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JP7517866B2 - Carbon Composite Materials - Google Patents
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JP7517866B2 - Carbon Composite Materials - Google Patents

Carbon Composite Materials Download PDF

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JP7517866B2
JP7517866B2 JP2020089681A JP2020089681A JP7517866B2 JP 7517866 B2 JP7517866 B2 JP 7517866B2 JP 2020089681 A JP2020089681 A JP 2020089681A JP 2020089681 A JP2020089681 A JP 2020089681A JP 7517866 B2 JP7517866 B2 JP 7517866B2
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pyrolytic carbon
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JP2021183553A (en
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比呂 北口
敏樹 伊藤
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Ibiden Co Ltd
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Ibiden Co Ltd
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    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81Coating or impregnation
    • C04B41/85Coating or impregnation with inorganic materials
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/26Deposition of carbon only
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/52Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
    • C04B41/524Multiple coatings, comprising a coating layer of the same material as a previous coating layer
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/56After-treatment

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  • Ceramic Engineering (AREA)
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Description

本発明は、炭素複合部材に関する。 The present invention relates to a carbon composite member.

黒鉛等の炭素材料は、化学的安定性、耐熱性、機械特性に優れていることから、半導体製造、化学工業、機械、原子力等、多くの分野にわたって使用されている。また、黒鉛自体は多孔体であるため、細孔の内部にガス、水分、不純物等を吸着しやすいため、細孔内部が汚染されやすい。そのため、これら汚染物質が細孔から再放出しないように熱分解炭素のコーティングを施すことで、黒鉛の悪影響を軽減する技術が知られている。 Carbon materials such as graphite are used in many fields, including semiconductor manufacturing, chemical industry, machinery, and atomic energy, due to their excellent chemical stability, heat resistance, and mechanical properties. In addition, graphite itself is porous, and so it is prone to adsorbing gases, moisture, impurities, etc. inside the pores, making the inside of the pores susceptible to contamination. For this reason, a technology is known that reduces the adverse effects of graphite by applying a pyrolytic carbon coating to prevent these contaminants from being re-released from the pores.

熱分解炭素は、硬く、気体不浸透で緻密な膜を形成するため、特に高純度の環境下での使用に適している。
特許文献1には、このような用途として、炭素材料からなり、少なくとも原料ガスと接する面に熱分解炭素層が形成されており、上記原料ガスと接する面の濡れ張力が、62.0mN/m以上である半導体製造装置用部材が記載されている。
Pyrolytic carbon forms a hard, gas-impermeable, dense film that is particularly suitable for use in high purity environments.
For such an application, Patent Document 1 describes a semiconductor manufacturing equipment component that is made of a carbon material, has a pyrolytic carbon layer formed on at least a surface that comes into contact with a raw material gas, and has a wetting tension of 62.0 mN/m or more on the surface that comes into contact with the raw material gas.

特開2007-12933号公報JP 2007-12933 A

しかしながら、上記記載された技術は、比較的小さなウェハを対象とする半導体製造装置に関するものであり、内部へのガス、水分、不純物の吸着やそれらの放出を防止するためには、コーティング時にできる支持点を塞ぎ、黒鉛基材のような炭素材料の全面を覆う必要があるとともに、特にサイズの大きな炭素複合部材では、取扱時に熱分解炭素のコーティングにかかる衝撃が大きく剥がれを防止する必要がある。
本発明は上記課題に鑑み、黒鉛基材の全体を覆うとともに強固な熱分解炭素層を有する炭素複合部材を提供することを目的とする。
However, the above-described technology relates to semiconductor manufacturing equipment that processes relatively small wafers, and in order to prevent the adsorption of gas, moisture, and impurities into the interior and the release of these substances, it is necessary to seal support points that are created during coating and to cover the entire surface of the carbon material such as the graphite substrate. In particular, with large-sized carbon composite members, the impact on the pyrolytic carbon coating during handling is large, and it is necessary to prevent peeling.
In view of the above problems, an object of the present invention is to provide a carbon composite member having a strong pyrolytic carbon layer that covers the entire graphite base material.

上記課題を解決するための本発明に係る炭素複合部材は、以下のとおりである。 The carbon composite member according to the present invention, which solves the above problems, is as follows:

(1)黒鉛基材上に複数の熱分解炭素層が形成された炭素複合部材であって、
一の前記熱分解炭素層とこれに隣接する他の前記熱分解炭素層との境界に、気孔が存在する気孔領域を有することを特徴とする炭素複合部材。
(1) A carbon composite member having a plurality of pyrolytic carbon layers formed on a graphite substrate,
A carbon composite member, comprising: a pore region in which pores exist at the boundary between one of said pyrolytic carbon layers and another of said pyrolytic carbon layers adjacent thereto.

本発明に係る炭素複合部材によれば、熱分解炭素層が複数層からなるため、黒鉛基材のガス、水分、不純物の吸着及び放出の防止効果を高めることができる。
一方、熱分解炭素層は、黒鉛の結晶が面方向に広がった異方性の高い材料であり、面方向には強固な黒鉛のa軸方向が広がり、厚み方向にファンデルワールス力で弱く結合した黒鉛のc軸方向につながっている。このため、複数積層された熱分解炭素層は、一の熱分解炭素層とこれに隣接する熱分解炭素層との境界が弱く、剥離しやすくなる。一方、本発明に係る炭素複合部材では、一の熱分解炭素層とこれに隣接する他の熱分解炭素層との境界に、気孔が存在する気孔領域を有するため、気孔の周囲で熱分解炭素の結晶方向が乱され、アンカー効果を強くすることができ、層間剥離を防止する効果がある。
According to the carbon composite member of the present invention, the pyrolytic carbon layer is made up of a plurality of layers, and therefore the effect of preventing the adsorption and release of gas, moisture, and impurities from the graphite base material can be enhanced.
On the other hand, the pyrolytic carbon layer is a highly anisotropic material in which graphite crystals extend in the planar direction, and the a-axis direction of the strong graphite extends in the planar direction and is connected in the thickness direction to the c-axis direction of the graphite weakly bonded by van der Waals forces. For this reason, in a pyrolytic carbon layer that is laminated in multiple layers, the boundary between one pyrolytic carbon layer and an adjacent pyrolytic carbon layer is weak and is prone to peeling. On the other hand, in the carbon composite member according to the present invention, the boundary between one pyrolytic carbon layer and another adjacent pyrolytic carbon layer has a pore region in which pores exist, so that the crystal orientation of the pyrolytic carbon is disturbed around the pores, which strengthens the anchor effect and has the effect of preventing interlayer peeling.

