CN108317197B - 一种生态环保有机复合材料制动闸片及其制备工艺 - Google Patents
一种生态环保有机复合材料制动闸片及其制备工艺 Download PDFInfo
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Abstract
本发明提供一种生态环保动车组用有机复合材料制动闸片，其配方包括液态乙烯基橡胶、固态高乙烯基橡胶、耐高温丁苯橡胶、芳香族改性酚醛树脂、摩擦粉、低碳钢纤维、高碳铸铁颗粒、人造矿物纤维、硅灰石纤维、短切腈纶纤维、芳纶浆粕、木质纤维、氧化铝抛光粉、空心漂珠、硫酸钡、氢氧化钙及有机材料助剂。本发明所使用的有机复合材料制动闸片能有效降低动车组运营因更换制动闸片造成的维护成本支出，对铁路周边居民噪音影响小，同时因配方中不含有毒重金属元素，不会对土壤和水体因有毒金属离子富集造成污染等生态环保优势。
Description
技术领域
本发明属于动车组制动领域，具体涉及一种生态环保的动车组用有机复合材料制动闸片及其制备工艺。
背景技术
截止2016年底，中国高速铁路的运营里程已经达到2.2万公里，占世界高速铁路运营总里程的60%多。国家发改委等部门出台的规划明确，到2025年中国高速铁路通车里程将达到3.8万公里，比现在差不多要翻一倍，形成“八纵八横”的高铁网。按照UIC 统计，截止2017年4月1日，境外共有23个国家和地区拥有动车组，总计2452标准列；中国的在役动车组已达到2742标准列，这样算的话我国的动车组保有量已经占到全世界的一半以上了。动车组制动装置利用制动闸片材料与配偶制动盘的摩擦力使车辆的动能转变为热能和其它形式的能量，从而使制动装置达到制动的效果；制动闸片属于易耗件，需定期强制更换。目前国内动车组除青岛四方庞巴迪铁路运输设备有限公司（简称BST）生产制造CRH1A/B/E型车使用德国克诺尔有机复合材料制动闸片外，其它同速度等级车型广泛使用价值昂贵的铜基粉末冶金制动闸片。美国汽车行业协会、美国国家环境委员会、美国环保局等多家机构签署合作备忘录，联合发起“无铜刹车片”行动，以求降低汽车刹车片中的铜以及其他有害物质的使用量，减少对河流等水域的污染。该举措以期减少化学物质在道路、溪流、河流和湖泊中的含量，避免危害相关动植物。在动车组停车减速时摩擦磨屑会飘散于高速铁路沿线周边，粉末冶金制动闸片中的钨、铜、铬、镍等金属元素在自然界的作用下会转变为有毒、有害的重金属离子，最终进入土壤和水体中造成重金属离子富集、污染生态。
发明内容
针对上述情况，本发明的目的在于：提供一种生态环保动车组用有机复合材料制动闸片及其制备工艺，其在满足动车组运营制动安全要求的前提条件下，有效降低动车组运营因更换制动闸片造成的维护成本支出，对铁路周边居民噪音影响小，同时因配方中不含有毒重金属元素，不会对土壤和水体因有毒金属离子富集造成污染等生态环保优势。
为实现上述目的，本发明所采取的技术方案是：提供一种生态环保动车组用有机复合材料制动闸片，其配方按照体积比例计算为：液态（3000mPa.s，25℃）乙烯基橡胶，3.8～7.5%；固态高乙烯基橡胶，20.2～25.5%；耐高温丁苯橡胶，5.7～9.6%；芳香族改性酚醛树脂，9.3～22.4%；-40目摩擦粉，3.6～7.2%；-40目低碳钢纤维，2.4～4.8%；-40目高碳铸铁颗粒，2.3～3.5%；-60目人造矿物纤维，2.7～8.5%；-80目硅灰石纤维，2.5～4.8%；短切腈纶纤维，1.5～2.5%；芳纶浆粕，1.2～2.0%；10～30目木质纤维，2.0～2.8%；-200目氧化铝抛光粉，1.4～2.7%；80～100目空心漂珠，3.6～8.0%；-200目硫酸钡，5.7～9.3%；-325目氢氧化钙，2.7～5.3%；有机材料助剂，1.0～2.0%。
