Bell particles, bell particle compact, method for producing bell particles, and method for manufacturing bell particle compact

Abstract

Bell particles comprise a plurality of core particles and porous particles having a plurality of accommodation voids for accommodating the plurality of core particles. A bell particle compact comprises any of the bell particles described above, and a compact containing the bell particles. A method for producing bell particles comprises: a coating step for coating core particles with a water-soluble material; a granulation step for mixing and granulating a plurality of coated core particles, in which the core particles are coated with the water-soluble material, and a plurality of granulation particles; and a washing step for washing granulated products of the plurality of coated core particles and the plurality of granulation particles with a dissolving solution for dissolving the water-soluble material.

Description

Bell particles, bell particle compact, method for manufacturing bell particles, and method for manufacturing bell particle compact

[0001] The present disclosure relates to bell particles having a bell structure, a bell particle compact, a method for manufacturing bell particles, and a method for manufacturing a bell particle compact.

[0002] Japanese Patent No. 5537258 describes bell-structured particles (bell particles) in which core particles smaller than the outer shell are enclosed within the pores of the shell. These bell particles convert the kinetic energy of vibrations and sounds into the movement of core particles within the pores of the shell and consume it, thereby enabling extremely high efficiency attenuation of vibrations and sounds.

[0003] Considering the vibration-damping performance of bell particles, it is conceivable to apply bell particles to various components. For example, adding bell particles to resin and then injection molding or extrusion molding can produce resin components with a bell structure. Adding bell particles to metal and then casting can produce metal components with a bell structure. However, in either case, high pressure is applied to the bell particles. The bell particles described in Japanese Patent No. 5537258 have a structure in which one large void is formed in a thin shell, and therefore cannot be said to have sufficient pressure resistance. For this reason, it is difficult to apply the bell particles described in Japanese Patent No. 5537258 to various components.

[0004] Furthermore, the bell particles described in Japanese Patent No. 5537258 have only one bell structure, and therefore there is a limit to how much vibration damping can be improved.

[0005] An object of the present disclosure is to provide bell particles, bell particle compacts, methods for manufacturing bell particles, and methods for manufacturing bell particle compacts that are highly pressure-resistant and vibration-damping.

[0006] The bell particle according to the present disclosure comprises a plurality of core particles and a porous particle having a plurality of accommodating pores for accommodating the plurality of core particles.

[0007] In this bell particle, multiple core particles are housed in multiple housing holes, resulting in a multiple bell structure. This allows for high vibration damping. Furthermore, the porous particle housing multiple core particles has a structure with higher rigidity than conventional bell particles, which have a structure in which one large hole is formed in a thin shell. This allows for high pressure resistance.

[0008] In the above-described bell particles, the porous particles may have a group of interconnected pores in which a plurality of pores are interconnected and open from the porous particles. As described below, the above-described bell particles can be produced by coating core particles with a water-soluble material, mixing a plurality of coated core particles and a plurality of granulation particles to granulate, and washing the granulated product with a dissolving liquid. In these bell particles, the porous particles have a group of interconnected pores in which a plurality of pores are interconnected and open from the porous particles, so that the water-soluble material can be easily discharged outside the porous particles when producing the bell particles. This makes it easy to produce bell particles.

[0009] In the above-described bell particles, the maximum particle size of the bell particles may be 10 μm or more and 2000 μm or less. By setting the maximum particle size of the bell particles to 10 μm or more and 2000 μm or less, the ease of manufacturing can be ensured and the bell particles can be easily applied to various components.

[0010] In the above-mentioned bell particles, the core particles may have a resin material, an inorganic material, or a metal material.

[0011] In the above-mentioned bell particles, the porous particles may have a resin material, an inorganic material, or a metal material.

[0012] The bell particle described above may further include a pressure-resistant reinforcement layer disposed on the outside of the porous particle. Since the bell particle includes the pressure-resistant reinforcement layer disposed on the outside of the porous particle, it is possible to obtain even higher pressure resistance.

[0013] In the bell particle described above, the porous particle may have a group of interconnected pores, each of which is formed by interconnecting a plurality of pores and opening from the porous particle, and the pressure-resistance reinforcing layer may cover the openings of the group of interconnected pores in the porous particle. In this bell particle, the pressure-resistance reinforcing layer covers the openings of the group of interconnected pores in the porous particle, thereby achieving even higher pressure resistance. Furthermore, when the bell particle is used in various components, it is possible to prevent other components, such as molten resin or molten metal, from entering the group of interconnected pores.

[0014] In the bell particle described above, the pressure-resistance reinforcing layer may cover the entire porous particle. By covering the entire porous particle with the pressure-resistance reinforcing layer, the bell particle can achieve even higher pressure resistance. Furthermore, when the bell particle is used in various components, it is possible to prevent other components, such as molten resin or molten metal, from entering the interconnected pores.

[0015] In the above-mentioned bell particle, the pressure-resistant layer may include a resin material or an inorganic material.

[0016] The present disclosure provides a bell particle compact comprising any of the bell particles described above and a compact containing the bell particles. Since the compact contains the bell particles described above, the bell particle compact can achieve high vibration damping properties.

[0017] In the above-described bell particle molded body, the molded body may be a resin molded body. In this bell particle molded body, since the molded body is a resin molded body, high pressure is applied to the bell particles during manufacturing. However, since the bell particles have high pressure resistance, it is possible to prevent the bell particles from being broken during manufacturing. This allows for high vibration damping properties to be obtained.

[0018] In the above-described bell grain compact, the compact may be a metal compact. In this bell grain compact, since the compact is a metal compact, high pressure is applied to the bell grains during manufacturing. However, since the bell grains have high pressure resistance, it is possible to prevent the bell grains from being broken during manufacturing. This allows for high vibration damping properties to be obtained.