また、上記課題を解決するための本発明に係る炭素複合部材は、以下の態様であることが好ましい。 In addition, the carbon composite member according to the present invention for solving the above problems preferably has the following features:

(2)前記複数の熱分解炭素層を、前記黒鉛基材に近い側から順に第1層、第2層、・・・、第n-1層、第n層とするとき、
前記第1層が第1の開口部を有し、前記第n層が第nの開口部を有するともに、
前記第1の開口部と前記第nの開口部とは、前記黒鉛基材に対して異なる位置に形成されていることを特徴とする(1)に記載の炭素複合部材。
(2) When the plurality of pyrolytic carbon layers are designated as a first layer, a second layer, ..., an (n-1)th layer, and an nth layer in order from the side closest to the graphite base material,
the first layer has a first opening, the nth layer has an nth opening,
The carbon composite member according to (1), wherein the first opening and the nth opening are formed at different positions with respect to the graphite substrate.

本発明の好ましい実施形態に係る炭素複合部材は、黒鉛基材に近い側の第1層にある第1の開口部と、最も外側の第n層にある第nの開口部とが黒鉛基材に対して異なる位置にあるため、第1の開口部が閉塞され、黒鉛基材からのガスや水分、不純物等の放出を防止するともに、外部からのガスや水分、不純物等の吸着を防止する。 In a carbon composite member according to a preferred embodiment of the present invention, the first opening in the first layer closest to the graphite substrate and the nth opening in the outermost nth layer are located at different positions relative to the graphite substrate, so that the first opening is blocked, preventing the release of gas, moisture, impurities, etc. from the graphite substrate and preventing the adsorption of gas, moisture, impurities, etc. from the outside.

(3)前記第2層が前記第1の開口部を覆うとともに、前記第1の開口部周辺における前記第1層と前記第2層との境界の前記気孔領域は、前記黒鉛基材に向かって傾斜して伸びていることを特徴とする(2)に記載の炭素複合部材。 (3) The carbon composite member described in (2) is characterized in that the second layer covers the first opening, and the pore region at the boundary between the first layer and the second layer around the first opening extends at an angle toward the graphite substrate.

本発明の好ましい実施形態に係る炭素複合部材は、第2層が第1層にある第1の開口部を覆っているため、黒鉛基材のガス、水分、不純物の放出及び外部からの吸着を防止する効果を高めることができる。また、第1の開口部の周辺における第1層と第2層との境界の気孔領域が、黒鉛基材に向かって傾斜して伸びているため、応力集中の起きやすい第1の開口部の境界部分の補強効果を高めることができる。 In a carbon composite member according to a preferred embodiment of the present invention, the second layer covers the first opening in the first layer, thereby enhancing the effect of preventing the graphite substrate from emitting gas, moisture, and impurities and from adsorbing them from the outside. In addition, the pore region at the boundary between the first and second layers around the first opening extends at an angle toward the graphite substrate, enhancing the reinforcing effect of the boundary portion of the first opening where stress concentration is likely to occur.

(4)前記第n層と前記第n層の直下の前記第n-1層との境界に前記気孔領域を有し、前記第n層は、前記第nの開口部に向かって徐々に薄くなっていることを特徴とする(2)または(3)に記載の炭素複合部材。 (4) A carbon composite member according to (2) or (3), characterized in that the pore region is present at the boundary between the nth layer and the n-1th layer immediately below the nth layer, and the nth layer is gradually thinner toward the nth opening.

本発明の好ましい実施形態に係る炭素複合部材は、第n層と第n層の直下の第n-1層との境界に前記気孔領域を有し、第n層が第nの開口部に向かって徐々に薄くなっているので、応力集中を緩和して、他の部位と比べて厚さの薄い第2の開口部の境界部分の補強効果を高めることができる。 A carbon composite member according to a preferred embodiment of the present invention has the pore region at the boundary between the nth layer and the n-1th layer immediately below the nth layer, and the nth layer becomes gradually thinner toward the nth opening, which can reduce stress concentration and increase the reinforcing effect of the boundary portion of the second opening, which is thinner than other portions.

(5)前記気孔は、最大気孔径が0.5~3.0μmであることを特徴とする(1)~(4)のいずれか1つに記載の炭素複合部材。 (5) A carbon composite member according to any one of (1) to (4), characterized in that the pores have a maximum pore diameter of 0.5 to 3.0 μm.

本発明の好ましい実施形態に係る炭素複合部材は、気孔の最大気孔径が0.5μm以上であることにより、気孔の周囲にできる配向の方向性の異なる熱分解炭素の成分を十分に確保することができ、気孔の生成によってアンカー効果を十分に発揮することができる。また、気孔の最大気孔径が3.0μm以下であることにより、気孔の周囲への応力集中を低減し、気孔が存在することにより強度が低下することを防止することができる。 In the carbon composite member according to the preferred embodiment of the present invention, the maximum pore diameter of the pores is 0.5 μm or more, so that the pyrolytic carbon components with different orientation directions formed around the pores can be sufficiently secured, and the anchor effect can be fully exerted by the formation of the pores. In addition, the maximum pore diameter of the pores is 3.0 μm or less, so that the stress concentration around the pores can be reduced, and the reduction in strength due to the presence of the pores can be prevented.

(6)前記熱分解炭素層の合計厚さが5~400μmであることを特徴とする(1)~(5)のいずれか1つに記載の炭素複合部材。 (6) A carbon composite member according to any one of (1) to (5), characterized in that the total thickness of the pyrolytic carbon layers is 5 to 400 μm.

本発明の好ましい実施形態に係る炭素複合部材は、熱分解炭素層の合計厚さが5μm以上であることにより、多孔体である黒鉛基材の凹凸を十分に覆うことができ、気体の不浸透性を確保することができる。また、熱分解炭素層の合計厚さが400μm以下であることにより、黒鉛基材と熱分解炭素層の熱歪みによる反りや剥がれを防止することができる。 In a carbon composite member according to a preferred embodiment of the present invention, the total thickness of the pyrolytic carbon layers is 5 μm or more, so that the irregularities of the porous graphite substrate can be sufficiently covered and gas impermeability can be ensured. In addition, the total thickness of the pyrolytic carbon layers is 400 μm or less, so that warping and peeling due to thermal distortion of the graphite substrate and pyrolytic carbon layers can be prevented.

(7)前記黒鉛基材が等方性黒鉛材であることを特徴とする(1)~(6)のいずれか1つに記載の炭素複合部材。 (7) A carbon composite member according to any one of (1) to (6), characterized in that the graphite base material is an isotropic graphite material.

本発明の好ましい実施形態に係る炭素複合部材は、黒鉛基材が等方性黒鉛材であり、等方性黒鉛は、特性の異方性が小さく均一性が高いため、熱分解炭素層との熱膨張係数差が場所、方向による差異が小さく、剥がれにくくすることができる。 In the carbon composite member according to a preferred embodiment of the present invention, the graphite base material is an isotropic graphite material. Since isotropic graphite has small anisotropy and high uniformity in its properties, the difference in the thermal expansion coefficient with the pyrolytic carbon layer is small depending on the location and direction, making it difficult to peel off.