本发明所述的生态环保动车组用有机复合材料制动闸片的制备方法，所涉及到的设备及配套包括：液压式切胶机、夹套水冷加压型密炼机、2MPa保压气泵站、片刀式破碎机等，工艺流程包括：物料准备，加压密炼，破碎冷却、模塑压制、热处理及摩擦面开刃磨平；其具体操作工艺如下：
（1）物料准备：按照体积比例计算，液态（3000mPa·s，25℃）乙烯基橡胶，3.8～7.5%；固态高乙烯基橡胶，20.2～25.5%；耐高温丁苯橡胶，5.7～9.6%；芳香族改性酚醛树脂，9.3～22.4%；-40目摩擦粉，3.6～7.2%；-40目低碳钢纤维，2.4～4.8%；-40目高碳铸铁颗粒，2.3～3.5%；-60目人造矿物纤维，2.7～8.5%；-80目硅灰石纤维，2.5～4.8%；短切腈纶纤维，1.5～2.5%；芳纶浆粕，1.2～2.0%；10～30目木质纤维，2.0～2.8%；-200目氧化铝抛光粉，1.4～2.7%；80～100目空心漂珠，3.6～8.0%；-200目硫酸钡，5.7～9.3%；-325目氢氧化钙，2.7～5.3%；有机材料助剂，1.0～2.0%。
（2）加压密炼，具体操作如下：
将固态高乙烯基橡胶、耐高温丁苯橡胶、低碳钢纤维及高碳铸铁颗粒，加入密炼机中，在1～2MPa，加压密炼至橡胶碎成颗粒状；
将硅灰石纤维、短切腈纶纤维、芳纶浆粕、木质纤维及空心漂珠按配方加入密炼机；在1～2MPa下加压密炼至纤维无结团形状；
将液态乙烯基橡胶、芳香族改性酚醛树脂、摩擦粉、人造矿物纤维、氧化铝抛光粉、硫酸钡及氢氧化钙按配方加入密炼机；1～2MPa加压密炼，适时打开回流冷却装置调节物料温度恒定到60℃～90℃之间，此温度区间密炼时间保持8min～20min；
将有机材料助剂1～2MPa加压密炼保持4min～10min后，倒出物料。
（3）破碎冷却；密炼后对物料进行破碎处理，具体是通过片刀式破碎机Ø8筛网破碎，然后在料盘中冷却至室温。
（4）模塑压制：采用液压机，压制压力：4000～8000 N·cm2；保压时间为5~20s；压制温度为室温下即可。
（5）热处理：其实起始温度为室温至230℃，设定温度为140℃～280℃，一般起始温度与设定温度的温度差为30℃~50℃，且升温时间为1h，保温时间为1h；然后自然平放，让其自然冷却至室温即可。
配料中，选用材料固态高乙烯基橡胶、耐高温丁苯橡胶、低碳钢纤维及高碳铸铁颗粒为一组，分别选用疏水性较强的固态高乙烯基橡胶解决制动闸片喷水状态摩擦系数不稳定问题，耐高温丁苯橡胶和芳香族改性酚醛树脂用以提高制动闸片热分解温度，低碳钢纤维有利于制动闸片导热、耐磨、稳定摩擦系数，高碳铸铁颗粒解决冬季摩擦界面接触不佳问题。固态高乙烯基橡胶、耐高温丁苯橡胶、低碳钢纤维及高碳铸铁颗粒为一组，放在一起在加压密炼时能使橡胶顺利分散成颗粒状态，低碳钢纤维和铸铁颗粒被橡胶均匀包裹。
配料中以硅灰石纤维、短切腈纶纤维、芳纶浆粕、木质纤维及空心漂珠为一组进行密炼，橡胶、芳纶浆粕和短切腈纶纤维在密炼机中摩擦状态时容易产生静电结团，不易分散成絮状。硅灰石纤维、木质纤维和空心漂珠能有效隔离含静电纤维集聚，并将静电消除或导出；同时木质纤维和空心漂珠能有限降低有机复合材料制动闸片产品密度，制动时有效消除震颤和噪音产生，稳定摩擦系数。