[0019] The method for producing bell particles according to the present disclosure is a method for producing bell particles, and includes a coating step of coating core particles with a water-soluble material, a granulation step of mixing and granulating a plurality of coated core particles, each of which is a core particle coated with a water-soluble material, and a plurality of granulation particles, and a washing step of washing the granulated product of the plurality of coated core particles and the plurality of granulation particles with a dissolving liquid that dissolves the water-soluble material.

[0020] In this method for producing bell particles, core particles are coated with a water-soluble material, and multiple coated core particles and multiple granulation particles are mixed and granulated, resulting in a state in which each of the multiple coated core particles is surrounded by multiple granulation particles. Since the granulated material is formed by granulation of multiple particles, gaps are formed between the multiple particles. Furthermore, at least two of the multiple coated core particles are connected to each other through the gaps between the particles and also to the outside of the granulated material through the gaps between the particles. Therefore, when the granulated material is washed with a solvent, the water-soluble material is dissolved in the solvent and discharged to the outside of the granulated material, forming gaps between each of the multiple core particles and the multiple granulation particles, allowing each of the multiple core particles to move freely. This allows the production of the above-mentioned bell particles.

[0021] In the above-described method for producing bell particles, the granulation step may be performed so that at least one coated core particle is disposed on the surface of the granulated product. In this method for producing bell particles, by granulating so that at least one coated core particle is disposed on the surface of the granulated product, a path for removing the water-soluble material can be secured. This allows the water-soluble material to be easily removed.

[0022] In the above-described method for producing bell particles, the granulation step may include a bonding step of bonding a plurality of granulation particles to each other. In this method for producing bell particles, by bonding a plurality of granulation particles to each other, it is possible to produce bell particles having even higher pressure resistance.

[0023] In the above-described method for producing bell particles, the coated core particles, the granulation particles, and the binder may be mixed and granulated in the granulation step. In this method for producing bell particles, the coated core particles, the granulation particles, and the binder are mixed and granulated, which allows for easy granulation.

[0024] The above-described method for producing bell particles may further include a pressure-resistant layer forming step of forming a pressure-resistant layer disposed on the outside of the granules after the washing step. In this method for producing bell particles, by forming a pressure-resistant layer disposed on the outside of the granules, it is possible to produce bell particles with even higher pressure resistance.

[0025] In the above-described method for manufacturing bell particles, the pressure-resistance reinforcing layer forming step may include forming a coating layer of thermosetting resin on the surface of the bell particle and thermally curing the coating layer to form the pressure-resistance reinforcing layer. In this method for manufacturing bell particles, a coating layer of thermosetting resin is formed on the surface of the bell particle and thermally curing the coating layer to form the pressure-resistance reinforcing layer of thermosetting resin.

[0026] In the above-described method for manufacturing bell particles, the pressure-reinforcing layer forming step may include forming a ceramic coating layer on the surface of the bell particles by a sol-gel method and sintering the coating layer to form the pressure-reinforcing layer. In this method for manufacturing bell particles, the ceramic pressure-reinforcing layer can be formed by forming a ceramic coating layer on the surface of the bell particles by a sol-gel method and sintering the coating layer.

[0027] The method for manufacturing a bell grain compact according to the present disclosure is a method for manufacturing a bell grain compact, and includes a molding step of adding any of the bell grains described above to a molding material from which the bell grain compact is molded to form the bell grain compact. In this method for manufacturing a bell grain compact, the bell grain compact can be easily manufactured because the bell grain compact is molded by adding the bell grains described above to the molding material.

[0028] In the above-mentioned manufacturing method of a bell particle molded body, the molding material may be a resin material, and in the molding process, the resin material to which bell particles have been added may be injection molded. In this manufacturing method of a bell particle molded body, by injection molding the resin material to which the bell particles have been added, it is possible to easily mold a resin bell particle molded body.

[0029] In the above-mentioned manufacturing method of a bell particle molded body, the molding material may be a resin material, and in the molding process, the resin material to which bell particles have been added may be extruded. In this manufacturing method of a bell particle molded body, the resin bell particle molded body can be easily molded by extruding the resin material to which the bell particles have been added.

[0030] In the above-described method for manufacturing a bell particle compact, the molding material may be a metal material, and the molding step may involve casting the metal material to which the bell particles have been added. In this method for manufacturing a bell particle compact, the above-described metal material to which the bell particles have been added may be cast, thereby easily forming a metal bell particle compact.

[0031] According to the present disclosure, it is possible to obtain bell particles, bell particle compacts, methods for manufacturing bell particles, and methods for manufacturing bell particle compacts that have high pressure resistance and vibration damping properties.

[0032] FIG. 1 is a schematic cross-sectional view of a bell particle according to a first embodiment. FIG. 2 is a schematic cross-sectional view of a bell particle compact according to the first embodiment. FIG. 3 is a schematic cross-sectional view for explaining a method for manufacturing bell particles according to the first embodiment. FIG. 4 is a schematic cross-sectional view for explaining a method for manufacturing bell particles according to the first embodiment. FIG. 5 is a schematic cross-sectional view for explaining a method for manufacturing bell particles according to the first embodiment. FIG. 6 is a schematic cross-sectional view of a bell particle according to a second embodiment. FIG. 7 is a schematic cross-sectional view of a bell particle compact according to the second embodiment. FIG. 8 is a schematic cross-sectional view for explaining a method for manufacturing bell particles according to the second embodiment.