本発明に係る炭素複合部材によれば、熱分解炭素層が複数層からなるため、黒鉛基材のガス、水分、不純物の吸着及び放出の防止効果を高めることができる。
一方、熱分解炭素層は、黒鉛の結晶が面方向に広がった異方性の高い材料であり、面方向には強固な黒鉛のa軸方向が広がり、厚み方向にファンデルワールス力で弱く結合した黒鉛のc軸方向につながっている。このため、複数積層された熱分解炭素層は、一の熱分解炭素層とこれに隣接する熱分解炭素層との境界が弱く、剥離しやすくなる。一方、本発明に係る炭素複合部材では、一の熱分解炭素層とこれに隣接する他の熱分解炭素層との境界に、気孔が存在する気孔領域を有するため、気孔の周囲で熱分解炭素の結晶方向が乱され、アンカー効果を強くすることができ、層間剥離を防止する効果がある。
According to the carbon composite member of the present invention, the pyrolytic carbon layer is made up of a plurality of layers, and therefore the effect of preventing the adsorption and release of gas, moisture, and impurities from the graphite base material can be enhanced.
On the other hand, the pyrolytic carbon layer is a highly anisotropic material in which graphite crystals extend in the planar direction, and the a-axis direction of the strong graphite extends in the planar direction and is connected in the thickness direction to the c-axis direction of the graphite weakly bonded by van der Waals forces. For this reason, in a pyrolytic carbon layer that is laminated in multiple layers, the boundary between one pyrolytic carbon layer and an adjacent pyrolytic carbon layer is weak and is prone to peeling. On the other hand, in the carbon composite member according to the present invention, the boundary between one pyrolytic carbon layer and another adjacent pyrolytic carbon layer has a pore region in which pores exist, so that the crystal orientation of the pyrolytic carbon is disturbed around the pores, which strengthens the anchor effect and has the effect of preventing interlayer peeling.

図1は、本発明の実施の形態1に係る炭素複合部材の断面の拡大図である。FIG. 1 is an enlarged view of a cross section of a carbon composite member according to a first embodiment of the present invention. 図2は、本発明の実施の形態1に係る炭素複合部材の製造工程を示す図である。FIG. 2 is a diagram showing a manufacturing process of the carbon composite member according to the first embodiment of the present invention. 図3は、本発明の実施の形態2に係る炭素複合部材の断面図である。FIG. 3 is a cross-sectional view of a carbon composite member according to a second embodiment of the present invention. 図4は、本発明の実施の形態2に係る炭素複合部材のA部断面の拡大図である。FIG. 4 is an enlarged view of a cross section of part A of a carbon composite member according to a second embodiment of the present invention. 図5は、本発明の実施の形態2に係る炭素複合部材のB部断面の拡大図である。FIG. 5 is an enlarged view of a cross section of part B of a carbon composite member according to a second embodiment of the present invention. 図6は、本発明の実施の形態2に係る炭素複合部材の製造工程を示す図である。FIG. 6 is a diagram showing a manufacturing process of a carbon composite member according to the second embodiment of the present invention. 図7は、図6に示す製造工程における、(C)工程、(D)工程及び(E)工程で形成される各層を示す拡大図である。FIG. 7 is an enlarged view showing the layers formed in steps (C), (D) and (E) in the manufacturing process shown in FIG.

(発明の詳細な説明)
<実施の形態1>
まず、本発明の実施の形態1について説明する。図1は、本発明の実施の形態1に係る炭素複合部材を示す図であり、詳細には表面近傍の断面の拡大図である。
黒鉛基材1の上には、一の熱分解炭素層である第1層2A、及び他の熱分解炭素層である第2層2Bが積層して形成されている。また、第1層2Aと第2層2Bとの境界には、多数の気孔3が層状に広がるように形成されている。気孔3が層状に存在している領域が、気孔領域4である。
Detailed Description of the Invention
<First embodiment>
First, a description will be given of a first embodiment of the present invention. Fig. 1 is a diagram showing a carbon composite member according to the first embodiment of the present invention, and more specifically, an enlarged view of a cross section near the surface.
A first layer 2A, which is one pyrolytic carbon layer, and a second layer 2B, which is another pyrolytic carbon layer, are laminated on the graphite substrate 1. A large number of pores 3 are formed so as to spread in a layered manner at the boundary between the first layer 2A and the second layer 2B. The region in which the pores 3 exist in a layered manner is a pore region 4.

第1層2A及び第2層2Bとなる熱分解炭素層は、CVD法により形成することができる。熱分解炭素層の主要部分では、黒鉛基材1の面方向に沿ってa軸方向が広がり、垂直方向に沿ってc軸方向が延びている。そのため、複数の熱分解炭素層が積層したものであると、熱歪みなどの発生した境界領域から剥がれが生じやすくなる。そこで、本実施の形態に係る炭素複合部材では、互いに隣接する第1層2Aと第2層2Bとの境界に、気孔3が存在する気孔領域4を形成することにより、熱分解炭素層の配列を乱して剥離しにくくしている。 The pyrolytic carbon layers that become the first layer 2A and the second layer 2B can be formed by a CVD method. In the main part of the pyrolytic carbon layer, the a-axis direction extends along the surface direction of the graphite substrate 1, and the c-axis direction extends along the vertical direction. Therefore, if multiple pyrolytic carbon layers are stacked, peeling is likely to occur at the boundary region where thermal distortion or the like occurs. Therefore, in the carbon composite member according to this embodiment, a pore region 4 containing pores 3 is formed at the boundary between the adjacent first layer 2A and second layer 2B, disrupting the arrangement of the pyrolytic carbon layers and making them less likely to peel off.

このような気孔領域4は、次のようにして得ることができる。
図2は、図1に示した炭素複合部材の製造工程を示す図である。まず、目的の形状の黒鉛基材1を準備する。黒鉛基材1に熱分解炭素層を形成すると、厚さ分だけ大きくなるので、炭素複合部材としてのサイズや、形成する熱分解炭素層の厚さに応じて小さ目に加工することが好ましい。また、熱分解炭素層との密着性を高めるために黒鉛基材1の表面を粗面に加工してもよい。
Such a pore region 4 can be obtained as follows.
Fig. 2 is a diagram showing a manufacturing process of the carbon composite member shown in Fig. 1. First, a graphite substrate 1 having a desired shape is prepared. When a pyrolytic carbon layer is formed on the graphite substrate 1, the substrate becomes larger by the thickness thereof, so it is preferable to process the substrate smaller according to the size of the carbon composite member and the thickness of the pyrolytic carbon layer to be formed. The surface of the graphite substrate 1 may be roughened to improve adhesion with the pyrolytic carbon layer.

