CN103665746A - 一种低磨耗高稳定系数的微孔型摩擦材料及其制造方法 - Google Patents

一种低磨耗高稳定系数的微孔型摩擦材料及其制造方法 Download PDF

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CN103665746A
CN103665746A CN201210316276.1A CN201210316276A CN103665746A CN 103665746 A CN103665746 A CN 103665746A CN 201210316276 A CN201210316276 A CN 201210316276A CN 103665746 A CN103665746 A CN 103665746A
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friction material
micro porous
low abrasion
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CN103665746B (zh
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张定权
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SHANGHAI RENFENG COMPOSITE MATERIALS CO Ltd
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Priority to PCT/CN2012/082790 priority patent/WO2014032360A1/zh
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Abstract

本发明涉及一种低磨耗高稳定系数的微孔型摩擦材料及其制造方法，该材料的原料配方如下：GM-15树脂15-50wt％、橡胶0-10wt％、成型助剂0.5-5wt％、烧结助剂0.5-5wt％、发泡助剂0.5-5wt％、高岭土粉0.5-20wt％、重晶石粉5-40wt％、碳纤维2-20wt％、KEVLAR1-5wt％、氧化锌1-10wt％、氧化铁红0-2wt％。与现有技术相比，本发明通过调整材料的亲水性能，控制材料表面张力，达到潮湿状态下摩擦系数不下降，干湿状态下摩擦系数均保持稳定。采用本发明技术，摩擦材料湿态摩擦系数仍可以保持在0.25以上，摩擦系数在MM1000试验机上稳定系数可达85％以上。

