600°C when the resin material contains a thermosetting resin alone, and between 1200°C and 1500°C if the resin material contains the filler as well. The temperature is preferred to be higher than 1400°C in either cases. When the thermosetting resin alone is used, glasslike carbon will be graphitized above 1600°C. The glasslike carbon material thus obtained will become easily worn due to delamination. Experiments showed that treatment at a pressure above 101.3 MPa (1000 atm) and a temperature above 1600°C resulted in a significant increase in wear. These appeared a d₀₀₂ peak of graphite near 2ϑ = 26.4° in the wide angle X-ray diffraction profile of the sample by Cu-Kα line. Wear resistance showed a marked decrease in correspondence with the appearance and growth of the graphite peak. These findings indicate that the final temperature of the treatment should not exceed 1600°C. When ultrafine particles or whiskers are mixed in the unhardened precursor, the stress will concentrate on the matrix at the filler surface when the temperature of the heat treatment under high pressure exceeds 1500°C, graphitizing the carbon surrounding the filler. The glasslike carbon material obtained by the treatment will be easily worn due to delamination. Experiments showed that carbonization at a pressure above 101.3 MPa (1000 atm) and at a temperature above 1500°C resulted in a significant increase in wear. It is therefore necessary to maintain the final temperature below 1500°C. Heat treatment under high pressure above 101.3 MPa (1000 atm), more preferably above 151.95 MPa (1500 atm), brings favorable effects. Ultrafine particles and/or whiskers may be subjected to pretreatment, as is done in the manufacture of fiber reinforced plastics (FRP). The pretreatment is conducted to improve the reliability of the final product composite material of glasslike carbon,and may include surface treatment of ultrafine particles and/or whiskers, addition of surfactant to promote dispersion of particles and/or whiskers, and dispersion of high physical shearing force. The glasslike carbon composite material according to the present invention retains the low coefficient of friction which is the characteristic of a glasslike carbon material while its wear resistance is improved. Use of the composite material will enable production of sliding parts which cause less friction with and no damage to the members to be contacted with and yet which in themselves are excellent in wear resistance and durability. Pretreatment of the thermosetting resin under appropriate conditions and subsequent heat treatment under high pressure will result in a glasslike carbon material of higher density and wear resistance as well as improved bending strength. Addition of ultrafine ceramic particles or whiskers to the precursor of the thermosetting resin followed by heat treatment will improve the wear resistance and the bending strength of the material while maintaining the low coefficient of friction of the glasslike carbon material itself. Thus use of the composite material will enable production of sliding parts which cause less friction with and no damage to the members to be contacted with and yet which in themselves are excellent in wear resistance and durability. Types of members to be contacted with the sliding parts differ depending on the use. In case the sliding parts are used as the magnetic head, a head slider of a floppy disk or a floating slider of a hard disk, and then the sliding parts will come in contact with the floppy disk, hard disk or magnetic tape. If the sliding parts are used as the thermal printing head, then the parts will come in contact with paper or polymer sheet whereas the parts will come in contact with steel such as SUJ 2 if used as the ball retainer of a bearing. Such members may have flat or curved surfaces, may be in any shape such as thread, and may be rigid or flexible in their shape. When the composite material of the present invention is used, for example, as a sliding part of a recording medium, its lubricity can be maintained over a long period of time without using a lubricant. The sliding part does not cause damages and scars on the recording medium and yet is in itself less susceptible to wear. Because of electric conductivity of the glasslike carbon material, generation of static electricity can be prevented and the portions in contact with the disk recording medium or the recording medium itself may be subject to less dust adhesion. The glasslike carbon composite material according to the present invention can be used as the head slider of a flexible disk, the floating slider of a hard disk, the thermal printing head, the sliding part of a magnetic head, the ball retainer of a bearing, the