そして、黒鉛基材1をCVD炉の中に置き、成膜温度まで上昇させたのち、原料ガスを導入する。成膜温度は特に限定されないが、例えば800~2000℃とすることができる。熱分解炭素層を得るための原料ガスは、炭化水素であれば特に限定されない。例えばメタン、エタン、プロパン、ブタン等のアルカン、エチレン、プロピレンなどのアルケン、アセチレン等のアルキンの他、ベンゼン、トルエン等の芳香族系の原料ガスを用いてもよい。
そして、成膜温度を保持し、一定時間原料ガスを導入することで、第1層2Aとなる一の熱分解炭素層を黒鉛基材1の表面に成膜する。なお、キャリアガスとしては、Ar等の不活性ガスを用いることができる。
The graphite substrate 1 is then placed in a CVD furnace, and the temperature is raised to the film formation temperature, after which a source gas is introduced. The film formation temperature is not particularly limited, but may be, for example, 800 to 2000° C. The source gas for obtaining the pyrolytic carbon layer is not particularly limited as long as it is a hydrocarbon. For example, source gases such as alkanes, such as methane, ethane, propane, and butane, alkenes, such as ethylene and propylene, and alkynes, such as acetylene, as well as aromatic source gases, such as benzene and toluene, may be used.
Then, the film formation temperature is maintained and the raw material gas is introduced for a certain period of time, thereby forming a pyrolytic carbon layer to become the first layer 2A on the surface of the graphite substrate 1. Note that an inert gas such as Ar can be used as the carrier gas.

続いて、熱分解炭素層である第1層2Aが所定の厚さになった段階で、第1層2Aの表面に、下記で詳述するような方法により気孔領域4を形成する。さらに、気孔領域4を形成した後、熱分解炭素を成膜のCVD条件で一定にして、気孔領域4が形成された熱分解炭素層の上に連続して、第2層2Bとなる他の熱分解炭素層を形成する。 Next, when the first layer 2A, which is the pyrolytic carbon layer, reaches a predetermined thickness, a pore region 4 is formed on the surface of the first layer 2A by a method described in detail below. Furthermore, after the pore region 4 is formed, the pyrolytic carbon is kept constant under the CVD conditions for film formation, and another pyrolytic carbon layer, which will become the second layer 2B, is formed continuously on the pyrolytic carbon layer on which the pore region 4 has been formed.

熱分解炭素層は、安定した成膜状態であれば、黒鉛基材1に対して水平方向(図中の左右方向)にa軸方向が広がり、黒鉛基材1に対して垂直方向(図中の上下方向)にc軸方向となるように、方向性の揃った状態で形成されるが、不安定な成膜状態であると黒鉛基材1の上方で原料ガスが熱分解し、パーティクルとなって黒鉛基材1に降り積もり、熱分解炭素層に配列の乱れを生じさせる。このような配列の乱れが、熱分解炭素層の主要部分に生成されると気密性が悪くなるなど熱分解炭素層の機能を低下させる原因となる。
しかし、本実施の形態に係る炭素複合部材では、第1層2Aと第2層2Bとの境界に気孔領域4を生成させるため、炭素複合部材の性能を劣化させる原因とはならず、むしろ複数の熱分解炭素層である第1層2Aと第2層2Bとの接合力を強めるように作用し、剥がれにくくする効果がある。
If the pyrolytic carbon layer is in a stable film-formation state, it is formed with uniform directionality, with the a-axis direction extending horizontally (left and right direction in the figure) relative to the graphite substrate 1 and the c-axis direction extending vertically (up and down direction in the figure) relative to the graphite substrate 1, but if the film-formation state is unstable, the source gas is pyrolyzed above the graphite substrate 1, turns into particles, and accumulates on the graphite substrate 1, causing a disorder in the arrangement of the pyrolytic carbon layer. If such a disorder in the arrangement is generated in the main part of the pyrolytic carbon layer, it will cause a decrease in the function of the pyrolytic carbon layer, such as a decrease in airtightness.
However, in the carbon composite member of this embodiment, since the pore region 4 is generated at the boundary between the first layer 2A and the second layer 2B, this does not cause a deterioration in the performance of the carbon composite member, but rather acts to strengthen the bonding strength between the first layer 2A and the second layer 2B, which are multiple pyrolytic carbon layers, making them less likely to peel off.

気孔領域4は、第1層2Aの成膜終了時、または第2層2Bの成膜開始時のいずれでも形成することができる。例えば、第2層2Bの成膜開始時に形成する場合には、開始時にガス分圧を上げる、または温度を上げるなど一旦不安定な状況におき、第1層2Aの表面にパーティクルを生成させたのち、安定な条件で第2層2Bとなる熱分解炭素層の形成を行う。また、第1層2Aの成膜終了時に形成する場合には、終了時にガス分圧を上げる、または温度を上げるなどして一旦不安定な状況におき、パーティクルを生成させたのち、安定な条件で第2層2Bとなる熱分解炭素層の形成を行う。パーティクルは第1層2Aの表面上に点在して降り積もるため、その上に第2層2Bとなる熱分解炭素層が成膜されると、パーティクルの周辺には気孔3が形成される。この気孔3は、第1層2Aと第2層2Bとの境界に層状に広がっており、気孔領域4となる。 The pore region 4 can be formed either at the end of the deposition of the first layer 2A or at the start of the deposition of the second layer 2B. For example, when forming the pore region 4 at the start of the deposition of the second layer 2B, an unstable situation is created at the start of the deposition by increasing the partial pressure of the gas or increasing the temperature, particles are generated on the surface of the first layer 2A, and then the pyrolytic carbon layer that will become the second layer 2B is formed under stable conditions. When forming the pore region 4 at the end of the deposition of the first layer 2A, an unstable situation is created at the end of the deposition by increasing the partial pressure of the gas or increasing the temperature, particles are generated, and then the pyrolytic carbon layer that will become the second layer 2B is formed under stable conditions. The particles are scattered and accumulated on the surface of the first layer 2A, so when the pyrolytic carbon layer that will become the second layer 2B is deposited on it, pores 3 are formed around the particles. The pores 3 spread in layers at the boundary between the first layer 2A and the second layer 2B, and become the pore region 4.