Description

一种低磨耗高稳定系数的微孔型摩擦材料及其制造方法
技术领域
本发明涉及一种摩擦材料，尤其是涉及一种低磨耗高稳定系数的微孔型摩擦材料及其制造方法。
背景技术
自从有了微孔材料的提出，对降低摩擦副摩擦温度有了一定的效果。但是在实际使用过程中，会产生微孔孔径不均匀，批次磨耗不稳定，在潮湿状态下摩擦系数不稳定等缺点。通过本发明可以达到降低制动温度，既可以解决制动时温度过高对对偶材料的热损害，又可以达到控制材料微孔孔径，减小材料磨损率，延长使用寿命，且可保证材料在潮湿状态下的摩擦系数保持不下降等优点。不失为应对高速、重载和频繁制动的有效途径。
发明内容
本发明的目的就是为了克服上述现有技术存在的缺陷而提供一种低磨耗高稳定系数的微孔型摩擦材料及其制造方法。
本发明的目的可以通过以下技术方案来实现：一种低磨耗高稳定系数的微孔型摩擦材料，其特征在于，该材料的原料配方如下：
  组分   重量百分比
  GM-15树脂   15-50
  橡胶   0-10
  成型助剂   0.5-5
  烧结助剂   0.5-5
  发泡助剂   0.5-5
  高岭土粉   0.5-20
  重晶石粉   5-40
  碳纤维   2-20
  KEVLAR   1-5
  氧化锌   1-10
  氧化铁红   0-2
。
所述的材料的原料优选以下配方：
  组分   重量百分比
  GM-15树脂   22-35
  橡胶   5-8
  成型助剂   1-3
  烧结助剂   1-4
  发泡助剂   2-3
  高岭土粉   10-15
  重晶石粉   15-35
  碳纤维   10-15
  KEVLAR   2-4
  氧化锌   2-7
  氧化铁红   1-2
。
所述的GM-15树脂为市售改性酚醛树脂。
所述的橡胶为丁腈粉末橡胶。
所述的成型助剂为包含但不限于4-叔丁基硫酚锌、五氯硫酚锌盐、丙烯酸酯共聚物。
所述的烧结助剂为包含但不限于有机硅树脂、二甲基硅油、聚四氟乙烯。
所述的发泡助剂为包含但不限于偶氮二甲酰胺、N.N-二亚硝基五次甲基四胺、偶氮二异丁晴。
所述的碳纤维为市售短切碳纤维。
所述的KEVLAR为市售芳纶浆粕。
一种低磨耗高稳定系数的微孔型摩擦材料的制备方法，其特征在于，该方法包括以下步骤：
(1)称取原料：
  组分   重量百分比
  GM-15树脂   15-50
  橡胶   0-10
  4-叔丁基硫酚锌   0.5-5
  烧结助剂   0.5-5
  发泡助剂   0.5-5
  高岭土粉   0.5-20
  重晶石粉   5-40
  碳纤维   2-20
  KEVLAR   1-5
  氧化锌   1-10
  氧化铁红   0-2
；
(2)将上述原料加入到高速犁耙式混料机中混合，混合时间2～50min，在室温～120℃下将物料在成型模具中以200～500kg/cm2的压力反应20～300秒，然后将成型的摩擦片在高温下烧结，烧结温度为160-260℃，烧结时间2-20小时，即可得到微孔型摩擦材料。成型模具中的反应压力优选250～300kg/cm2，反应时间优选100～200秒，烧结温度优选180-220℃，烧结时间优选10～12小时。
原有技术生产的微孔型摩擦材料，微孔的孔径多为1-4μm，孔隙率多为5-20％。其平均磨损率为0.35cm3/MJ，在台架试验条件下湿态μ平均＜0.20，摩擦系数在MM1000试验机上的稳定系数小于80％。
与目前微孔摩擦材料相比，本发明的提出，可以通过调整材料的亲水性能，控制材料表面张力，达到潮湿状态下摩擦系数不下降，干湿状态下摩擦系数均保持稳定。原有技术下，摩擦材料在潮湿状态下，摩擦系数会迅速下降至0.2以下。采用本发明技术，摩擦材料湿态摩擦系数仍可以保持在0.25以上，摩擦系数在MM1000试验机上稳定系数可达85％以上。
与现有技术相比，本发明中通过发泡助剂的添加，使得微孔材料的孔径控制在0.5-1μm，由于摩擦过程中磨粒的直径大多在2μm以上(60％)，磨粒不会对微孔产生堵塞，可以顺利排出，可以减少磨粒磨损的几率，避免了金属镶嵌物的产生。
本发明的提出，通过改变摩擦材料的成型温度与成型压力，成型助剂的添加，达到控制微孔材料孔径，可保持在0.2-1μm，孔隙率在15-35％以上。通过此技术，可以大幅度降低产品的磨耗，平均磨损率均小于0.16cm3/MJ，延长产品的使用寿命一倍以上，是一种低碳绿色环保的摩擦材料。
具体实施方式
下面结合具体实施例对本发明进行详细说明。
实施例1
1)原料的配制：
  组分   重量百分比
  GM-15树脂   22
  丁腈橡胶粉末   5
  4-叔丁基硫酚锌   3
  有机硅树脂   1
  发泡剂AC(偶氮二甲酰胺)   2
  高岭土粉   15
  重晶石粉   35
  碳纤维   7
  KEVLAR   2
  氧化锌   7
  氧化铁红   1
(2)制备：
将上述原料按比例、分步骤的加入到高速犁耙式混料机中混合，混合时间25min，在80℃下将物料在成型模具中以250kg/cm2的压力反应150秒。然后将成型的摩擦片在高温下烧结。烧结温度为200℃，烧结时间10小时，即可得到微孔型摩擦材料。