[0033] Hereinafter, embodiments of the bell particle, bell particle compact, bell particle manufacturing method, and bell particle compact manufacturing method according to the present disclosure will be described in detail with reference to the drawings. In the drawings, the same or corresponding parts are designated by the same reference numerals, and redundant explanations will be omitted.

[0034] [First embodiment] (Bell particle) Fig. 1 is a schematic cross-sectional view of a bell particle according to the first embodiment. As shown in Fig. 1, the bell particle 1 according to this embodiment includes a plurality of core particles 2 and a porous particle 3 having a plurality of accommodation cavities 4 that accommodate (enclose) the plurality of core particles 2.

[0035] The plurality of core particles 2 are accommodated in the plurality of accommodation holes 4 of the porous particle 3. Each of the plurality of core particles 2 (hereinafter also simply referred to as a "core particle 2") is not fixed to the porous particle 3 and can move freely within the accommodation hole 4.

[0036] The material of the core particle 2 is not particularly limited, but may be, for example, one or more of a resin material, an inorganic material, and a metal material.

[0037] When the core particle 2 has a resin material or is made of a resin material, the resin material that constitutes the core particle 2 can be, for example, a thermosetting resin such as a phenol resin or an epoxy resin.

[0038] When the core particle 2 has an inorganic material or is made of an inorganic material, the inorganic material that constitutes the core particle 2 may be, for example, a ceramic or a carbon material.

[0039] When the core particle 2 has a metal material or is made of a metal material, the metal material that constitutes the core particle 2 may be, for example, iron, copper, tin, aluminum, or other simple substances or various alloys.

[0040] The maximum particle size of the core particle 2 is not particularly limited, but can be, for example, 0.1 μm to 500 μm, 1 μm to 100 μm, or 1 μm to 10 μm. The core particle 2 may be spherical, such as a perfect sphere, or may be non-spherical, such as a columnar or flat shape. The maximum particle size of the core particle 2 refers to the diameter of the core particle 2 at the position where the particle size of the core particle 2 is greatest.

[0041] The porous particles 3 are porous bodies having a plurality of pores formed therein. The porous particles 3 can be formed, for example, from a granulated body made of a plurality of particles, a sintered granulated body, a compacted body, or a sintered body after being compacted.

[0042] The porous particle 3 has a plurality of voids including a plurality of storage cavities 4. In other words, the plurality of storage cavities 4 are a part of a plurality of voids formed in the porous particle 3. The plurality of voids formed in the porous particle 3 may include voids that do not house core particles 2. Each of the plurality of storage cavities 4 (hereinafter simply referred to as "storage cavities 4") may house one core particle 2 or two or more core particles 2.

[0043] The porous particle 3 has a group of interconnected voids 5 in which the plurality of storage voids 4 are interconnected and open from the porous particle 3. That is, the group of interconnected voids 5 is a space having a plurality of storage voids 4 that are interconnected and also a space that is open from the porous particle 3. The group of interconnected voids 5 may include voids that do not accommodate core particles 2. The number of groups of interconnected voids 5 that the porous particle 3 has is not particularly limited and may be one or more. The porous particle 3 may have isolated voids that are not interconnected with other voids, may have a group of interconnected voids in which a plurality of voids that do not include a plurality of storage voids 4 are interconnected and open from the porous particle 3, or may have a group of interconnected voids in which a plurality of voids are interconnected and do not open from the porous particle 3.

[0044] The material of the porous particles 3 is not particularly limited, but may be, for example, one or more of a resin material, an inorganic material, and a metal material.

[0045] When the porous particles 3 have a thermosetting resin or are made of a thermosetting resin, the resin material that constitutes the porous particles 3 can be, for example, a thermosetting resin such as a phenolic resin or an epoxy resin.

[0046] When the porous particles 3 contain an inorganic material or are made of an inorganic material, the inorganic material that constitutes the porous particles 3 may be, for example, a ceramic or a carbon material.

[0047] When the porous particles 3 contain a metal material or are made of a metal material, the metal material that constitutes the porous particles 3 can be, for example, iron, copper, tin, aluminum, or other simple substances or various alloys.

[0048] The minimum inner diameter of the accommodation cavity 4 is not particularly limited, but may be, for example, 0.2 μm to 1000 μm, 2 μm to 200 μm, or 2 μm to 20 μm. The minimum inner diameter of the accommodation cavity 4 refers to the diameter of a sphere inscribed in the accommodation cavity 4.

[0049] The maximum particle size of the bell particle 1 is not particularly limited, but can be, for example, 10 μm to 2000 μm, 20 μm to 1000 μm, or 40 μm to 500 μm. The bell particle 1 may be spherical, such as a perfect sphere, or non-spherical, such as a columnar or flat shape. The maximum particle size of the bell particle 1 refers to the diameter of the bell particle 1 at the point where the particle size of the bell particle 1 is largest.

[0050] (Bell Grain Compaction) Fig. 2 is a schematic cross-sectional view of a bell grain compaction according to the first embodiment. As shown in Fig. 2, a bell grain compaction 10 according to this embodiment includes a compaction 11 and bell grains 1 arranged within the compaction 11. The number of bell grains 1 arranged within the compaction 11 is not particularly limited, and may be one or more.

[0051] The material of the molded body 11 is not particularly limited, but may be, for example, a material containing either or both of a resin material and a metal material.

[0052] When the molded body 11 has a resin material or is made of a resin material, the resin material that constitutes the molded body 11 can be, for example, plastic materials such as polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polystyrene (PS), acrylonitrile butadiene styrene (ABS), polyphenylene sulfide (PPS), polyurethane (PU), epoxy resin, phenolic resin, melamine resin, etc., or rubber materials such as natural rubber (NR), styrene butadiene rubber (SBR), acrylonitrile butadiene rubber (NBR), chloroprene rubber (CR), ethylene propylene rubber (EPM), ethylene propylene diene rubber (EPDM), silicone rubber, urethane rubber, various thermoplastic elastomers, etc.