ring for high speed throat twisting, the blade of a vane pump, and the bobbins and guides of various types. These parts may be constructed with the composite material alone as an integral part. It is also possible to use the composite material at portions where such parts come in contact with other members such as the recording medium. The glasslike carbon composite material of the present invention can also be used in the separator for fuel cells, mechanical parts and jigs of various types. (Brief Description of the Drawing) Fig. 1 shows the shape of a test piece used in the measurement of coefficient of friction. Fig. 2 shows the shape of a test piece used in the measurement of volume. (Preferred Embodiment of the Invention) The present invention will now be described in more detail by referring to examples. These, however, are given merely as exampels and in no way limit the technical scope of the present inveniton. It is noted that "parts" used in the examples denote parts by weight. (Example 1) One hundred parts of furfuryl alcohol (Kao Quaker Co., Ltd.) are added with 5 parts of 0.011 N-HCl aqueous solution, reacted for 6 hours at 96°C and dehydrated under reduced pressure to obtain a thermosetting resin. The thermosetting resin thus obtained was added with 2 wt% of ultrafine particles of alumina (Nippon Aerogel Co., Ltd., Aluminium oxide C) having the primary particle size of ca. 20 nm and mixed for dispersion in a ball mill. The initial condensate of furfuryl alcohol thus obtained (100 parts) was added and thoroughly agitated with 1.5 parts of aqueous solution containing 70% p-toluene sulfonic acid. The mixture was then charged into a mold of 3 mm in thickness and degassed under the reduced pressure. The mixture was then heated for 3 hours at 50°C - 60°C and further for 5 days at 90°C to obtain a strip of hardened composite resin. The composite resin was placed in a tube furnace, heated to 1200°C in a nitrogen stream at a rate of 10°C/hr and maintained at 1200°C for 2 hours before cooling. The sample had a bending strength of 1050 kg/cm², which is a slight increase from 1000 kg/cm² obtained in a glasslike carbon material without addition of ultrafine alumina particles. The density of the main component glasslike carbon was 1.5 g/cm³. The apparent specific gravity of alumina added thereto was 75 g/liter. The carbon yield, or the weight ratio before and after carbonization, of the resin used was ca. 50%. As 2 parts of ultrafine alumina particles are added to 100 parts of the resin for hardening and carbonization, the alumina addition in respect of 50 parts of glasslike carbon amounts to 2 parts. In view of the specific gravity of ca. 3.9 of the alumina particles, the volume ratio becomes 50/1.5 against 2/3.9; in other words, the volume of alumina is 1.45 against 100 volume parts of the glasslike carbon. Likewise, the volume ratio becomes 3.08, 6.15 and 19.2 respectively when 4 parts, 8 parts and 25 parts of alumina particles are mixed to 100 parts of the resin. Accurate volume ratios can be quantitatively determined by measuring the residual alumina after heat treating the composite material in the air to remove the carbon content. The volume ratios calculated from the weight ratio substantially agree with the accurate volume ratios as measured. (Example 2) Ultrafine alumina particles were added in the ratios of 0.7, 1, 2, 4, 8, 15 and 20 wt% respectively to the thermosetting resin obtained in Example 1, and mixed for dispersion in a sand mill. Carbonization was conducted at 1200°C as in Example 1. Measurement of the samples by X-ray diffraction showed that the vitreous carbon composite material obtained was uniformly dispersed with ultrafine alumina particles. The bending strength of the samples with the alumina additions of 0.7, 1, 2, 4, 8, 15 and 20 wt% was 1000, 1020, 1050, 1080, 1080, 1060 and 1010 kg/cm² respectively. (Example 3) Ultrafine particles of titanium oxide (Nippon Aerogel, Titanium oxide P25) with the average primary particle size of 21 nm were added in the ratios of 2 and 5 wt% respectively to the thermosetting resin obtained in Example 1 and mixed for dispersion in a sand mill. Carbonization was conducted at 1200°C as in Example 1. Measurement of the samples by X-ray diffraction showed that the glasslike carbon composite material obtained was uniformly dispersed with ultrafine particles of titanium carbide. The bending strength of the samples with the additions of 2 and 5 wt% was 1020 and 1050 kg/cm² respectively. (Example 4) To 100 parts of a mixture of spheric semi-hardened phenol resin (Kanebo Co., Ltd., Bell Pearl) and novolac resin powder were added with 2 parts by weight and 5 parts by weight respectively of ultrafine alumina particles used in