所制得的摩擦材料性能如下：
一、物理机械性能
  测试项目   测试结果
  气孔率   27％
  孔径   0.5-1μm
  密度   1.48g/cm3
二、摩擦性能
  测试项目   测试结果
  平均摩擦系数(80km/h)   0.303
  摩擦系数稳定系数   88.08％
  湿态平均摩擦系数   0.287
  平均磨损率   0.11cm3/MJ
实施例2
1)原料的配制：
  组分   重量百分比
  GM-15树脂   35
  丁腈橡胶粉末   0
  五氯硫酚锌盐   1
  二甲基硅油   1.5
  发泡剂DPT(N.N-二亚硝基五次甲基四胺)   2.5
  高岭土粉   10
  重晶石粉   29
  碳纤维   15
  KEVLAR   1
  氧化锌   5
  氧化铁红   0
(2)制备：
将上述原料按比例、分步骤的加入到高速犁耙式混料机中混合，混合时间30min，在100℃下将物料在成型模具中以200kg/cm2的压力反应200秒。然后将成型的摩擦片在高温下烧结。烧结温度为220℃，烧结时间12小时，即可得到微孔型摩擦材料。
制得材料性能如下：
一、物理机械性能
  测试项目   测试结果
  气孔率   30％
  孔径   0.3-0.8μm
  密度   1.42g/cm3
二、摩擦性能
  测试项目   测试结果
  平均摩擦系数(80km/h)   0.305
  摩擦系数稳定系数   88.35％
  湿态平均摩擦系数   0.284
  平均磨损率   0.09cm3/MJ
实施例3
1)原料的配制：
  组分   重量百分比
  GM-15树脂   15
  丁腈橡胶粉末   10
  丙烯酸酯共聚物   5
  聚四氟乙烯   4
  发泡剂AIBN(偶氮二异丁晴)   5
  高岭土粉   20
  重晶石粉   15
  碳纤维   10
  KEVLAR   4
  氧化锌   10
  氧化铁红   2
(2)制备：
将上述原料按比例、分步骤的加入到高速犁耙式混料机中混合，混合时间30min，在50℃下将物料在成型模具中以300kg/cm2的压力反应100秒。然后将成型的摩擦片在高温下烧结。烧结温度为180℃，烧结时间20小时，即可得到微孔型摩擦材料。
制得材料性能如下：
一、物理机械性能
  测试项目   测试结果
  气孔率   29％
  孔径   0.55-1.0μm
  密度   1.46g/cm3
二、摩擦性能
  测试项目   本发明所制材料
  平均摩擦系数   0.317
  摩擦系数稳定系数   85.19％
  湿态平均摩擦系数   0.292
  平均磨损率   0.12cm3/MJ
实施例4
1)原料的配制：
  组分   重量百分比
  GM-15树脂   50
  丁腈橡胶粉末   0
  丙烯酸酯共聚物   0.5
  聚四氟乙烯   0.5
  发泡剂AIBN(偶氮二异丁晴)   0.5
  高岭土粉   0.5
  重晶石粉   40
  碳纤维   2
  KEVLAR   5
  氧化锌   1
  氧化铁红   0
(2)制备：
将上述原料按比例、分步骤的加入到高速犁耙式混料机中混合，混合时间2min，在120℃下将物料在成型模具中以200kg/cm2的压力反应300秒。然后将成型的摩擦片在高温下烧结。烧结温度为260℃，烧结时间2小时，即可得到微孔型摩擦材料。
制得材料性能如下：
一、物理机械性能
  测试项目   测试结果
  气孔率   27％
  孔径   0.5-0.8μm
  密度   1.49g/cm3
二、摩擦性能
  测试项目   测试结果
  平均摩擦系数(80km/h)   0.32
  摩擦系数稳定系数   87.45％
  湿态平均摩擦系数   0.295
  平均磨损率   0.08cm3/MJ
实施例5
1)原料的配制：
  组分   重量百分比
  GM-15树脂   40
  丁腈橡胶粉末   8
  五氯硫酚锌盐   3
  二甲基硅油   5
  发泡剂DPT(N.N-二亚硝基五次甲基四胺)   3
  高岭土粉   10
  重晶石粉   5
  碳纤维   20
  KEVLAR   3
  氧化锌   2
  氧化铁红   1
(2)制备：
将上述原料按比例、分步骤的加入到高速犁耙式混料机中混合，混合时间50min，在室温下将物料在成型模具中以500kg/cm2的压力反应20秒。然后将成型的摩擦片在高温下烧结。烧结温度为160℃，烧结时间20小时，即可得到微孔型摩擦材料。
制得材料性能如下：
一、物理机械性能
  测试项目   测试结果
  气孔率   20％
  孔径   0.4-0.9μm
  密度   1.46g/cm3
二、摩擦性能
  测试项目   本发明所制材料
  平均摩擦系数   0.308
  摩擦系数稳定系数   86.77％
  湿态平均摩擦系数   0.285
  平均磨损率   0.10cm3/MJ