[0053] When the molded body 11 has a metal material or is made of a metal material, the metal material constituting the molded body 11 may be, for example, aluminum, an aluminum alloy, or the like.

[0054] Examples of the bell grain molded body 10 include structural members, housings, gears, three-dimensional members such as bearings, and sheet-like members such as vibration dampers and sound insulating plates.

[0055] (Method for manufacturing bell particles) Next, a method for manufacturing bell particles will be described with reference to Figs. 3 to 5. Figs. 3 to 5 are schematic cross-sectional views for explaining the method for manufacturing bell particles according to the first embodiment. The method for manufacturing bell particles according to this embodiment is a method for manufacturing the bell particles 1 described above. Note that the method for manufacturing bell particles described below is one example of a method for manufacturing bell particles 1, and bell particles 1 may also be manufactured by other methods.

[0056] First, a plurality of core particles 2 are prepared. When the manufactured bell particles 1 are added to a resin for injection molding or extrusion molding, a resin material such as a thermosetting resin, an inorganic material, or a metallic material can be used as the core particles 2. On the other hand, when the manufactured bell particles 1 are added to a metal such as aluminum for casting, an inorganic material or a metallic material can be used as the core particles 2. Note that casting also includes die casting, in which molten metal is forced into a mold at high pressure.

[0057] 3, a coating step is carried out to coat the core particles 2 with a water-soluble material 21. In the coating step, coated core particles 22 in which the core particles 2 are coated with the water-soluble material 21 are obtained.

[0058] The water-soluble material 21 is a material that dissolves in water. In other words, the water-soluble material 21 is a material that can be removed from the core particle 2 by washing the core particle 2 coated with the water-soluble material 21 with water. The water-soluble material 21 is not particularly limited, and examples of the water-soluble material that can be used include water-soluble polymers such as polysaccharides and polyacrylic acid, sugars, and salts. The water-soluble material 21 can be coated on the core particle 2 by, for example, wet coating using water or an organic solvent, dry coating using a binder, or heating and melting the water-soluble material to coat the core particle 2.

[0059] Next, as shown in Fig. 4, a granulation step is performed in which a plurality of coated core particles 22, each of which is a core particle 2 coated with a water-soluble material 21, and a plurality of granulation particles 23 are mixed and granulated. In the granulation step, a granulated product 24 is obtained, which is granulated from the plurality of coated core particles 22 and the plurality of granulation particles 23.

[0060] The plurality of granulation particles 23 become the porous particles 3 of the bell particle 1. The material of the granulation particles 23 can be the same as that of the porous particles 3. When the manufactured bell particle 1 is added to a resin for injection molding or extrusion molding, a resin material such as a thermosetting resin can be used as the granulation particles 23. On the other hand, when the manufactured bell particle 1 is added to a metal such as aluminum for casting, an inorganic material or a metal material can be used as the granulation particles 23.

[0061] The maximum particle size of each of the multiple granulation particles 23 (hereinafter simply referred to as "granulation particles 23") is not particularly limited, but can be, for example, 0.1 μm to 500 μm, 1 μm to 100 μm, or 1 μm to 10 μm. The maximum particle size of the granulation particles 23 refers to the diameter of the granulation particles 23 at the position where the particle size of the granulation particles 23 is largest. Furthermore, the granulation particles 23 may be spherical, such as true spheres, or non-spherical, such as columnar or flat. The maximum particle size of the granulation particles 23 may be smaller than the maximum particle size of the bell particles 1. Furthermore, the multiple granulation particles 23 may include particles of different particle sizes.

[0062] In the granulation step, granulation may be performed so that at least one coated core particle 22 is disposed on the surface of the granulated product 24. In addition, in the granulation step, the granulated product 24 may be granulated using a plurality of coated core particles 22 and a plurality of granulation particles 23 while adding a binder. That is, in the granulation step, a plurality of coated core particles 22, a plurality of granulation particles 23, and a binder may be mixed and granulated.

[0063] When the manufactured bell particles 1 are added to a resin for injection molding or extrusion molding, a resin material such as a thermosetting resin can be used as the granulating particles 23, and a thermosetting resin such as a phenolic resin or an epoxy resin can be used as the binder. On the other hand, when the manufactured bell particles 1 are added to a metal such as aluminum for casting, an inorganic material or a metal material can be used as the granulating particles 23, and an inorganic binder such as a clay mineral such as bentonite, montmorillonite, or kaolin, or a sol of fine oxide particles such as alumina, silica, or ...

[0064] The granulation step may include a bonding step of bonding the plurality of granulation particles 23 to one another in the granulated material 24. For example, when granulation particles 23 made of a thermosetting resin are used, the bonding step may involve heating and curing the granulated material 24 to bond the plurality of granulation particles 23 constituting the granulated material 24 to one another. When granulation particles 23 made of a metallic material or an inorganic material are used, the bonding step may involve sintering the granulated material 24 to bond the plurality of granulation particles 23 constituting the granulated material 24 to one another. When granulation particles 23 made of a metallic material are used, the bonding step may involve pressing the granulated material 24 to bond the plurality of granulation particles 23 constituting the granulated material 24 to one another.

[0065] 5, a washing step is carried out in which the granulated product 24 of the plurality of coated core particles 22 and the plurality of granulation particles 23 is washed with a dissolving liquid that dissolves the water-soluble material 21. The dissolving liquid is not particularly limited, but for example, water or an organic solvent such as alcohol can be used depending on the solubility of the water-soluble material.