Example 1 and molded by heating using a heat press, to obtain strips of composite hardened resin. The strips of composite hardened resin were heated to 1200°C in a nitrogen stream at a rate of 10°C/hr and then maintained at this temperature for 2 hours before cooling. The bending strength of the samples with the additions of 2 parts by weight and 5 parts by weight was 1050 and 1060 kg/cm² respectively. (Example 5) A mixture containing 500 parts of furfuryl alcohol and 480 parts of 92% paraformaldehyde was agitated and dissolved at 80°C. A mixture containing 520 parts of phenol, 8.8 parts of sodium hydroxide and 45 parts of water was added dropwise under agitation. After addition was completed, the mixture was reacted for 3 hours at 80°C. A mixture containing 80 parts of phenol, 8.8 parts of sodium hydroxide and 45 parts of water was further added and the resultant mixture was reacted for 4.5 hours at 80°C, and then cooled to 30°C. The mixture was then neutralized with 70% p-toluene sulfonic acid. The neutralized mixture was dehydrated under reduced pressure to remove 150 parts of water and then added with 500 parts of furfuryl alcohol. Viscosity of the resin thus obtained was 680 mPa.s (cps) at 25°C. The amount of water which the resin could hold was measured to be 38%. The initial condensate of the thermosetting resin was added with 2 wt% and 5wt% respectively of ultrafine alumina particles, and mixed for dispersion in a sand mill. Carbonization as in Example 1 was conducted at 1200°C. The bending strength of the sampels with the additions of 2 and 5 wt% was 1070 and 1090 kg/cm² respectively. (Example 6) The initial condensate of the thermosetting resin obtained in Example 1 was added with ultrafine particles of alpha-type silicon carbide (Hakusui Chemical Co., Ltd.) in the ratios of 2 wt% and 5 wt% respectively and mixed for dispersion in a sand mill. Carbonization as in Example 1 was conducted at 1200°C. Measurement by X-ray diffraction showed that the samples obtained were a glasslike carbon composite material containing alpha-type silicon carbide. The bending strength of the samples with the additions of 2 and 5 wt% was 1080 and 1090 kg/cm² respectively. (Example 7) A mixture containing 500 parts of furfuryl alcohol and 480 parts of 92% paraformaldehyde was agitated and dissolved at 80°C. A mixture containing 520 parts of phenol, 8.8 parts of sodium hydroxide and 45 parts of water was added dropwise under agitation. After addition was completed, the mixture was reacted for 3 hours at 80°C. A mixture containing 80 parts of phenol, 8.8 parts of sodium hydroxide and 45 parts of water was further added, and the resultant mixture was reacted for 4.5 hours at 80°C and cooled to 30°C. The mixture was then neutralized with 70% p-toluene sulfonic acid. The neutralized mixture was dehydrated under reduced pressure to remove 150 parts of water and then added with 500 parts of furfuryl alcohol. The viscosity of the resin obtained was 680 cps at 25°C. Amount of water which the resin could hold was measured to be 38%. The thermosetting resin was charged into a mold of 5 mm in thickness and defoamed under reduced pressure. The resin was then reacted for 3 hours at 50 - 60°C and for another 5 days at 90°C. The strip of resin was placed in a tube furnace, heated to 1200°C in a nitrogen stream at a rate of 2 - 5°C/hr and maintained at this temperature for 2 hours before cooling. The glasslike carbon material was then inserted in the probe of an HIP equipment and treated for 2 hours under a pressure of 202.6 MPa (2000 atm) at 1400°C. The density of the sample obtained was 1.60 g/cm³ and the bending strength 1200 kg/cm². (Example 8) The initial condensate of the thermosetting resin obtained in example 7 was added with ultrafine alumina particles (Nippon Aerogel, Aluminum oxide C (Delta Alumina)) having the average primary particle size of ca. 20 nm in the ratios of 2 wt% and 5wt% respectively, and mixed for dispersion. Carbonization as in Example 7 was conducted at 1200°C. The carbonized material was inserted in the probe of an HIP equipment and treated for 2 hours at 1400°C and 202.6 MPa (2000 atm). Measurement by X-ray diffraction showed that the samples obtained were a glasslike carbon composite material containing delta alumina. The density of the samples was 1.65 g/cm³ with the addition of 2 wt% of ultrafine particles and 1.73 g/cm³ with 5 wt% addition respectively. The bending strength was 1260 and 1300 kg/cm² respectively. (Example 9) The thermosetting resin obtained in Example 7 was added with ultrafine particles of titanium oxide (Nippon Aerogel, Titanium oxide P25) having the average primary particle size of 21 nm in the ratios of 2 wt% and 5 wt% respectively. The resultant mixture