Claims (10)

1.一种低磨耗高稳定系数的微孔型摩擦材料，其特征在于，该材料的原料配方如下：
  组分   重量百分比   GM-15树脂   15-50   橡胶   0-10   成型助剂   0.5-5   烧结助剂   0.5-5   发泡助剂   0.5-5   高岭土粉   0.5-20   重晶石粉   5-40   碳纤维   2-20   KEVLAR   1-5   氧化锌   1-10   氧化铁红   0-2
2.根据权利要求1所述的一种低磨耗高稳定系数的微孔型摩擦材料，其特征在于，所述的材料的原料优选以下配方：
  组分   重量百分比   GM-15树脂   22-35   橡胶   5-8   成型助剂   1-3   烧结助剂   1-4   发泡助剂   2-3   高岭土粉   10-15   重晶石粉   15-35   碳纤维   10-15
  KEVLAR   2-4   氧化锌   2-7   氧化铁红   1-2
3.根据权利要求1所述的一种低磨耗高稳定系数的微孔型摩擦材料，其特征在于，所述的GM-15树脂为市售改性酚醛树脂。
4.根据权利要求1所述的一种低磨耗高稳定系数的微孔型摩擦材料，其特征在于，所述的橡胶为丁腈粉末橡胶。
5.根据权利要求1所述的一种低磨耗高稳定系数的微孔型摩擦材料，其特征在于，所述的成型助剂为包含但不限于4-叔丁基硫酚锌、五氯硫酚锌盐、丙烯酸酯共聚物。
6.根据权利要求1所述的一种低磨耗高稳定系数的微孔型摩擦材料，其特征在于，所述的烧结助剂为包含但不限于有机硅树脂、二甲基硅油、聚四氟乙烯。
7.根据权利要求1所述的一种低磨耗高稳定系数的微孔型摩擦材料，其特征在于，所述的发泡助剂为包含但不限于偶氮二甲酰胺、N.N-二亚硝基五次甲基四胺、偶氮二异丁晴。
8.根据权利要求1所述的一种低磨耗高稳定系数的微孔型摩擦材料，其特征在于，所述的碳纤维为市售短切碳纤维。
9.根据权利要求1所述的一种低磨耗高稳定系数的微孔型摩擦材料，其特征在于，所述的KEVLAR为市售芳纶浆粕。
10.一种如权利要求1所述的低磨耗高稳定系数的微孔型摩擦材料的制备方法，其特征在于，该方法包括以下步骤：
(1)称取原料：
  组分   重量百分比   GM-15树脂   15-50   橡胶   0-10   4-叔丁基硫酚锌   0.5-5   烧结助剂   0.5-5   发泡助剂   0.5-5
  高岭土粉   0.5-20   重晶石粉   5-40   碳纤维   2-20   KEVLAR   1-5   氧化锌   1-10   氧化铁红   0-2
；
(2)将上述原料加入到高速犁耙式混料机中混合，混合时间2～50min，在室温～120℃下将物料在成型模具中以200～500kg/cm2的压力反应20～300秒，然后将成型的摩擦片在高温下烧结，烧结温度为160-260℃，烧结时间2～20小时，即可得到微孔型摩擦材料。
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