CN108626282A - 一种高耐磨碳纤维复合汽车离合器面片的制备方法 - Google Patents
一种高耐磨碳纤维复合汽车离合器面片的制备方法 Download PDFInfo
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Abstract
本发明公了一种高耐磨碳纤维复合汽车离合器面片的制备方法，包括以下步骤：S1、无金属碳纤维复合线的制备；S2、无金属碳纤维复合线浸渍树脂；S3、橡胶料的制备；S4、浸胶；S5、绕胚、热压成型和热处理；S6、磨加工、检验包装。本发明不仅可解决传统汽车用离合器面片用复合线使用铜导致铜资源浪费、环境污染以及产品性能方面存在的问题，更可促进国产高性能碳纤维生产、推广和使用，经济效益和社会效益显著，该碳纤维复合线制备的离合器面片还具有优异的耐高温性能，在高温时摩擦系数没有明显降低，而且无明显热衰退，可见碳纤维复合线离合器面片高温性能较好，耐磨性能较高。
Description
技术领域
本发明属于车用离合器面片术领域，具体涉及一种高耐磨碳纤维复合汽车离合器面片的制备方法。
背景技术
离合器面片的基本结构由骨架材料（增强材料）、粘结剂丁苯橡胶和（或）树脂、填充材料重晶石及碳黑等要素所组成。为了消除石棉增强摩擦材料对环境及人体的危害，满足摩擦材料的技术要求，研究者一直致力于非石棉摩擦材料的研究，以各种纤维复合使用代替石棉以满足其作为摩擦片的增强材料所要求的性能，因而在配套和零售市场上出现了不同材质的缠绕式离合器面片。由于缠绕式离合器面片制备、成型及加工工艺的限制，实验室关于这方面的研究较少。目前实际生产的缠绕式离合器面片大多数是复合线作增强材料生产的缠绕式离合器面片，而这些复合线中，除有机纤维和无机纤维外，为达到增强、导热、耐磨的作用几乎都含有金属纤维尤其是铜丝，如很多中国专利公开的无石棉离合器面片，涉及其骨架材料均有金属纤维尤其是铜丝。由于使用金属铜使得面片的摩擦系数、磨损性能、制品密度及爆裂强度等指标都还不是很理想，在面片的实际使用过程中导致汽车离合器工作时的平顺性、耐磨性不高、使用寿命较短。而且大量使用铜，将是严重的资源浪费并造成环境污染。
为此，我们提出一种耐磨性好的，且不会造成环境污染的高耐磨碳纤维复合汽车离合器面片的制备方法来解决上述问题。
发明内容
本发明的目的在于提供一种高耐磨碳纤维复合汽车离合器面片的制备方法，以解决上述背景技术中提出的问题。
为实现上述目的，本发明提供如下技术方案：一种高耐磨碳纤维复合汽车离合器面片的制备方法，一种高耐磨碳纤维复合汽车离合器面片的制备方法，包括以下步骤：
S1、无金属碳纤维复合线的制备：所述无金属碳纤维复合线由玻璃纤维无捻粗纱、玻璃纤维膨化纱、碳纤维包芯纱以及化纤粗纱四部分组成，所述玻璃纤维膨化纱由玻璃纤维无捻粗纱膨化处理得到，所述化纤粗纱由腈纶短纤混合开松制条后制得，所述碳纤维包芯纱由粘胶纤维和腈纶短纤维，混合开松，制条后和高碳纤维长丝进行纺纱制得，将上述璃纤维无捻粗纱、玻璃纤维膨化纱、碳纤维包芯纱以及化纤粗纱合股加捻制得；然后络纱成卷备用；
S2、无金属碳纤维复合线浸渍树脂：将酚醛树脂和六次甲基四胺按等量粗混粉碎，粉碎后的物料放入搅拌机中，加入其质量倍数为1.20-1.30酒精制得树脂溶液，将无金属碳纤维复合线放入具有上述树脂溶液浸胶机中浸渍；