[0066] Here, the granulated product 24 is formed by granulating a plurality of particles, and therefore, gaps are formed between the plurality of particles in the granulated product 24. Furthermore, at least two or more of the plurality of coated core particles 22 are in communication with each other through the gaps between the particles, and are also in communication with the outside of the granulated product 24 through the gaps between the particles. Therefore, the washing liquid penetrates into the gaps between the particles and dissolves the water-soluble material 21 of the coated core particles 22. Furthermore, the washing liquid penetrates between the core particles 2 and the plurality of granulation particles 23 while dissolving the water-soluble material 21 of the coated core particles 22. Meanwhile, the water-soluble material dissolved by the washing liquid passes through the gaps between the particles and between the core particles 2 and the plurality of granulation particles 23, and is discharged to the outside of the plurality of coated core particles 22 together with the washing liquid.

[0067] As a result, gaps are generated between the plurality of core particles 2 and the plurality of granulation particles 23, allowing the plurality of core particles 2 to move around freely, thereby obtaining the above-mentioned bell particles 1. In other words, the plurality of granulation particles 23 become porous particles 3, and the spaces surrounding the core particles 2 of the plurality of granulation particles 23 become storage voids 4.

[0068] (Method for manufacturing bell grain compact) Next, an example of a method for manufacturing a bell grain compact will be described. The method for manufacturing a bell grain compact according to this embodiment is a method for manufacturing the above-described bell grain compact 10. Note that the method for manufacturing a bell grain compact described below is one example of a method for manufacturing the bell grain compact 10, and the bell grain compact 10 may also be manufactured by other methods.

[0069] In the manufacturing method of the bell grain compact, first, a molding material for molding the bell grain compact 10 and the above-mentioned bell grains 1 are prepared. Next, a molding step is performed in which the bell grains 1 are added to the molding material to mold the bell grain compact 10. The above-mentioned bell grain compact 10 is obtained by the molding step.

[0070] As the molding material, a resin material, a metal material, or the like can be used.

[0071] Examples of resin materials that can be used as molding materials include plastic materials such as polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polystyrene (PS), acrylonitrile butadiene styrene (ABS), polyphenylene sulfide (PPS), polyurethane (PU), epoxy resin, phenolic resin, and melamine resin, and rubber materials such as natural rubber (NR), styrene butadiene rubber (SBR), acrylonitrile butadiene rubber (NBR), chloroprene rubber (CR), ethylene propylene rubber (EPM), ethylene propylene diene rubber (EPDM), silicone rubber, urethane rubber, and various thermoplastic elastomers.

[0072] As the metal material that is the molding material, for example, aluminum, aluminum alloy, etc. can be used.

[0073] When the molding material is a resin material, the molding process may involve injection molding the resin material to which bell particles 1 have been added, or extrusion molding the resin material to which bell particles 1 have been added, to form the bell particle molding body 10.

[0074] When the molding material is a metal material, the molding step may involve casting the metal material to which the bell particles 1 have been added to mold the bell particle compact 10 .

[0075] As explained above, the bell particle 1 according to this embodiment has a plurality of core particles 2 housed in a plurality of housing cavities 4, and thus has a plurality of bell structures. This allows for high vibration damping. The porous particle 3 housing a plurality of core particles 2 has a structure with higher rigidity than conventional bell particles, which have a structure in which one large cavity is formed in a thin shell. This allows for high pressure resistance.

[0076] Furthermore, in this bell particle 1, the porous particle 3 has a group of interconnected pores 5 in which the plurality of accommodating pores 4 are interconnected and open from the porous particle 3, so that when the bell particle 1 is produced, the water-soluble material 21 can be easily discharged outside the porous particle 3. This allows the bell particle 1 to be produced easily.

[0077] Furthermore, the maximum particle size of the bell particles 1 is 10 μm or more and 2000 μm or less, 20 μm or more and 1000 μm or less, or 40 μm or more and 500 μm or less, which ensures ease of manufacturing and makes it easy to apply to various components.

[0078] In the bell particle compact 10 according to this embodiment, the compact 11 is configured to contain the bell particles 1 described above, and therefore, high vibration damping properties can be obtained.

[0079] Furthermore, in this bell particle molding, when the molding 11 is a resin molding or a metal molding, high pressure is applied to the bell particles during manufacturing. However, since the bell particles 1 have high pressure resistance, it is possible to prevent the bell particles 1 from being broken during manufacturing. This allows for high vibration damping properties to be obtained.

[0080] In the method for producing bell particles according to this embodiment, core particles 2 are coated with a water-soluble material 21, and then multiple coated core particles 22 and multiple granulation particles 23 are mixed and granulated, resulting in a state in which each of the multiple coated core particles 22 is surrounded by multiple granulation particles 23. At this time, since the granulated product 24 is formed by granulating multiple particles, gaps are formed between the multiple particles. Furthermore, at least two of the multiple coated core particles 22 are connected to each other through the gaps between the particles and also to the outside of the granulated product 24 through the gaps between the particles. Therefore, when the granulated product 24 is washed with a solvent, the water-soluble material 21 is dissolved in the solvent and discharged to the outside of the granulated product 24, forming gaps between each of the multiple core particles 2 and the multiple granulation particles 23, allowing each of the multiple core particles 2 to move freely. This allows the production of the bell particles 1 described above.

[0081] Furthermore, in this method for producing bell particles, granulation is performed so that at least one coated core particle 22 is disposed on the surface of the granulated product 24, thereby ensuring a path for removing the water-soluble material 21. This allows the water-soluble material 21 to be easily removed.

