CN108162510A - 金属和石墨层压件 - Google Patents

金属和石墨层压件 Download PDF

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CN108162510A
CN108162510A CN201711362935.4A CN201711362935A CN108162510A CN 108162510 A CN108162510 A CN 108162510A CN 201711362935 A CN201711362935 A CN 201711362935A CN 108162510 A CN108162510 A CN 108162510A
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foil
plate
layer
metal core
shape metal
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R·阿贝斯曼
N·法姆
W·迈克尔威
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Gripmitt Co Ltd
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Manu Grip Mitter Co Ltd
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
    • B32B9/007—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile comprising carbon, e.g. graphite, composite carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
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    • F16J15/121—Sealings between relatively-stationary surfaces with solid packing compressed between sealing surfaces with non-metallic packing with metal reinforcement or covering with metal reinforcement
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    • B32—LAYERED PRODUCTS
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    • B32—LAYERED PRODUCTS
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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  • Engineering & Computer Science (AREA)
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Abstract

本发明是一种具有两个层状体的层压片材。第一层状体是相对硬质材料，具有第一表面和第二表面。所述第一表面具有多个凸起且大体带尖的穿刺结构，每个结构均具有末端。所述第二层状体是石墨箔材料，其与所述相对硬质材料配合，使得至少一些穿刺结构穿透石墨箔材料。在一个实施例中，所述第一层状不具有穿孔且均匀地平滑。在另一实施例中，第二表面也具有多个穿刺结构，包括石墨箔的第三层状体与第二表面配合。

Description

金属和石墨层压件
本申请为国际申请号为PCT/CA2014/000579，国际申请日为2014年7月21日，发明名称为“金属和石墨层压件”的PCT申请于2016年3月24日进入中国国家阶段后申请号为201480052555.9的中国国家阶段专利申请的分案申请。