was carbonized as in Example 7 at 1200°C and then treated in an HIP equipment at 1400°C and 202.6 MPa (2000 atm). Measurement by X-ray diffraction showed that the samples were a glasslike carbon composite material containing titanium carbide. The density and the bending strength of the samples added with 2 wt% and 5 wt% were respectively 1.63 g/cm³ and 1220 kg/cm², and 1.68 g/cm³ and 1300 kg/cm². (Example 10) The thermosetting resin obtained in Example 7 was added with ultrafine particles of silicon carbide (Hakusui Chemical Co., Ltd., alpha-SiC) having the average primary particle size of 0.06 µm at the ratios of 2 wt% and 5 wt% respectively and mixed for dispersion in a sand mill. The resultant mixture was carbonized as in Example 7 at 1200°C and then treated in an HIP equipment at 1400°C and 202.6 MPa (2000 atm). Measurement by X-ray diffraction showed that the samples obtained were a glasslike carbon composite material containing alpha-type silicon carbide. The density and the bending strength of these samples with the additions of 2 wt% and 5 wt% were respectively 1.68 g/cm³ and 1250 kg/cm², and 1.75 g/cm³ and 1280 g/cm². (Example 11) The thermosetting resin obtained in Example 7 was added with whiskers of beta-type silicon carbide having the diameter of 0.05 - 1.5 µm, the length of 20 - 200 µm and the specific gravity of 3.18 (Tateho Chemical Industries Co., Ltd., Silicon carbide whisker SCW) at the ratios of 2 wt% and 5 wt% respectively. Polyethylene oxide (molecular weight 600,000 - 1,100,000) was added at the ratio of 0.25 wt% as an aqueous surfactant, and mixed for dispersion in a sand moll. The resultant mixture was carbonized as in Example 7 at 1200°C and then treated in an HIP equipment at 1400°C and 202.6 MPa (2000 atm). Measurement by X-ray diffraction showed that the glasslike carbon composite material obtained contained beta-type silicon carbide. The density and the bending strength with the additions of 2 wt% and 5 wt% were respectively 1.67 g/cm³ and 1900 kg/cm², and 1.74 g/cm³ and 2400 kg/cm². (Comparison 1) For comparison with Examples 1 through 10, alumina ceramics (Nippon Electric Glass Co., Ltd., "Neoceram") was used in the Comparison 1 in the following tests. (Comparison 2) Likewise, calcium titanate (Sumitomo Special Metals Co., Ltd., "TC-105") was used as Comparison 2. (Comparison 3) In order to compare the effects of the mixing ratio 0.3% by volume of ultrafine alumina particles was added to the glasslike carbon in the same manner as in Example 1 to prepare a composite material. (Comparison 4) In the same manner as in Example 1, 25% by volume of ultrafine alumina particles was added to the glasslike carbon to obtain composite material. (Comparison 5) In order to compare the effects of carbonization treatments, strips of thermosetting resin obtained in the process of Example 6 were heated to 1400°C without the treatment in an HIP equipment. The density of the obtained sample was 1.51 g/cm³ and the bending strength 1000 kg/cm². (Comparison 6) In the same manner as in Example 10, the thermosetting resin obtained in Example 7 was added with ultrafine particles of silicon carbide at the ratios of 2 wt% and 5 wt% respectively and mixed for dispersion in a sand mill. Heat treatment was conducted by raising the temperature to 1400°C. No HIP treatment was conducted. Measurement by X-ray diffraction showed that the samples obtained was a composite material of alpha-type silicon carbide and glasslike carbon. The density and the bending strength of the samples with the additions of 2 wt% and 5 wt% were respectively 1.55 g/cm³ and 1080 kg/cm², and 1.59 g/cm³ and 1090 kg/cm². (Comparison 7) In the same manner as in Example 10, the thermosetting resin obtained in Example 1 was added with ultrafine particles of silicon carbide at the ratios of 2 wt% and 5 wt% respectively and mixed for dispersion in a sand mill. The mixtures were heat treated at 700°C and HIP treated at 1400°C and 202.6 MPa (2000 atm). Measurement by X-ray diffraction showed that the samples obtained were a composite material containing alpha-type silicon carbide and glasslike carbon. The density and the bending strength of the samples with the additions of 2 wt% and 5 wt% were respectively 1.67 g/cm³ and 1000 kg/cm², and 1.74 g/cm³ and 1050 kg/cm². (Comparison 8) In the same manner as in Example 10, the thermosetting resin obtained in Example 7 was added with ultrafine particles of silicon carbide at the ratios of 2 wt% and 5 wt% respectively and mixed for dispersion in a sand mill. The mixtures were heat treated at 1200°C and HIP treated at 1600°C and 202.6 MPa (2000 atm). Measurement by X-ray diffraction showed that the samples were a composite material containing alpha-type silicon carbide and