[0082] Furthermore, in this method for producing bell particles, by bonding a plurality of particles 23 for granulation to each other, bell particles 1 having even higher pressure resistance can be produced.

[0083] Furthermore, in this method for producing bell particles, the coated core particles, granulation particles, and binder are mixed and granulated, which allows for easy granulation.

[0084] In the method for manufacturing a bell grain compact according to this embodiment, the bell grain compact 10 is molded by adding the above-described bell grains 1 to a molding material, so that the bell grain compact 10 can be easily manufactured.

[0085] Furthermore, in this manufacturing method for a bell particle molding, the resin material to which the above-mentioned bell particles 1 have been added is injection molded or extrusion molded to easily form a resin bell particle molding 10.

[0086] Furthermore, in this method for manufacturing a bell grain compact, the metal material to which the above-described bell grains 1 have been added is cast, whereby the metal bell grain compact 10 can be easily formed.

[0087] In the method for manufacturing a bell grain compact according to this embodiment, the bell grain compact 10 is molded by adding the above-described bell grains 1 to a molding material, so that the bell grain compact 10 can be easily manufactured.

[0088] Furthermore, when the molding material is a resin material, the resin material to which the above-mentioned bell particles 1 have been added can be injection molded or extrusion molded to easily form a resin bell particle molding 10.

[0089] Furthermore, when the molding material is a metal material, the metal bell particle compact 10 can be easily molded by casting the metal material to which the above-described bell particles 1 have been added.

[0090] [Second embodiment] Next, we will explain the bell particles, bell particle compacts, bell particle manufacturing method, and bell particle compact manufacturing method according to the second embodiment. The second embodiment is basically the same as the first embodiment, but differs from the first embodiment in that the bell particles have a pressure-resistant reinforced layer. Therefore, below, we will only explain the differences from the first embodiment, and omit explanations of the same aspects as the first embodiment.

[0091] (Bell particle) Fig. 6 is a schematic cross-sectional view of a bell particle according to the second embodiment. As shown in Fig. 6, a bell particle 1A according to this embodiment includes a plurality of core particles 2, a porous particle 3 having a plurality of accommodation cavities 4 that accommodate (enclose) the plurality of core particles 2, and a pressure-resistant reinforced layer 6 disposed on the outside of the porous particle 3. In other words, the bell particle 1A includes the bell particle 1 of the first embodiment that includes a plurality of core particles 2 and porous particles 3, and the pressure-resistant reinforced layer 6.

[0092] The pressure-resistant layer 6 is a layer for strengthening the pressure resistance of the bell particle 1A. The pressure-resistant layer 6 may cover a part of the porous particle 3, may cover the openings of the interconnected pores 5 in the porous particle 3, or may cover the entire porous particle 3.

[0093] The material of the pressure-resistant layer 6 is not particularly limited, and may be, for example, a material containing either or both of a resin material and an inorganic material.

[0094] When the pressure-resistant reinforcement layer 6 has a resin material or is made of a resin material, the resin material constituting the pressure-resistant reinforcement layer 6 can be, for example, a thermosetting resin such as a phenolic resin or an epoxy resin.

[0095] When the pressure-resistant layer 6 has an inorganic material or is made of an inorganic material, the inorganic material that constitutes the pressure-resistant layer 6 can be, for example, alumina, silica, a sol of oxide fine particles such as alumina or silica, water glass, or a metal alkoxide.

[0096] Furthermore, the material of the pressure-resistant layer 6 may be the same as that of the porous particles 3, or may be a different material from that of the porous particles 3. When the material of the pressure-resistant layer 6 is the same as that of the porous particles 3, the porous particles 3 and the pressure-resistant layer 6 may be integrated, or an interface between the porous particles 3 and the pressure-resistant layer 6 may not be formed. In this case, at least a part of the surface of the bell particle 1A can be the pressure-resistant layer 6. When the group of communicating pores 5 is not open to the outside of the bell particle 1A, the entire surface layer of the bell particle 1A can be the pressure-resistant layer 6.

[0097] (Bell Grain Compaction) Fig. 7 is a schematic cross-sectional view of a bell grain compaction according to a second embodiment. As shown in Fig. 7, a bell grain compaction 10A according to this embodiment comprises a compaction 11 and bell grains 1A arranged within the compaction 11. The number of bell grains 1A arranged within the compaction 11 is not particularly limited, and may be one or more.

[0098] (Method for manufacturing bell particles) Next, an example of a method for manufacturing bell particles will be described with reference to Fig. 8. Fig. 8 is a schematic cross-sectional view for explaining a method for manufacturing bell particles according to a second embodiment. The method for manufacturing bell particles according to this embodiment is a method for manufacturing the bell particles 1A described above. Note that the method for manufacturing bell particles described below is one example of a method for manufacturing bell particles 1A, and bell particles 1A may also be manufactured by other methods.

[0099] First, similarly to the first embodiment, the coating step (see FIG. 3), the granulation step (see FIG. 4), and the washing step (see FIG. 5) are carried out to obtain the bell particles 1 of the first embodiment.

[0100] 8, a pressure-resistant layer forming step is performed to form a pressure-resistant layer 6 that is arranged on the outside of the granulated material 24, i.e., on the outside of the bell particle 1. By the pressure-resistant layer forming step, a bell particle 1A in which the pressure-resistant layer 6 is arranged on the outside of the bell particle 1 is obtained.

[0101] When the manufactured bell particles 1A are added to a resin and subjected to injection molding or extrusion molding, a resin material such as a thermosetting resin can be used for the pressure-resistant reinforcement layer 6. In this case, for example, a coating layer of a thermosetting resin can be formed on the surface of the bell particles 1, and the coating layer can be thermally cured to form the pressure-resistant reinforcement layer 6 of a thermosetting resin.