技术领域
本发明一般地涉及层压材料，更特别地涉及包括与至少一个石墨箔层结合的至少一个加纹理金属片层的层压材料。
背景技术
对于更轻、更硬、更廉价的结构材料的需求渐增，优选地具备这三种品质，用这种结构材料制作更好的产品。
与石墨箔层压的不锈钢是一种广泛使用的材料，其具有使其适合于多种用途诸如制作垫圈的特性。这种垫圈能够提供高的防爆性并且因此能够用于具有高密封应力的应用中。这种材料在宽温度范围内永久性地有弹性，诸如-200℃至550℃。这种材料不会老化，不易碎且提供无关于温度长期均匀性和弹性，使其能够承受高的压缩应力。这种材料还能够承受高压，诸如高达500巴。钢或“载体”层典型地为0.10-0.12mm厚的“冲齿”不锈钢板。然后，通过将石墨箔片压到金属板的各表面上从而形成具有典型地1至4mm的厚度的层压件来形成层压件。金属冲齿的使用使各层能够机械地结合，不需要任何粘合剂，因为金属的每个表面上的冲齿穿入被压到各表面上的石墨箔。
这种金属冲齿片材是通过金属箔冲孔机而形成的，金属箔冲压机采用穿透箔的针，使得冲齿从片材的与针穿入的一侧相反的一侧延伸出。结果，片材由于穿孔而弱化。而且，如果金属板仅层压在一侧上，未经层压的金属表面由于穿孔不是平滑的。此外，金属层的厚度受限制，因为它必须足够薄以使冲孔机的针能够穿过它。期望的是提供一种使得石墨箔层压到不会遇到由于使用这种金属冲齿而带来缺陷的至少一侧上的材料。
在圆盘闸卡钳中，液压致动的活塞通过作用力和反作用力迫使一对对置的制动衬块夹住附接到车轮上的转子。制动衬块具有刚性的底板，摩擦摩擦垫附着到一侧。薄型材料的垫片通常用在活塞所接触的板的一侧。垫片的作用是降低来自本来是机械上完美的制动器的大声的、烦人的尖声噪声的发生频率。至少一些噪声来自于如下事实：为防止堵塞，板具有一定的在卡钳内径向移动的自由度，使得转子能够被释放，而活塞具有极小的运动自由度。在制动中，刚性的转子由硬的制动衬块(其又由其硬的底板支撑)摩擦接合。制动衬块能够抵靠刚性的活塞和卡钳在一定程度上摩擦地滑动。在该滑动运动期间产生高的摩擦力，这会导致尖声。类似于以一定角度用力划过刚性板的粉笔，摩擦会导致极其严重的振动噪声。同样，这些再发的力会导致活塞边缘磨损和刨削。制动尖声对于汽车和制动器制造商而言是非常昂贵的问题，因为顾客总是希望在保修期内改善噪声，即使制动器本来很完美。
在过去几年已经尝试了大量的使用各种材料的垫片设计以装配在活塞与板之间以减少这种摩擦和所得到的尖声。没有任何一个设计令人非常满意。虽然石墨片材具有使其非常适合用于降噪的特性，但是由于他的易碎性它本身不适合用作垫片。使用石墨箔和金属冲齿的层压件一般不适合，因为这种金属冲齿不足够强而不是很适合用于制动衬块的垫片。期望的是提供一种适合用作垫片的在至少一侧有石墨的材料。
发明概述
根据本发明的第一方面，提供了一种具有作为第一层状体的相对硬质的材料的层压片，所述第一层状体具有第一表面和第二表面。第一表面具有从其延伸出的可以为尖的穿刺结构。每个结构具有称为末端的顶部。第二层状体是石墨箔材料，其与相对硬质的材料配合。所述配合是通过一些所述穿刺结构突出到所述石墨箔材料中而穿刺所述石墨箔的内表面来实现的。
所述相对硬质的材料优选地不被穿孔，所述第二表面可以是平坦的。至少一些所述穿刺结构可以完全地延伸穿过所述石墨箔材料，穿过所述石墨箔的外表面突出而露出它们的末端。至少一些露出的所述穿刺结构的末端可以被钉牢，意思是它们被翻转到遍布于所述石墨箔材料上、翻转到所述石墨箔材料上或者翻转进入到所述石墨箔材料中。在其他实施例中，所述穿刺结构可以不完全地延伸穿过所述石墨箔材料，使得所述箔的外表面仍是均匀地平滑。
所述相对硬质的材料优选的是金属，优选地是钢。该材料可具有至少0.2mm的厚度或者可以具有至少5.0mm的厚度，但是厚度可以小于或等于0.2mm。