配料中以液态乙烯基橡胶、芳香族改性酚醛树脂、摩擦粉、人造矿物纤维、氧化铝抛光粉、硫酸钡及氢氧化钙为一组，液态乙烯基橡胶能有效实现配方材料室温模塑成型并在无夹具夹持的情况下保证产品尺寸稳定性；氧化铝抛光粉有助于制动闸片和配偶制动盘接触面自洁自净，摩擦磨屑顺利从界面处脱落，有助于摩擦系数稳定。氢氧化钙让有机复合制动闸片材料呈弱碱性状态，不生锈且不腐蚀配偶制动盘。
配料中所选用的有机材料助剂，是橡胶和酚醛树脂性能改善和增强的必须材料，能有效提高橡胶的耐热温度、增强酚醛树脂的柔韧性、显著提高复合材料中各组分的相容性，稳定摩擦系数。
本发明的有益效果是：所使用的有机复合材料制动闸片能有效降低动车组运营因更换制动闸片造成的维护成本支出，对铁路周边居民噪音影响小，同时因配方中不含有毒重金属元素，不会对土壤和水体因有毒金属离子富集造成污染等生态环保优势。
附图说明
图1是有机复合材料制动闸片摩擦制动性能测试图；
图2是制动闸片的结构示意图；
图3是制动闸片的剖视图；
图4是制动闸片侧面剖视图。
具体实施方式
实施例1
本发明所述的生态环保动车组用有机复合材料制动闸片的制备方法，所涉及到的设备及配套包括：液压式切胶机、夹套水冷加压型密炼机、2MPa保压气泵站、片刀式破碎机等，工艺流程包括：物料准备，加压密炼，破碎冷却、模塑压制、热处理及摩擦面开刃磨平；其具体操作工艺如下：
（1）物料准备：液态乙烯基橡胶，5.7%；固态高乙烯基橡胶，23.0%；耐高温丁苯橡胶，7.6%；芳香族改性酚醛树脂，15.9%；摩擦粉，5.4%；低碳钢纤维，3.6%；高碳铸铁颗粒，2.9%；人造矿物纤维，5.6%；硅灰石纤维，3.5%；短切腈纶纤维，2.0%；芳纶浆粕，1.6%；木质纤维，2.4%；氧化铝抛光粉，2.0%；空心漂珠，5.8%；硫酸钡，7.5%；氢氧化钙，4.0%；有机材料助剂，1.5%。
（2）加压密炼，具体操作如下：
将固态高乙烯基橡胶、耐高温丁苯橡胶、低碳钢纤维及高碳铸铁颗粒，加入密炼机中，在1～2MPa，加压密炼至橡胶碎成颗粒状；
将硅灰石纤维、短切腈纶纤维、芳纶浆粕、木质纤维及空心漂珠按配方加入密炼机；在1～2MPa下加压密炼至纤维无结团形状；
将液态乙烯基橡胶、芳香族改性酚醛树脂、摩擦粉、人造矿物纤维、氧化铝抛光粉、硫酸钡及氢氧化钙按配方加入密炼机；1～2MPa加压密炼，适时打开回流冷却装置调节物料温度恒定到75℃之间，此温度区间密炼时间保持14min；
将有机材料助剂1.5MPa加压密炼保持7min后，倒出物料，片刀式破碎机Ø8筛网破碎后在料盘中冷却至室温。
（3）破碎冷却；密炼后对物料进行破碎处理，具体是通过片刀式破碎机Ø8筛网破碎，然后在料盘中冷却至室温。
（4）模塑压制，采用液压机，压制压力：6000 N·cm2；保压时间为15s；压制温度为室温下即可；
（5）热处理：其实起始温度，设定温度为140℃，升温时间为1h，保温时间为1h；然后自然平放，让其自然冷却至室温即可。
实施例2
本发明所述的生态环保动车组用有机复合材料制动闸片的制备方法，所涉及到的设备及配套包括：液压式切胶机、夹套水冷加压型密炼机、2MPa保压气泵站、片刀式破碎机等，工艺流程包括：物料准备，加压密炼，破碎冷却、模塑压制、热处理及摩擦面开刃磨平；其具体操作工艺如下：