[0102] On the other hand, when the manufactured bell particle 1A is added to a metal such as aluminum and cast, an inorganic material such as ceramic can be used for the pressure-resistant reinforcing layer 6. In this case, for example, a ceramic coating layer can be formed on the surface of the bell particle 1 by a sol-gel method, and this coating layer can be sintered to form the ceramic pressure-resistant reinforcing layer 6.

[0103] (Method for manufacturing a bell grain compact) Next, a method for manufacturing a bell grain compact will be described. The method for manufacturing a bell grain compact according to this embodiment is a method for manufacturing the above-described bell grain compact 10A. The method for manufacturing a bell grain compact according to this embodiment is the same as the method for manufacturing a bell grain compact according to the first embodiment, except that bell grain 1A is used instead of bell grain 1. In other words, a molding step is performed in which the above-described bell grain 1A is added to the molding material for molding the bell grain compact 10A to mold the bell grain compact 10A. This results in the above-described bell grain compact 10A.

[0104] As described above, the bell particle 1A according to this embodiment has the pressure-resistance reinforcing layer 6 disposed on the outside of the porous particle 3, and therefore can obtain even higher pressure resistance.

[0105] Furthermore, in the bell particle 1A, the pressure-resistance reinforcing layer 6 covers the openings of the interconnected pores 5 in the porous particle 3, thereby achieving even higher pressure resistance. Furthermore, when the bell particle 1A is applied to various components, it is possible to prevent other components, such as molten resin or molten metal, from entering the interconnected pores 5.

[0106] Furthermore, in the bell particle 1A, higher pressure resistance can be obtained by covering the entire porous particle 3 with the pressure-resistant reinforcing layer 6. Furthermore, when the bell particle 1A is applied to various components, it is possible to prevent other components such as molten resin or molten metal from entering the group of interconnected pores 5.

[0107] In this method for manufacturing bell particles according to this embodiment, by forming a pressure-resistant reinforced layer 6 that is placed on the outside of the granulated material 24, i.e., the outside of the bell particle 1, bell particles with even higher pressure resistance can be manufactured.

[0108] In addition, in this manufacturing method of bell particles, a coating layer of thermosetting resin is formed on the surface of the bell particle 1, and the coating layer is thermally cured to form a pressure-resistant reinforcement layer 6 of thermosetting resin.

[0109] In addition, in this manufacturing method of bell particles, a ceramic coating layer is formed on the surface of the bell particle 1 by the sol-gel method, and the coating layer is sintered to form a ceramic pressure-resistant strengthening layer 6.

[0110] The present disclosure is not limited to the above-described embodiments, and modifications can be made as appropriate without departing from the spirit of the present disclosure.

[0111] The gist of the present disclosure is as follows: [1] to

[28] . [1] A bell particle comprising a plurality of core particles and a porous particle having a plurality of storage voids for storing the plurality of core particles. [2] The bell particle according to [1], wherein the porous particle has a group of interconnected voids that open from the porous particle, with the plurality of storage voids being interconnected with each other. [3] The bell particle according to [1] or [2], wherein the maximum particle size of the bell particle is 10 μm or more and 2000 μm or less. [4] The bell particle according to any one of [1] to [3], wherein the core particle comprises a resin material. [5] The bell particle according to any one of [1] to [3], wherein the core particle comprises an inorganic material. [6] The bell particle according to any one of [1] to [3], wherein the core particle comprises a metal material. [7] The bell particle according to any one of [1] to [6], wherein the porous particle comprises a resin material. [8] The bell particle according to any one of [1] to [6], wherein the porous particle comprises an inorganic material. [9] The bell particle according to any one of [1] to [6], wherein the porous particle comprises a metal material.

[10] The bell particle according to any one of [1] to [9], further comprising a pressure-resistant reinforcing layer disposed on the outside of the porous particle.

[11] The bell particle according to

[10] , wherein the porous particle has a group of interconnected pores that open from the porous particle by interconnecting the plurality of accommodating pores, and the pressure-resistant reinforcing layer covers the openings of the group of interconnected pores in the porous particle.

[12] The bell particle according to

[10] or

[11] , wherein the pressure-resistant reinforcing layer covers the entire porous particle.

[13] The bell particle according to any one of

[10] to

[12] , wherein the pressure-resistant reinforcing layer comprises a resin material.

[14] The bell particle according to any one of

[10] to

[12] , wherein the pressure-resistant reinforcing layer comprises an inorganic material.

[15] A bell particle compact comprising the bell particle according to any one of [1] to

[14] and a compact containing the bell particle.

[16] The compact is a resin compact.

[17] The bell particle compact according to

[15] , which is a metal compact.

[18] A method for producing bell particles, comprising: a coating step of coating core particles with a water-soluble material; a granulation step of mixing and granulating a plurality of coated core particles, each of which has been coated with the water-soluble material, and a plurality of particles for granulation; and a washing step of washing a granulated product of the plurality of coated core particles and the plurality of particles for granulation with a solution that dissolves the water-soluble material.

[19] A method for producing bell particles according to

[18] , in which the granulation step involves granulating the product so that at least one coated core particle is disposed on the surface of the granulated product.

[20] A method for producing bell particles according to

[18] or

[19] , in which the granulation step includes a bonding step of bonding the plurality of particles for granulation to each other.

[21] A method for producing bell particles according to

[18] or

[19] , in which the granulation step involves mixing and granulating the coated core particles, the particles for granulation, and a binder.

[22] The method for manufacturing bell particles according to any one of

[18] to

[21] , further comprising, after the washing step, a pressure-reinforcing layer-forming step of forming a pressure-reinforcing layer disposed on the outside of the granules.