この熱分解炭素のパーティクルを生成し、沈積させるための条件の一例としては、CVD炉内の圧力を10~10000Pa、温度を800~2000℃とすることが挙げられる。
また、より多くの熱分解炭素のパーティクルを第1層2Aの表面に沈積させ、気孔3をより多く形成させるためには、CVD炉において、熱分解炭素層の上部空間が広くなるようにすればよい。上部空間が広いと、生成する熱分解炭素のパーティクルの量が多くなり、より多くの熱分解炭素のパーティクルを第1層2Aの表面に沈積させることができる。
One example of the conditions for generating and depositing these pyrolytic carbon particles is a pressure of 10 to 10,000 Pa and a temperature of 800 to 2,000° C. within the CVD furnace.
Furthermore, in order to deposit more pyrolytic carbon particles on the surface of the first layer 2A and form more pores 3, the upper space above the pyrolytic carbon layer in the CVD furnace should be made larger. If the upper space is larger, a larger amount of pyrolytic carbon particles are generated, and more pyrolytic carbon particles can be deposited on the surface of the first layer 2A.

なお、上記では熱分解炭素層を第1層2Aと第2層2Bとの2層構造とした場合を例として示しているが、本実施の形態に係る熱分解炭素層は3層以上の複数層とすることができる。その場合に、気孔領域4の形成は、同様にして各層の製膜の開始時に形成してもよいし、終了時に形成することもできる。さらに、熱分解炭素層が3層以上の場合において、上記気孔領域4は、少なくとも1組の隣接する熱分解炭素層間の境界に有していれば、本願発明の効果を奏するが、層間剥離を防止する効果を十分に発揮するためには、隣接する1組の熱分解炭素層間の境界すべてに気孔領域4を有することが好ましい。 In the above, the pyrolytic carbon layer is shown as a two-layer structure of the first layer 2A and the second layer 2B, but the pyrolytic carbon layer according to this embodiment can be a multi-layer structure of three or more layers. In that case, the pore region 4 can be formed at the start or end of the deposition of each layer in the same manner. Furthermore, when the pyrolytic carbon layer has three or more layers, the effect of the present invention can be achieved as long as the pore region 4 is present at the boundary between at least one pair of adjacent pyrolytic carbon layers. However, in order to fully exert the effect of preventing delamination, it is preferable to have the pore region 4 at all boundaries between a pair of adjacent pyrolytic carbon layers.

また、熱分解炭素層は、黒鉛基材1の両面に形成することができ、黒鉛基材1のある表面に熱分解炭素層を形成した後、黒鉛基材1を裏返して他方の面が上面となる成膜を行えばよい。または、黒鉛基材1の全面を覆うように熱分解炭素層を形成してもよい。そして、各層の成膜開始時、または成膜終了時に同様にして気孔領域4を形成すればよい。 The pyrolytic carbon layer can be formed on both sides of the graphite substrate 1. After forming a pyrolytic carbon layer on one surface of the graphite substrate 1, the graphite substrate 1 can be turned over and deposition can be performed with the other surface as the upper surface. Alternatively, the pyrolytic carbon layer can be formed so as to cover the entire surface of the graphite substrate 1. Then, the pore region 4 can be formed in the same manner at the start or end of deposition of each layer.

続いて、気孔3は、最大気孔径が0.5~3.0μmであることが好ましい。気孔3の最大気孔径が0.5μm以上であることにより、気孔3の周囲にできる配向の方向性の異なる熱分解炭素の成分を十分に確保することができ、気孔3の生成によってアンカー効果を十分に発揮することができる。また、気孔3の最大気孔径が3.0μm以下であることにより、気孔3の周囲への応力集中を低減し、気孔3が存在することにより強度が低下することを防止することができる。なお、より好ましい気孔3の最大気孔径は、1~2μmである。 Next, it is preferable that the maximum pore diameter of the pores 3 is 0.5 to 3.0 μm. By having the maximum pore diameter of the pores 3 be 0.5 μm or more, it is possible to secure a sufficient amount of pyrolytic carbon components with different orientation directions that are formed around the pores 3, and the formation of the pores 3 can fully exert the anchor effect. Furthermore, by having the maximum pore diameter of the pores 3 be 3.0 μm or less, it is possible to reduce stress concentration around the pores 3 and prevent a decrease in strength due to the presence of the pores 3. It is more preferable that the maximum pore diameter of the pores 3 be 1 to 2 μm.

気孔領域4は、厚すぎると気孔3を起点とする剥離が生じやすく、薄すぎると熱分解炭素の配向を乱す効果が少なく、上下の熱分解炭素層同志の接合力を強める効果が得られなくなる。したがって、気孔領域4の厚さは、0.5~20μmが好ましく、1~5μmがより好ましい。 If the pore region 4 is too thick, peeling is likely to occur starting from the pores 3, and if it is too thin, the effect of disturbing the orientation of the pyrolytic carbon is small, and the effect of strengthening the bonding strength between the upper and lower pyrolytic carbon layers is not obtained. Therefore, the thickness of the pore region 4 is preferably 0.5 to 20 μm, and more preferably 1 to 5 μm.

熱分解炭素層の合計厚さは5~400μmであることが好ましい。熱分解炭素層の合計厚さが5μm以上であることにより、多孔体である黒鉛基材1の凹凸を十分に覆うことができ、気体の不浸透性を確保することができる。また、熱分解炭素層の合計厚さが400μm以下であることにより、黒鉛基材1と熱分解炭素層の熱歪みによる反りや剥がれを防止することができる。なお、より好ましい熱分解炭素層の合計厚さは、10~200μmである。 The total thickness of the pyrolytic carbon layers is preferably 5 to 400 μm. When the total thickness of the pyrolytic carbon layers is 5 μm or more, the irregularities of the porous graphite substrate 1 can be sufficiently covered, ensuring gas impermeability. Furthermore, when the total thickness of the pyrolytic carbon layers is 400 μm or less, warping and peeling due to thermal distortion of the graphite substrate 1 and the pyrolytic carbon layers can be prevented. A more preferable total thickness of the pyrolytic carbon layers is 10 to 200 μm.

ここで、熱分解炭素層の厚さは、気孔領域4を除いた厚さであって、例えば、第1層2Aの厚さについては、黒鉛基材1に成膜した第1層2Aの膜厚であり、パーティクルを生成させるために成膜条件を変えて成膜した熱分解炭素の堆積厚さは含まれない。また、第2層2Bの厚さについては、パーティクルを生成した後に成膜したときの熱分解炭素層の膜厚である。 The thickness of the pyrolytic carbon layer here is the thickness excluding the pore region 4. For example, the thickness of the first layer 2A is the thickness of the first layer 2A formed on the graphite substrate 1, and does not include the thickness of the pyrolytic carbon deposited by changing the deposition conditions to generate particles. The thickness of the second layer 2B is the thickness of the pyrolytic carbon layer when deposited after particles are generated.

黒鉛基材1となる黒鉛材料としては、等方性黒鉛材であることが好ましい。等方性黒鉛は、特性の異方性が小さく均一性が高いため、熱分解炭素層との熱膨張係数差が場所、方向による差異が小さく剥がれにくくすることができる。 The graphite material that will become the graphite substrate 1 is preferably an isotropic graphite material. Since isotropic graphite has small anisotropy and high uniformity in its properties, the difference in thermal expansion coefficient between the pyrolytic carbon layer and the substrate is small depending on the location and direction, making it difficult to peel off.