（1）物料准备：液态乙烯基橡胶，3.8%；固态高乙烯基橡胶，20.2%；耐高温丁苯橡胶，9.6%；芳香族改性酚醛树脂，22.4%；摩擦粉，3.6%；低碳钢纤维，2.4%；高碳铸铁颗粒，3.5%；人造矿物纤维，8.5%；硅灰石纤维，2.5%；短切腈纶纤维，2.5%；芳纶浆粕，1.2%；木质纤维，2.8%；氧化铝抛光粉，1.4%；空心漂珠，3.6%；硫酸钡，5.7%；氢氧化钙，5.3%；有机材料助剂，1.0%。
（2）加压密炼，具体操作如下：
将固态高乙烯基橡胶、耐高温丁苯橡胶、低碳钢纤维及高碳铸铁颗粒，加入密炼机中，在1.5MPa，加压密炼至橡胶碎成颗粒状；
将硅灰石纤维、短切腈纶纤维、芳纶浆粕、木质纤维及空心漂珠按配方加入密炼机；在1.5MPa下加压密炼至纤维无结团形状；
将液态乙烯基橡胶、芳香族改性酚醛树脂、摩擦粉、人造矿物纤维、氧化铝抛光粉、硫酸钡及氢氧化钙按配方加入密炼机；1.5MPa加压密炼，适时打开回流冷却装置调节物料温度恒定到65℃之间，此温度区间密炼时间保持20min；
将有机材料助剂1.5MPa加压密炼保持10min后，倒出物料，片刀式破碎机Ø8筛网破碎后在料盘中冷却至室温。
（3）破碎冷却；密炼后对物料进行破碎处理，具体是通过片刀式破碎机Ø8筛网破碎，然后在料盘中冷却至室温。。
（4）模塑压制，采用液压机，压制压力：4000N·cm2；保压时间为20s；压制温度为室温下即可。
（5）热处理：其实起始温度为170℃，设定温度为200℃，升温时间为1h，保温时间为1h；然后自然平放，让其自然冷却至室温即可。
实施例3
本发明所述的生态环保动车组用有机复合材料制动闸片的制备方法，所涉及到的设备及配套包括：液压式切胶机、夹套水冷加压型密炼机、2MPa保压气泵站、片刀式破碎机等，工艺流程包括：物料准备，加压密炼，破碎冷却、模塑压制、热处理及摩擦面开刃磨平；其具体操作工艺如下：
（1）物料准备：液态乙烯基橡胶，7.5%；固态高乙烯基橡胶，25.5%；耐高温丁苯橡胶，5.7%；芳香族改性酚醛树脂，9.3%；摩擦粉，7.2%；低碳钢纤维，4.8%；高碳铸铁颗粒，2.3%；人造矿物纤维，2.7%；硅灰石纤维，4.8%；短切腈纶纤维，1.5%；芳纶浆粕，2.0%；木质纤维，2.0%；氧化铝抛光粉，2.7%；空心漂珠，8.0%；硫酸钡，9.3%；氢氧化钙，2.7%；有机材料助剂，2.0%。
（2）加压密炼，具体操作如下：
将固态高乙烯基橡胶、耐高温丁苯橡胶、低碳钢纤维及高碳铸铁颗粒，加入密炼机中，在2MPa，加压密炼至橡胶碎成颗粒状；
将硅灰石纤维、短切腈纶纤维、芳纶浆粕、木质纤维及空心漂珠按配方加入密炼机；在2MPa下加压密炼至纤维无结团形状；
将液态乙烯基橡胶、芳香族改性酚醛树脂、摩擦粉、人造矿物纤维、氧化铝抛光粉、硫酸钡及氢氧化钙按配方加入密炼机； 2MPa加压密炼，适时打开回流冷却装置调节物料温度恒定到90℃之间，此温度区间密炼时间保持8min；
将有机材料助剂2MPa加压密炼保持4min后，倒出物料，片刀式破碎机Ø8筛网破碎后在料盘中冷却至室温。
（3）破碎冷却；密炼后对物料进行破碎处理，具体是通过片刀式破碎机Ø8筛网破碎，然后在料盘中冷却至室温。。
（4）模塑压制，采用液压机，压制压力：8000 N·cm2；保压时间为5s；压制温度为室温下即可。
（5）热处理：其实起始温度为230℃，设定温度为280℃，升温时间为1h，保温时间为1h；然后自然平放，让其自然冷却至室温即可。