S3、橡胶料的制备：将8.5-9.5㎏的丁苯橡胶置于炼胶机素练包辊后，将0.35-0.45㎏的防老剂丁、0.15-0.25㎏促进剂DM、氧化锌 0.1㎏、氧化铝0.2㎏置于炼胶机混炼均匀，打三角包2～3次后加入5.5-7.5㎏硫酸钡、碳黑0.2㎏、长石粉1.0-2.0㎏以及硫磺混炼，连续打3～4次三角包将胶料辊薄下料，裁条备用；将裁切好的胶条与酚醛树脂和六次甲基四胺粗混粉碎树脂、陶土、硅灰石、轻质氧化镁、钾长石、硫酸钡以及溶剂油按质量比为50：12：4：2：6：3：62投入打浆机内打浆
S4、浸胶：将浸过树脂的无金属碳纤维复合线放入步骤S3制备橡胶料中通过浸胶机进行浸胶；
S5、绕胚、热压成型和热处理：将浸过胶料的无金属碳纤维复合线绕胚，热压成型以及烘干热处理，即可得到离合器片面的半成品；
S6、磨加工、检验包装：将制得的离合器片面的半成品进行机床的打磨精磨加工，检验、打标包装后得到高性能汽车无石棉离合器面片成品。；
优选的，所述步骤S1中所述碳纤维包芯纱由高碳纤维长丝和纺织组成，所述高碳纤维长丝为6Ｋ高碳纤维长丝，皮纱由粘胶纤维和腈纶纤维按质量百分比40％与60％组成，将得到碳纤维包芯纱。
优选的，所述步骤S1中无金属碳纤维复合线的线密度为2100tex、捻度为S260TPM、含水率不大于1.5％、烧失量为22％以及抗拉强度不小于350N。
本发明的技术效果和优点：该高耐磨碳纤维复合汽车离合器面片的制备方法，使用碳纤维复合线制备离合器面片是可行的，其不仅可解决传统汽车用离合器面片用复合线使用铜导致铜资源浪费、环境污染以及产品性能方面存在的问题，更可促进国产高性能碳纤维生产、推广和使用，经济效益和社会效益显著，该碳纤维复合线制备的离合器面片还具有优异的耐高温性能，在高温时摩擦系数没有明显降低，而且无明显热衰退，可见碳纤维复合线离合器面片高温性能较好，耐磨性能较高。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
一种高耐磨碳纤维复合汽车离合器面片的制备方法，包括以下步骤：
S1、无金属碳纤维复合线的制备：所述无金属碳纤维复合线由玻璃纤维无捻粗纱、玻璃纤维膨化纱、碳纤维包芯纱以及化纤粗纱四部分组成，所述玻璃纤维膨化纱由玻璃纤维无捻粗纱膨化处理得到，所述化纤粗纱由腈纶短纤混合开松制条后制得，所述碳纤维包芯纱由粘胶纤维和腈纶短纤维，混合开松，制条后和高碳纤维长丝进行纺纱制得，将上述璃纤维无捻粗纱、玻璃纤维膨化纱、碳纤维包芯纱以及化纤粗纱合股加捻制得；然后络纱成卷备用；
S2、无金属碳纤维复合线浸渍树脂：将酚醛树脂和六次甲基四胺按等量粗混粉碎，粉碎后的物料放入搅拌机中，加入其质量倍数为1.20-1.30酒精制得树脂溶液，将无金属碳纤维复合线放入具有上述树脂溶液浸胶机中浸渍；
S3、橡胶料的制备：将8.5-9.5㎏的丁苯橡胶置于炼胶机素练包辊后，将0.35-0.45㎏的防老剂丁、0.15-0.25㎏促进剂DM、氧化锌 0.1㎏、氧化铝0.2㎏置于炼胶机混炼均匀，打三角包2～3次后加入5.5-7.5㎏硫酸钡、碳黑0.2㎏、长石粉1.0-2.0㎏以及硫磺混炼，连续打3～4次三角包将胶料辊薄下料，裁条备用；将裁切好的胶条与酚醛树脂和六次甲基四胺粗混粉碎树脂、陶土、硅灰石、轻质氧化镁、钾长石、硫酸钡以及溶剂油按质量比为50：12：4：2：6：3：62投入打浆机内打浆