<実施の形態2>
続いて、本発明の実施の形態2について説明する。図3は、本発明の実施の形態2に係る炭素複合部材の断面図である。
<Embodiment 2>
Next, a description will be given of a second embodiment of the present invention. Fig. 3 is a cross-sectional view of a carbon composite member according to the second embodiment of the present invention.

図3で示すような形態、すなわち黒鉛基材1の全面に複数の熱分解炭素層を形成するような形態の炭素複合部材は、例えば、特開2016-169422号の図1で示すような所定の支持具を用いた製造方法により製造することができる(本製造方法の詳細については後述する。)。この場合において、熱分解炭素層の一部に第1の開口部10や第2の開口部11が形成される。 A carbon composite member having the configuration shown in FIG. 3, that is, a configuration in which multiple pyrolytic carbon layers are formed over the entire surface of the graphite substrate 1, can be manufactured, for example, by a manufacturing method using a predetermined support as shown in FIG. 1 of JP 2016-169422 A (the details of this manufacturing method will be described later). In this case, a first opening 10 and a second opening 11 are formed in part of the pyrolytic carbon layer.

図3に示すように、本実施の形態に係る炭素複合部材では、黒鉛基材1が第1層2A及び第2層2Bで覆われているとともに、第1層2Aは黒鉛基材1の一方の面(図中の上面)に第1の開口部10(図3では2箇所)を有し、第2層2Bが第1の開口部10を覆っている。そのため、第1の開口部10から黒鉛基材1への気密性は、第2層2Bで確保されている。一方、黒鉛基材1の他方の面(図中の下面)には第1の開口部10はなく、全面が第1層2Aで覆われているとともに、第2層2Bに第2の開口部11(図3では2箇所)を有する。そのため、第2の開口部11から黒鉛基材1への気密性は、第1層2Aで確保されている。 As shown in FIG. 3, in the carbon composite member according to this embodiment, the graphite substrate 1 is covered with the first layer 2A and the second layer 2B, and the first layer 2A has a first opening 10 (two openings in FIG. 3) on one side (top side in FIG. 3) of the graphite substrate 1, and the second layer 2B covers the first opening 10. Therefore, the airtightness from the first opening 10 to the graphite substrate 1 is ensured by the second layer 2B. On the other hand, the other side (bottom side in FIG. 3) of the graphite substrate 1 does not have the first opening 10, is entirely covered by the first layer 2A, and has the second opening 11 (two openings in FIG. 3) in the second layer 2B. Therefore, the airtightness from the second opening 11 to the graphite substrate 1 is ensured by the first layer 2A.

すなわち、黒鉛基材に近い側の第1層2Aにある第1の開口部10と、外側の第2層2Bにある第2の開口部11とが黒鉛基材1に対して異なる位置にあるため、第1の開口部10が閉塞され、黒鉛基材1からのガスや水分、不純物等の放出を防止するともに、外部からのガスや水分、不純物等の吸着を防止することができる。なお、第1の開口部10や第2の開口部11は、第1層2A及び第2層2Bのそれぞれに1つでもよいし、複数箇所に形成されていてもよい。 That is, the first opening 10 in the first layer 2A closer to the graphite substrate and the second opening 11 in the outer second layer 2B are located at different positions relative to the graphite substrate 1, so that the first opening 10 is blocked, preventing the release of gas, moisture, impurities, etc. from the graphite substrate 1 and preventing the adsorption of gas, moisture, impurities, etc. from the outside. The first opening 10 and the second opening 11 may be formed in one place in each of the first layer 2A and the second layer 2B, or in multiple places.

図3においては、複数の熱分解炭素層として第1層2A及び第2層2Bの2層の場合について説明しているが、例えば、複数の熱分解炭素層を、黒鉛基材1に近い側から順に第1層、第2層、・・・、第n-1層、第n層とするとき、第1層が第1の開口部を有し、第n層が第nの開口部を有するともに、第1の開口部と第nの開口部とは、黒鉛基材1に対して異なる位置に形成されていれば、上記と同様の効果を奏することができる。なお、nは2以上の整数である。 In FIG. 3, the case of two layers, a first layer 2A and a second layer 2B, is described as the multiple pyrolytic carbon layers. However, for example, if the multiple pyrolytic carbon layers are the first layer, the second layer, ..., the n-1th layer, and the nth layer in order from the side closest to the graphite substrate 1, and the first layer has the first opening and the nth layer has the nth opening, and the first opening and the nth opening are formed at different positions relative to the graphite substrate 1, the same effect as above can be achieved. Here, n is an integer of 2 or more.

図4は、図3のA部断面の拡大図であり、第1層2Aに形成された第1の開口部10の周辺(図中のC領域)を詳細に示している。 Figure 4 is an enlarged cross-sectional view of part A in Figure 3, showing in detail the periphery of the first opening 10 formed in the first layer 2A (area C in the figure).

図4に示すように、第2層2Bが第1の開口部10を覆うとともに、第1の開口部周辺(C領域)における第1層2Aと第2層2Bとの境界の気孔領域4が、黒鉛基材1に向かって傾斜して伸びている。すなわち、第2層2Bが第1層2Aにある第1の開口部10を覆っているため、黒鉛基材1のガス、水分、不純物の放出及び外部からの吸着を防止する効果を高めることができる。また、第1の開口部の周辺(C領域)における第1層2Aと第2層2Bとの境界の気孔領域4が、黒鉛基材1に向かって傾斜して伸びているため、応力集中の起きやすい第1の開口部10の境界部分の補強効果を高めることができる。 As shown in FIG. 4, the second layer 2B covers the first opening 10, and the pore region 4 at the boundary between the first layer 2A and the second layer 2B in the periphery of the first opening (region C) extends at an incline toward the graphite substrate 1. That is, since the second layer 2B covers the first opening 10 in the first layer 2A, the effect of preventing the graphite substrate 1 from emitting gas, moisture, and impurities and from adsorbing them from the outside can be enhanced. In addition, since the pore region 4 at the boundary between the first layer 2A and the second layer 2B in the periphery of the first opening (region C) extends at an incline toward the graphite substrate 1, the reinforcing effect of the boundary portion of the first opening 10 where stress concentration is likely to occur can be enhanced.

図5は、図3のB部断面の拡大図であり、第2層2Bに形成された第2の開口部11の周辺(D領域)を詳細に示している。 Figure 5 is an enlarged cross-sectional view of part B in Figure 3, showing in detail the periphery (area D) of the second opening 11 formed in the second layer 2B.