vitreous carbon, and the portion of which have been graphitized. The density and the bending strength of the samples with the additions of 2 wt% and 5 wt% were respectively 1.69 g/cm³ and 1200 kg/cm², and 1.76 g/cm³ and 1200 kg/cm². (Tests and Results) Samples obtained in the above Examples 1 through 11 and Comparisons 1 through 8 were processed, and coefficient of friction and the amount of wear were measured. (i) Measurement of coefficient of friction Fig. 1 shows the shape of a test piece used for the measurement of coefficient of friction. The test pieces were obtained by cutting out a piece each from the samples obtained in Examples 1 through 11 and Comparisons 1 through 8 in the shape of a rectangular parallelepiped (width ª 4.0 mm x depth b 6.0 mm x height h 3.0 mm). The sliding surface A was gradually polished from coarse to fine finish, to finally obtain a mirror finish using Emery paper #15000. The edges surrounding the sliding surface A were rounded off using coarser Emery paper to a radius of 0.2 ∼ 0.3 mm to prepare test pieces for measuring coefficient of friction. Using the test pieces, coefficient of friction was measured by the so-called "pin-on-disk method". The test pieces were mounted on a gimbal spring used as the driving device of a floppy disk, applied with a load of ca. 20 g from above and slid against the spindle rotating at an arbitrary speed as well as against the floppy disk mounted on a rotating plate. The force of friction was measured using a strain gauge attached to the arm of the device to estimate the coefficient of friction µ. (ii) Measurement of wear Fig. 2 shows the shape of a test piece used for the measurement of wear. Each test piece is grooved to a size of width w in 0.5 mm and depth d in several µm on its sliding surface A using a slicing machine. The distance r from the edge of the groove is 2.0 mm. Using a precision measurement device (Kosaka Laboratories, Co., Ltd., HIPOSS ET-10), the sectional profile of the groove was obtained to determine the groove depth. The test piece was mounted on a gimbal spring which was attached to the head of a floppy disk driving device. The test piece was applied with a load of 20 g and slid against the floppy disk. By moving the head for one track each time the floppy disk rotates to cause wear of the test piece. The groove depth of the test piece was chronologically measured to determine the depth of wear. (iii) Test results Test results are shown in Tables 1 through 8; Tables 1 through 6 show the test results in Examples 1 through 6 respectively, wherein ultrafine particles are added; Table 7 shows the results obtained from Examples 7 through 11, wherein pretreatment and heat treatment under high pressure were conducted. Table 8 shows the test results in Comparisons 1 through 8. In these Tables, "amount of fine particles" or "amount of addition" represent the amount of addition in parts by volume with respect to 100 parts by volume of the glasslike carbon. Under the column of "disk type", the reference A denotes a gamma-Fe₂O₃ coated disk and B a Co-Cr sputtered disk.

Claims: A method for preparing a glasslike carbon composite material comprising the steps of hardening a material containing a thermosetting resin as the main component as liquid and carbonizing the material thus treated by heating, wherein said carbonization process further includes a pretreatment by heating at a temperature between 800°C and 1200°C and a heat treatment under high pressure by heating in an inert atmosphere at a pressure of 101.3 MPa (1000 atm) or higher and at a temperature between 1200°C and 1600°C. The method according to claim 1, wherein the material containing a thermosetting resin as its main component is added as its unhardened precursor with one or more types of whiskers selected from silicon carbide, silicon nitride and graphite and said heat treatment under high pressure is conducted at a temperature between 1200°C and 1500°C. The method according to claim 1 or 2, comprising the steps of mixing an unhardened precursor of a thermosetting resin with ultrafine particles having the average particle size of 1µm or less and containing one or more types selected from metal oxides, metal nitrides, metal carbides and metal borides; hardening the resin; and pretreating the resin by heating at a temperature between 800°C and 1200°C and then carbonizing the resin under high pressure by heating in an inert atmosphere at a pressure of 101.3 MPa (1000 atm) or higher and at a temperature between 1200°C and 1500°C.

Inventors: ISHIKAWA, ATSUSHI, NAGAMORI, HIROYUKI, WAKASA, MASANOBU, YAMAUCHI, MICHIHIDE
Applicants: KAO CORPORATION
Application year: 1987
Main classification: C04B35
IPC codes: G11B15, C04B35, G11B5, F16C33, G11B17