根据本发明的第二方面，提供了一种多层层压片，其具有作为相对硬质材料的双面片材的第一层状体，在该双面片材的两个表面上加纹理。所述表面纹理是通过多个凸起的以及大致尖锐的穿刺结构形成的，每个结构具有称为末端的顶部。所述层压件包括两个石墨箔材料的外层，在双面片材的每一个表面上各有一层。通过使所述相对硬质材料构成的穿刺结构中的一些突出穿过箔的内表面而进入石墨箔材料，所述石墨箔材料与所述相对硬质材料配合。所述相对硬质材料优选地不被穿孔。至少一些所述穿刺结构可以完全地延伸穿过所述石墨箔材料的一层，突出穿过所述箔的外表面，而露出它们的末端。可以通过翻转到遍布于所述石墨箔材料上、翻转到所述石墨箔材料上或者翻转进入到所述石墨箔材料中来钉牢至少一些露出的穿刺结构的末端。在其他实施例中，所述穿刺结构可以不完全地延伸穿过所述石墨箔材料，使得所述箔的外表面仍均匀地平滑。
根据本发明的第三方面，提供一种减噪垫片。该垫片具有相对硬质材料构成的第一层，所述相对硬质材料具有第一表面和第二表面。所述第一表面具有多个凸起和大致尖锐的穿刺结构并且与所述石墨箔材料的第二层配合，使得至少一些所述穿刺结构穿透所述石墨箔材料。所述垫片可以被构造为接合制动衬块，使其充当所述制动系统的所述底板与活塞之间的中间元件(或缓冲件)。
附图说明
图1示出了由两个供给卷料生产层压片材的连续的过程，下面的层状体具有穿刺结构，上面的层状体由石墨箔材料制成。
图2示出了相对硬质材料的加纹理层状体片材的细节，加纹理层状体片材具有位于表面的穿刺结构，穿刺结构具有终止于尖锐末端的锥形截面。
图3示出了结构穿透过石墨箔材料并且尖锐的末端在其表面之上的实施例。
图4示出了相对硬质材料的加纹理层状体片材的实施例，两个面加有穿刺结构的纹理。
图5示出了三层层压件的另一实施例，其中相对硬质材料的中央加纹理层状体片材具有由穿刺结构加纹理的两个表面，并且外石墨箔层压件已由穿刺结构的带尖的末端刺透。
图6示出了钉牢的细节，其中末端顺次地向下卷到可穿透石墨箔层状体的上表面上的最终钉牢位置。
图7示出了嵌入石墨箔层状体的单个穿刺结构的细节，石墨箔层状体过厚而不能刺穿。
图8示出了另一实施例，其中芯材是较硬的穿刺层状体，在两个面上加了纹理，外层状体是可穿刺石墨箔材料并且被强压到较硬的芯上。
图9示出了呈制动衬块垫片形式的两层金属-石墨层压件的石墨箔侧。
发明详述
在下面的说明书中，词语“钉牢”(钉牢，可钉牢、钉牢的)用于描述弯转使得已经刺穿两个以上层且从其延伸出的销或钉状结构的露出的顶部的动作。钉牢是木材建造交易上的惯常实践。钉牢类似于在金属工件中铆接，或者类似于紧固件的任何其他变形以防止其易于退回。钉牢的目的是赋予如此连结的两个层压层之间的更大的附着力。
术语“带尖的结构”和“穿刺结构“此处同义使用，作为描述任何类型的在材料表面上凸起(用于嵌入或刺入)而能够穿刺以及随后穿透石墨箔表面的钉或销状结构(或带钩的或带倒刺的结构)的一般术语。适当选择材料的硬度以及穿刺结构的构造的选择来确保该穿刺能力。
在本发明中，穿刺结构已经从由诸如不锈钢板的相对硬质材料构成的层状体的表面凸出。它们可以刺入相邻的石墨箔层状体的内表面，并且如果比石墨箔厚度长，则能够穿透箔的外表面。突出的末端可以弯转或钉牢以形成本发明的“锁定层压件”实施例。在层压件中，第一层状体与仅一个另一层状体配合，第一层状体的与另一层状体配合的表面或面称为内表面，而不与另一层状体配合的另一表面称为外表面。
图1示出了制成连续层压金属和石墨材料的过程。卷101供给加纹理金属104的第一层状体，一面加有穿刺结构105的纹理，穿刺结构105具有带尖的末端106。卷102供给石墨箔103的第二层状体。两层层状体馈送到加压辊100、100a之间。在来自辊100、100a的压力下，两个层状体的内表面被强压在一起，而使得加纹理金属板104的一些或者优选地大部分或全部的穿刺结构穿透石墨箔103的外表面。这些穿刺结构可以不穿透石墨箔103的上表面，如图1所示。可选地，加纹理金属板104的穿刺结构可以穿透石墨箔103的上部，使得它们的顶部或“末端”露出(如图3所示)，然后由第二辊套件(未示出)或其他工具钉牢。
第一层状体可以由任何相对硬质的合适材料形成，但是优选地由诸如钢板的可锻材料制成。可使用各种材料。在一个优选的实施例中，第一材料具有大于约80的布氏硬度。未加纹理的第一层状体的一侧(外表面)优选地为平坦的且均匀地平滑，没有孔或穿孔通过其中。
因此，两个层压件连续地锁在一起作为层压件108，层压件108随后可以被切割成层压件的单个片材107。可选地，层压件108可以被收集为拾取卷轴(未示出)上的成批产品(因此，该过程可以是卷对卷过程)。成批产品可以进一步被切割或成形而用于具体应用，包括在施工现场的切割-测量应用。