図5に示すように、第1層2Aには開口部がなく、また、第2層2Bは第1層2Aの上面(図中では下側)に積層して形成されており、第2層2Bには第2の開口部11を有する。そして、第2層2Bと第2層2Bの直下の第1層2Aとの境界に気孔領域4を有し、図中のD領域で示されるように、第2層2Bが第2の開口部11に向かって徐々に薄くなっているので、応力集中を緩和して、他の部位と比べて厚さの薄い第2の開口部の境界部分の補強効果を高めることができる。 As shown in FIG. 5, the first layer 2A has no openings, and the second layer 2B is formed by laminating it on the upper surface of the first layer 2A (the lower side in the figure), with the second layer 2B having a second opening 11. The second layer 2B has a pore region 4 at the boundary between the first layer 2A and the second layer 2B directly below it, and as shown by region D in the figure, the second layer 2B gradually becomes thinner toward the second opening 11, which can alleviate stress concentration and enhance the reinforcing effect of the boundary portion of the second opening, which is thinner than other portions.

図5においては、複数の熱分解炭素層として第1層2A及び第2層2Bの2層の場合について説明しているが、図3において説明した場合と同様、第n層と第n層の直下の第n-1層との境界に気孔領域4を有し、第n層が第nの開口部に向かって徐々に薄くなっていれば、上記と同様の効果を奏することができる。なお、nは2以上の整数である。 In FIG. 5, the case where the multiple pyrolytic carbon layers are two layers, a first layer 2A and a second layer 2B, is described, but as in the case described in FIG. 3, if there is a pore region 4 at the boundary between the nth layer and the n-1th layer immediately below the nth layer, and the nth layer becomes gradually thinner toward the nth opening, the same effect as above can be achieved. Note that n is an integer of 2 or more.

続いて、本発明の実施の形態2に係る炭素複合部材の製造方法について詳述する。このような炭素複合部材を製造するには、例えば図6に示す工程に従うことができる。
同図の(A)は黒鉛基材1、(B)は第1層2Aの形成工程、(C)は黒鉛基材1の第1面1a側に対する気孔領域4の形成工程、(D)は黒鉛基材1の第2面1b側(すなわち、第1の開口部10が形成された側)に対する気孔領域4の形成工程、(E)は第2層2Bの形成工程を、それぞれ示している。なお、同図(A)に示すように、黒鉛基材1の一方の面(図中の上面)を第1面1a、他方の面(図中の下面)を第2面1bとしている。また、図7に、図6の(C)工程、(D)工程及び(E)工程で形成される各層を拡大して示す。
Next, a detailed description will be given of a method for manufacturing a carbon composite member according to the second embodiment of the present invention. To manufacture such a carbon composite member, for example, the steps shown in FIG.
In the figure, (A) shows the graphite substrate 1, (B) shows the process of forming the first layer 2A, (C) shows the process of forming the pore regions 4 on the first surface 1a side of the graphite substrate 1, (D) shows the process of forming the pore regions 4 on the second surface 1b side of the graphite substrate 1 (i.e., the side where the first openings 10 are formed), and (E) shows the process of forming the second layer 2B. As shown in the figure (A), one surface (upper surface in the figure) of the graphite substrate 1 is the first surface 1a, and the other surface (lower surface in the figure) is the second surface 1b. In addition, Fig. 7 shows an enlarged view of each layer formed in the steps (C), (D), and (E) of Fig. 6.

まず、(B)工程に示すように、黒鉛基材1を支持具20に載置する。支持具20は、CVD装置の基板ホルダ(図示せず)に載置される。支持具20は、例えば円柱形状の支持具本体21と、支持具本体21の中央部から突出する支持部22とを有しており、一体的に形成されている。なお、これらを一体化させるには、例えば、支持具本体21と支持部22とが得られるように加工したり、支持具本体21と支持部22とを接着剤等で接着することにより実現できる。 First, as shown in step (B), the graphite substrate 1 is placed on the support 20. The support 20 is placed on a substrate holder (not shown) of a CVD device. The support 20 has, for example, a cylindrical support body 21 and a support part 22 protruding from the center of the support body 21, and is formed integrally. To integrate these, for example, the support body 21 and the support part 22 can be processed to obtain them, or the support body 21 and the support part 22 can be bonded together with an adhesive or the like.

支持部22は全体が円錐台形状を呈しており、軸線に沿った断面において、頂面23から支持具本体21に向かって漸次拡径する傾斜面を有する形状を呈している。また、頂面23は、図示されるような平面の他、先端が尖る形状(円錐形状)とすることも可能である。この支持部22に、黒鉛基材1の第2面1bが接して支持される。 The support part 22 has a truncated cone shape as a whole, and in a cross section along the axis, it has a shape with an inclined surface that gradually expands in diameter from the top surface 23 toward the support body 21. The top surface 23 can be flat as shown in the figure, or it can be a pointed shape (cone shape). The second surface 1b of the graphite base material 1 is in contact with and supported by this support part 22.

この状態で、安定したCVD法を行って熱分解炭素層を成膜する。それにより、図示されるように、支持具20の支持部22の周辺を除いて黒鉛基材1を覆うように第1層2Aが形成される。その際、第1層2Aには、第1の開口部10が支持部22に外形に沿った形状に形成される。 In this state, a stable CVD method is performed to form a pyrolytic carbon layer. As a result, as shown in the figure, a first layer 2A is formed to cover the graphite substrate 1 except for the periphery of the support portion 22 of the support 20. At that time, a first opening 10 is formed in the first layer 2A in a shape that conforms to the outer shape of the support portion 22.

次いで、(C)工程に示すように、不安定なCVDを行って、第1層2Aの黒鉛基材1の第1面1aの側に、気孔領域4を全面にわたり十分に形成する。なお、黒鉛基材1の第2面1bの側にも少なからず気孔領域4が形成されると考えられるが、黒鉛基材1の第1面1aの側と比べると少ない。 Next, as shown in step (C), unstable CVD is performed to sufficiently form pore regions 4 over the entire surface of the first surface 1a of the graphite substrate 1 of the first layer 2A. Note that it is believed that pore regions 4 are also formed to some extent on the second surface 1b of the graphite substrate 1, but the amount is smaller than that on the first surface 1a of the graphite substrate 1.