本实施例中所制备的有机复合材料制动闸片结构如图2~4所示，其摩擦性能检测结果如图1所示：密度为2.2±0.1 g/cm3；洛氏硬度为≤60 HRR，或≥30HRX；冲击强度为≥3.0 kJ/m2；压缩模量为≤1.2×103MPa；压缩强度≥20 MPa。
Claims (2)
1.一种生态环保有机复合材料制动闸片，其特征在于：配方按照体积比例计算为：液态乙烯基橡胶，3.8～7.5%；固态高乙烯基橡胶，20.2～25.5%；耐高温丁苯橡胶，5.7～9.6%；芳香族改性酚醛树脂，9.3～22.4%；-40目摩擦粉，3.6～7.2%；-40目低碳钢纤维，2.4～4.8%；-40目高碳铸铁颗粒，2.3～3.5%；-60目人造矿物纤维，2.7～8.5%；-80目硅灰石纤维，2.5～4.8%；短切腈纶纤维，1.5～2.5%；芳纶浆粕，1.2～2.0%；10～30目木质纤维，2.0～2.8%；-200目氧化铝抛光粉，1.4～2.7%；80～100目空心漂珠，3.6～8.0%；-200目硫酸钡，5.7～9.3%；-325目氢氧化钙，2.7～5.3%；有机材料助剂，1.0～2.0%。
2.一种生态环保有机复合材料制动闸片的制备方法，所涉及到的设备及配套包括：液压式切胶机、夹套水冷加压型密炼机、2MPa保压气泵站及片刀式破碎机，工艺流程包括：物料准备，加压密炼，破碎冷却、模塑压制、热处理及摩擦面开刃磨平；其特征在于，具体操作工艺如下：
（1）物料准备：按照体积比例计算，液态乙烯基橡胶，3.8～7.5%；固态高乙烯基橡胶，20.2～25.5%；耐高温丁苯橡胶，5.7～9.6%；芳香族改性酚醛树脂，9.3～22.4%；-40目摩擦粉，3.6～7.2%；-40目低碳钢纤维，2.4～4.8%；-40目高碳铸铁颗粒，2.3～3.5%；-60目人造矿物纤维，2.7～8.5%；-80目硅灰石纤维，2.5～4.8%；短切腈纶纤维，1.5～2.5%；芳纶浆粕，1.2～2.0%；10～30目木质纤维，2.0～2.8%；-200目氧化铝抛光粉，1.4～2.7%；80～100目空心漂珠，3.6～8.0%；-200目硫酸钡，5.7～9.3%；-325目氢氧化钙，2.7～5.3%；有机材料助剂，1.0～2.0%；
（2）加压密炼，具体操作如下：
将固态高乙烯基橡胶、耐高温丁苯橡胶、低碳钢纤维及高碳铸铁颗粒，加入密炼机中，在1～2MPa，加压密炼至橡胶碎成颗粒状；
将硅灰石纤维、短切腈纶纤维、芳纶浆粕、木质纤维及空心漂珠按配方加入密炼机；在1～2MPa下加压密炼至纤维无结团形状；
将液态乙烯基橡胶、芳香族改性酚醛树脂、摩擦粉、人造矿物纤维、氧化铝抛光粉、硫酸钡及氢氧化钙按配方加入密炼机；1～2MPa加压密炼，适时打开回流冷却装置调节物料温度恒定到60℃～90℃之间，此温度区间密炼时间保持8min～20min；
将有机材料助剂1～2MPa加压密炼保持4min～10min后，倒出物料；
（3）破碎冷却；密炼后对物料进行破碎处理，具体是通过片刀式破碎机Ø8筛网破碎，然后在料盘中冷却至室温；
（4）模塑压制：采用液压机，压制压力：4000～8000 N·cm2；保压时间为5~20s；压制温度为室温下即可；
（5）热处理：其实起始温度为室温至230℃，设定温度为140℃～280℃，一般起始温度与设定温度的温度差为30℃~50℃，且升温时间为1h，保温时间为1h；然后自然平放，让其自然冷却至室温即可。
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