[23] The method for manufacturing bell particles according to

[22] , in the pressure-reinforcing layer-forming step, a coating layer of a thermosetting resin is formed on the surface of the bell particles, and the coating layer is thermally cured to form the pressure-reinforcing layer.

[24] The method for manufacturing bell particles according to

[22] , in the pressure-reinforcing layer-forming step, a ceramic coating layer is formed on the surface of the bell particles by a sol-gel method, and the coating layer is sintered to form the pressure-reinforcing layer.

[25] A method for manufacturing a bell particle compact for manufacturing a bell particle compact, comprising a molding step of adding the bell particles according to any one of [1] to

[14] to a molding material for molding the bell particle compact, and molding the bell particle compact.

[26] The manufacturing method according to

[25] , wherein the molding material is a resin material, and the molding step involves injection molding the resin material to which the bell particles have been added.

[27] The manufacturing method according to

[25] , wherein the molding material is a resin material, and the molding step involves extrusion molding the resin material to which the bell particles have been added.

[28] The manufacturing method according to

[25] , wherein the molding material is a metal material, and the molding step involves casting the metal material to which the bell particles have been added.

[0112] 1... bell particle, 1A... bell particle, 2... core particle, 3... porous particle, 4... containing void, 5... group of interconnected voids, 6... pressure-resistant reinforced layer, 10... bell particle compact, 10A... bell particle compact, 11... compact, 21... water-soluble material, 22... coated core particle, 23... granulation particle, 24... granulated product

Claims

1. A bell particle comprising: a plurality of core particles; and a porous particle having a plurality of accommodation pores for accommodating the plurality of core particles.

2. The bell particle according to claim 1, wherein the porous particle has a group of interconnected pores that open out from the porous particle and are connected to each other by the plurality of accommodating pores.

3. The bell particles according to claim 1 or 2, wherein the maximum particle size of the bell particles is 10 μm or more and 2000 μm or less.

4. The bell particle according to any one of claims 1 to 3, wherein the core particle comprises a resin material.

5. The bell particle according to any one of claims 1 to 3, wherein the core particle comprises an inorganic material.

6. The bell particle according to any one of claims 1 to 3, wherein the core particle comprises a metal material.

7. The bell particle according to any one of claims 1 to 6, wherein the porous particle comprises a resin material.

8. The bell particle according to any one of claims 1 to 6, wherein the porous particle comprises an inorganic material.

9. The bell particle according to any one of claims 1 to 6, wherein the porous particle comprises a metal material.

10. The bell particle according to any one of claims 1 to 9, further comprising a pressure-reinforcing layer disposed on the outside of the porous particle.

11. The bell particle according to claim 10, wherein the porous particle has a group of interconnected voids that open from the porous particle by interconnecting the multiple voids, and the pressure-resistant reinforcement layer covers the openings of the group of interconnected voids in the porous particle.

12. The bell particle according to claim 10 or 11, wherein the pressure-resistant reinforcement layer covers the entire porous particle.

13. The bell particle according to any one of claims 10 to 12, wherein the pressure-resistant reinforcement layer comprises a resin material.

14. The bell particle according to any one of claims 10 to 12, wherein the pressure-resistant layer comprises an inorganic material.

15. A bell particle compact comprising: the bell particle according to any one of claims 1 to 14; and a compact containing the bell particle.

16. The bell grain molding according to claim 15, wherein the molding is a resin molding.

17. The bell grain compact according to claim 15, wherein the compact is a metal compact.

18. A method for producing bell particles, comprising: a coating step of coating a core particle with a water-soluble material; a granulation step of mixing and granulating a plurality of coated core particles in which the core particles are coated with the water-soluble material and a plurality of particles for granulation; and a washing step of washing the granulated product of the plurality of coated core particles and the plurality of particles for granulation with a dissolving liquid that dissolves the water-soluble material.

19. The method for producing bell particles according to claim 18, wherein in the granulation process, granulation is carried out so that at least one of the coated core particles is disposed on the surface of the granulated material.

20. A method for producing bell particles as described in claim 18 or 19, wherein the granulation process includes a bonding process for bonding the plurality of granulation particles to each other.

21. The method for producing bell particles according to claim 18 or 19, wherein in the granulation step, the coated core particles, the particles for granulation, and a binder are mixed and granulated.

22. A method for producing bell particles as described in any one of claims 18 to 21, further comprising a pressure-resistant layer forming step of forming a pressure-resistant layer to be placed on the outside of the granulated material after the washing step.

23. The method for manufacturing bell particles described in claim 22, wherein in the pressure-resistance reinforcement layer forming process, a coating layer of a thermosetting resin is formed on the surface of the bell particle, and the coating layer is thermally cured to form the pressure-resistance reinforcement layer.

24. The method for manufacturing bell particles described in claim 22, wherein in the pressure-resistance reinforcing layer forming process, a ceramic coating layer is formed on the surface of the bell particle by a sol-gel method, and the coating layer is sintered to form the pressure-resistance reinforcing layer.

25. A method for manufacturing a bell particle compact, comprising a molding step of adding bell particles according to any one of claims 1 to 14 to a molding material for molding the bell particle compact, and molding the bell particle compact.

26. The manufacturing method according to claim 25, wherein the molding material is a resin material, and the molding step comprises injection molding the resin material to which the bell particles have been added.

27. The manufacturing method according to claim 25, wherein the molding material is a resin material, and the molding step comprises extrusion molding the resin material to which the bell particles have been added.

28. The manufacturing method according to claim 25, wherein the molding material is a metal material, and the molding step includes casting the metal material to which the bell particles have been added.

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