次いで、(D)工程に示すように、黒鉛基材1を表裏反転(上下反転)させて第1面1aを支持具20に載置する。それに伴い、第1層2Aの第1の開口部10が、図中の上方を向く。そして、再び不安定なCVDを行って、黒鉛基材1の第2面1b側(すなわち、第1の開口部10が形成された側)に、気孔領域4を全面にわたり十分に形成する。その際、第1の開口部10上にも熱分解炭素のパーティクルが降り積もるため、第1の開口部10上においても気孔領域4が形成される(図4参照)。 Next, as shown in step (D), the graphite substrate 1 is turned over (upside down) and the first surface 1a is placed on the support 20. Accordingly, the first opening 10 of the first layer 2A faces upward in the figure. Then, unstable CVD is performed again to sufficiently form the pore region 4 over the entire surface on the second surface 1b side of the graphite substrate 1 (i.e., the side on which the first opening 10 is formed). At that time, the pyrolytic carbon particles also fall and accumulate on the first opening 10, so that the pore region 4 is also formed on the first opening 10 (see FIG. 4).

次いで、(E)工程に示すように、安定したCVDを行って第2層2Bを形成する。以上の工程を経て、第1の開口部10は第2層2Bにより閉塞されて図4に示す状態となり、また、第2の開口部11にも気孔領域4が形成されて図5に示す状態となる。すなわち、上記製造方法によれば、第2層2Bが第1の開口部10を覆うとともに、第1の開口部周辺(C領域)における第1層2Aと第2層2Bとの境界の気孔領域4が、黒鉛基材1に向かって傾斜して伸びており、更に、第2層2Bが第2の開口部11に向かって徐々に薄くなっているような炭素複合部材を製造することができる。 Next, as shown in step (E), stable CVD is performed to form the second layer 2B. Through the above steps, the first opening 10 is blocked by the second layer 2B, as shown in FIG. 4, and a pore region 4 is also formed in the second opening 11, as shown in FIG. 5. That is, according to the above manufacturing method, a carbon composite member can be manufactured in which the second layer 2B covers the first opening 10, the pore region 4 at the boundary between the first layer 2A and the second layer 2B around the first opening (area C) extends at an angle toward the graphite substrate 1, and the second layer 2B gradually becomes thinner toward the second opening 11.

なお、上述したように、支持具20として例えば円柱形状の支持具本体21と、支持具本体21の中央部から突出する円錐台形状の支持部22とを用いて、第1層2A及び第2層2Bを形成しているため、各層の開口部(第1の開口部10、第2の開口部11)において、各開口部に向かって徐々に薄くなる熱分解炭素層を形成することができる。 As described above, the first layer 2A and the second layer 2B are formed using the support 20, for example, a cylindrical support body 21 and a truncated cone-shaped support part 22 protruding from the center of the support body 21. Therefore, at the openings of each layer (first opening 10, second opening 11), a pyrolytic carbon layer that gradually becomes thinner toward each opening can be formed.

以上、本発明に関して実施の形態1及び2を挙げて説明したが、これら実施の形態に限らず、変形、改良や変更等を適宜行うことができる。 The present invention has been described above using the first and second embodiments, but it is not limited to these embodiments and can be modified, improved, changed, etc. as appropriate.

本発明の炭素複合部材は、黒鉛基材を複数層の熱分解炭素層で覆ったことにより、全体としてより高性能であり、また熱分解炭素層同士の剥離も抑えられており、耐久性にも優れる。そのため、半導体製造、化学工業、機械、原子力等、多くの分野にわたって有効である。 The carbon composite member of the present invention has higher overall performance due to the graphite base material being covered with multiple pyrolytic carbon layers, and also has excellent durability as it prevents the pyrolytic carbon layers from peeling off from each other. Therefore, it is effective in many fields such as semiconductor manufacturing, chemical industry, machinery, and atomic energy.

1 黒鉛基材
2A 第1層(一の熱分解炭素層)
2B 第2層(他の熱分解炭素層)
3 気孔
4 気孔領域
10 第1の開口部
11 第2の開口部
20 支持具
21 支持具本体
22 支持部
23 頂面
1 Graphite substrate 2A First layer (first pyrolytic carbon layer)
2B 2nd layer (another pyrolytic carbon layer)
3: pore 4: pore region 10: first opening 11: second opening 20: support 21: support body 22: support portion 23: top surface

Claims (6)

黒鉛基材上に複数の熱分解炭素層が形成された炭素複合部材であって、
一の前記熱分解炭素層とこれに隣接する他の前記熱分解炭素層との境界に、気孔が存在する気孔領域を有し、
前記気孔領域の厚さは、0.5~20μmであり、かつ、前記熱分解炭素層の合計厚さが5~400μmであることを特徴とする炭素複合部材。
A carbon composite member having a plurality of pyrolytic carbon layers formed on a graphite substrate,
a pore region in which pores exist at a boundary between one of the pyrolytic carbon layers and another of the pyrolytic carbon layers adjacent thereto ;
A carbon composite member, characterized in that the thickness of the pore region is 0.5 to 20 μm, and the total thickness of the pyrolytic carbon layer is 5 to 400 μm .
前記複数の熱分解炭素層を、前記黒鉛基材に近い側から順に第1層、第2層、・・・、第n-1層、第n層とするとき、
前記第1層が第1の開口部を有し、前記第n層が第nの開口部を有するともに、
前記第1の開口部と前記第nの開口部とは、前記黒鉛基材に対して異なる位置に形成されていることを特徴とする請求項1に記載の炭素複合部材。
When the plurality of pyrolytic carbon layers are designated as a first layer, a second layer, ..., an (n-1)th layer, and an nth layer in order from the side closest to the graphite base material,
the first layer has a first opening, the nth layer has an nth opening,
The carbon composite member according to claim 1 , wherein the first opening and the nth opening are formed at different positions with respect to the graphite substrate.
前記第2層が前記第1の開口部を覆うとともに、前記第1の開口部周辺における前記第1層と前記第2層との境界の前記気孔領域は、前記黒鉛基材に向かって傾斜して伸びていることを特徴とする請求項2に記載の炭素複合部材。 The carbon composite member according to claim 2, characterized in that the second layer covers the first opening, and the pore region at the boundary between the first layer and the second layer around the first opening extends at an angle toward the graphite substrate. 前記第n層と前記第n層の直下の前記第n-1層との境界に前記気孔領域を有し、前記第n層は、前記第nの開口部に向かって徐々に薄くなっていることを特徴とする請求項2または3に記載の炭素複合部材。 The carbon composite member according to claim 2 or 3, characterized in that the pore region is present at the boundary between the nth layer and the n-1th layer immediately below the nth layer, and the nth layer is gradually thinner toward the nth opening. 前記気孔は、最大気孔径が0.5~3.0μmであることを特徴とする請求項1~4のいずれか1項に記載の炭素複合部材。 The carbon composite member according to any one of claims 1 to 4, characterized in that the pores have a maximum pore diameter of 0.5 to 3.0 μm. 前記黒鉛基材が等方性黒鉛材であることを特徴とする請求項1~のいずれか1項に記載の炭素複合部材。 The carbon composite member according to any one of claims 1 to 5 , characterized in that the graphite base material is an isotropic graphite material.
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