辊100、100a能够挤压“夹在”或只位于局域化区域(例如，边缘)中的材料的整个宽度。
图2示出了加纹理金属板104的加纹理面201和普通面200，这些面可以为相同的或不同的材料，诸如钢-钢或钢-铝。穿刺结构105具有穿刺的、带尖的末端106。在图3中，末端106被显示为穿透石墨箔103的外表面并且在其上方延伸。例如，弯曲或钩形的穿刺结构105可以固有地形成于初始过程以制备加纹理的金属板104(例如，使用在2012年5月29日递交于加拿大的同一申请人的、加拿大专利申请号为2,778,455的申请“Bulk TexturedMaterial Sheeting”所描述的工艺，或者例如在加拿大专利1,330,521、1,337,622或2,127,339中的任一个专利中所描述的工艺，这些专利文献公开的内容均通过引用方式合并于本文中)。可选地，可以采用更竖直(例如，钉状)结构。这些可以预弯曲成更呈钩状的结构。这些预弯曲可以利用平坦压板之间的辊或挤压装置从而将较细的末端弯折成钩来完成。
图4示出了金属板400，其两个面加有穿刺结构105的纹理，使得其能够形成两个石墨箔层103、103a之间的芯。在图5中，相同的双纹理金属板400显示为第一(芯)层状体，在任一侧上有石墨箔层103、103a，形成三层层压件。
图6示出了层压件108，其末端106被钉牢，同时通过抵靠诸如砧的硬质第三表面被一起挤压而穿过辊之间到达完全钉牢位置600。而且，图6示出了末端106如何被反转601而挤入石墨箔或压扁602的示例，其中效果类似于铆钉。
图7示出了在加纹理金属板104的加纹理面201上的一个穿刺结构700的细节。穿刺结构700具有终止于带尖末端的锥形截面。石墨箔103的内表面由穿刺结构700穿透，但是穿刺结构700不刺透石墨箔103的外表面并且因此穿刺结构700完全嵌入石墨箔103中。当然，这适用于在该层压过程中的所有穿刺结构。
图8示出了适用于外层压件均为石墨箔103、103a的双纹理金属板800的芯的辊层压工艺，石墨箔103、103a从上卷102和下卷102a馈送。辊100、100a抵靠金属板800的加纹理的上表面挤压石墨箔103的上片，使得金属板800的顶面上的穿刺结构穿透上石墨片材的下表面并且嵌入石墨箔103中、以配合层压件800中的层。类似地，辊100、100a抵靠金属板800的加纹理的下表面而挤压石墨箔103的下片，使得金属板800的下表面上的穿刺结构穿透下石墨片材的上表面并且嵌入石墨箔103中、而配合层压件800中的层。所得到的层压件801可以切割成单个的层压片材802。
不同于现有技术，相对硬质材料的第一层状体可以由能够适当加纹理的任何期望厚度的材料形成。例如，第一层状体的厚度可以大于或等于0.3mm、1.0mm、5.0mm或10.0mm，但是对于一些应用来说，厚度可以小于0.3mm、0.2mm或0.1mm。加纹理可被执行从而确保穿刺结构的垂直(即，垂直于层状体的表面)高度不超过待使用的石墨箔层状体的厚度，在该情况下穿刺结构将不穿透层状体中的箔的外表面，使得层状体的外表面均匀地平滑。可选地，穿刺结构可以具有充分大于待用于形成层压件的石墨箔的厚度(例如，大1.3倍至1.5倍)的垂直高度，使得一些、大部分或全部穿刺结构的末端刺透且突出于石墨箔的外表面且露出。如上所述，穿刺结构的露出的末端随后可以被钉牢。
垫片是任何形状或轮廓的降噪内层材料片。如上所述，垫片广泛地用在制动器活塞与制动衬块的底板之间，以减少当在制动期间活塞接合底板时会发生的噪声，诸如尖声。
石墨具有降噪特性，该特性使其非常适合于用作噪声绝缘体。然而，它本身过于易碎而不能用作垫片。但是，本文所述的金属-石墨层压件非常适合用作垫片，诸如制动衬块垫片。层压件是有效的减噪介质。由于其润滑特性，石墨调节摩擦衬里的制动效果并且贡献于制动舒适感以及降噪。石墨的优良的导热性也在层压件在存在较大温度变化诸如汽车制动的应用中的使用中起到重要作用。石墨具有比通常用于生产垫片的材料低得多的摩擦系数，使得层压件充当滑移剂，这贡献于其降噪能力。石墨也耐氧化。
在穿刺结构突出于外表面并且任选地钉牢的实施例中，所得到的石墨箔的外表面变得“起泡”，如图9所示。图9示出了呈制动衬块垫片形式的两层金属-石墨层压件的石墨箔侧。每个露出的末端900表现为箔表面上的起泡。只要露出的末端被钉牢或者尺寸定为使得仅露出少量的末端，则得到的起泡的表面在触到时仍相对平滑。
应当理解的是，本发明的上述实施例，尤其是任何“优选的”实施例，仅为实现方式的示例，仅阐述以便于本发明原理的清楚理解。可以地本发明的上述实施例做出许多变型和修改，这是本领域技术人员易于实现的。
在该文档中，一个或多个项的列表前面用了“诸如”或“包括”的表达，后面用了缩略“等”，或者前面或后面用了表达“例如”或“e.g.”，这样做是为了明确地传达和强调该列表不是穷尽的，无论列表的长度如何。这样的表达或另外类似表达的缺失也绝不意味着该列表是穷尽的。除非明确陈述或清楚地暗示，否则该列表应理解为包含所列项的所有类似或等同的变型例，并且本领域技术人员将理解的列表中的项的替代物将适合于列出该一个或多个项的目的。
当在本说明书和权利要求书中使用时，用语“包括”和“包括有”用于指定所述特征、元件、整数、步骤或组件的存在，而不排除也不暗指一个或多个其他特征、元件、整数、步骤或其组件或组的存在或添加的必要性。
随附的权利要求的范围不由在说明书阐述的实施例限定。权利要求应当被给予与说明书整体一致的最宽的有目的的构造。

Claims (13)

1.一种多层层压片材，包括：
a)板状金属芯，所述板状金属芯具有第一表面和相对的第二表面，所述第一表面加有第一多个凸起的和大致尖锐的穿刺结构的纹理，并且所述第二表面加有第二多个凸起的和大致尖锐的穿刺结构的纹理；
b)第一石墨箔层，所述第一石墨箔层具有与所述板状金属芯的所述第一表面相配合的第一层内表面和相对的第一层外表面，所述第一层内表面由所述第一多个凸起的和大致尖锐的穿刺结构刺透；和
c)第二石墨箔层，所述第二石墨箔层具有与所述板状金属芯的所述第二表面相配合的第二层内表面和相对的外表面，所述第二层内表面被第二多个凸起的和大致尖锐的穿刺结构刺透。
2.根据权利要求1所述的多层层压片材，其中所述板状金属芯是板状钢芯。
3.根据权利要求1所述的多层层压片材，其中所述板状金属芯不包括与所述第一多个凸起的和大致尖锐的穿刺结构或所述第二多个凸起的和大致尖锐的穿刺结构相关联的穿孔。
4.根据权利要求1所述的多层层压片材，其中所述第一多个凸起的和大致尖锐的穿刺结构不突出穿过所述第一层外表面，并且所述第一层外表面平滑。
5.根据权利要求1所述的多层层压片材，其中所述第二多个凸起的和大致尖锐的穿刺结构不突出穿过所述第二层外表面，并且所述第二层外表面是平滑的。
6.一种用于制造多层层压片材的方法，所述方法包括：
a)将板状金属芯供给至层压工作台，所述板状金属芯具有第一表面和相对的第二表面，所述第一表面加有第一多个凸起的和大致尖锐的穿刺结构的纹理，所述第二表面加有第二多个凸起的和大致尖锐的穿刺结构的纹理；
b)将第一石墨箔层供给至所述层压工作台，所述第一石墨箔层具有第一层内表面和相对的第一层外表面，
c)将所述板状金属芯和所述第一石墨箔层压在一起以使用所述第一多个凸起的和大致尖锐的穿刺结构刺穿所述第一层内表面；
d)将第二石墨箔层供给至层压工作台，第二石墨箔层具有第二层内表面和相对的第一层外表面；和
e)将所述板状金属芯和所述第二石墨箔层压在一起以使用所述第二多个凸起的和大致尖锐的穿刺结构刺穿所述第二层内表面。
7.根据权利要求6所述的方法，其中在步骤c)中，所述第一多个凸起的和大致尖锐的穿刺结构不突出穿过所述第一层外表面。
8.根据权利要求6所述的方法，其中在步骤e)中，所述第二多个凸起的和大致尖锐的穿刺结构不突出穿过所述第二层外表面。
9.根据权利要求6所述的方法，其中步骤a)，b)和d)同时执行。
10.如权利要求6所述的方法，其中步骤c)和e)同时执行。
11.根据权利要求10所述的方法，其中步骤c)和e)包括在辊之间供给所述板状金属芯、所述第一石墨箔层和所述第二石墨箔层。
12.根据权利要求6所述的方法，其中所述板状金属芯是板状钢芯。
13.根据权利要求6所述的方法，其中所述板状金属芯不包括与所述第一多个凸起的和大致尖锐的穿刺结构或所述第二多个凸起的和大致尖锐的穿刺结构相关联的穿孔。
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