S4、浸胶：将浸过树脂的无金属碳纤维复合线放入步骤S3制备橡胶料中通过浸胶机进行浸胶；
S5、绕胚、热压成型和热处理：将浸过胶料的无金属碳纤维复合线绕胚，热压成型以及烘干热处理，即可得到离合器片面的半成品；
S6、磨加工、检验包装：将制得的离合器片面的半成品进行机床的打磨精磨加工，检验、打标包装后得到高性能汽车无石棉离合器面片成品。；
具体的，所述步骤S1中所述碳纤维包芯纱由高碳纤维长丝和纺织组成，所述高碳纤维长丝为6Ｋ高碳纤维长丝，皮纱由粘胶纤维和腈纶纤维按质量百分比40％与60％组成，将得到碳纤维包芯纱。
具体的，所述步骤S1中无金属碳纤维复合线的线密度为2100tex、捻度为S260TPM、含水率不大于1.5％、烧失量为22％以及抗拉强度不小于350N。
该高耐磨碳纤维复合汽车离合器面片的制备方法，使用碳纤维复合线制备离合器面片是可行的，其不仅可解决传统汽车用离合器面片用复合线使用铜导致铜资源浪费、环境污染以及产品性能方面存在的问题，更可促进国产高性能碳纤维生产、推广和使用，经济效益和社会效益显著，该碳纤维复合线制备的离合器面片还具有优异的耐高温性能，在高温时摩擦系数没有明显降低，而且无明显热衰退，可见碳纤维复合线离合器面片高温性能较好，耐磨性能较高。
最后应说明的是：以上所述仅为本发明的优选实施例而已，并不用于限制本发明，尽管参照前述实施例对本发明进行了详细的说明，对于本领域的技术人员来说，其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。
Claims (3)
1.一种高耐磨碳纤维复合汽车离合器面片的制备方法，其特征在于，包括以下步骤：
S1、无金属碳纤维复合线的制备：所述无金属碳纤维复合线由玻璃纤维无捻粗纱、玻璃纤维膨化纱、碳纤维包芯纱以及化纤粗纱四部分组成，所述玻璃纤维膨化纱由玻璃纤维无捻粗纱膨化处理得到，所述化纤粗纱由腈纶短纤混合开松制条后制得，所述碳纤维包芯纱由粘胶纤维和腈纶短纤维，混合开松，制条后和高碳纤维长丝进行纺纱制得，将上述璃纤维无捻粗纱、玻璃纤维膨化纱、碳纤维包芯纱以及化纤粗纱合股加捻制得；然后络纱成卷备用；
S2、无金属碳纤维复合线浸渍树脂：将酚醛树脂和六次甲基四胺按等量粗混粉碎，粉碎后的物料放入搅拌机中，加入其质量倍数为1.20-1.30酒精制得树脂溶液，将无金属碳纤维复合线放入具有上述树脂溶液浸胶机中浸渍；
S3、橡胶料的制备：将8.5-9.5㎏的丁苯橡胶置于炼胶机素练包辊后，将0.35-0.45㎏的防老剂丁、0.15-0.25㎏促进剂DM、氧化锌 0.1㎏、氧化铝0.2㎏置于炼胶机混炼均匀，打三角包2～3次后加入5.5-7.5㎏硫酸钡、碳黑0.2㎏、长石粉1.0-2.0㎏以及硫磺混炼，连续打3～4次三角包将胶料辊薄下料，裁条备用；将裁切好的胶条与酚醛树脂和六次甲基四胺粗混粉碎树脂、陶土、硅灰石、轻质氧化镁、钾长石、硫酸钡以及溶剂油按质量比为50：12：4：2：6：3：62投入打浆机内打浆
S4、浸胶：将浸过树脂的无金属碳纤维复合线放入步骤S3制备橡胶料中通过浸胶机进行浸胶；
S5、绕胚、热压成型和热处理：将浸过胶料的无金属碳纤维复合线绕胚，热压成型以及烘干热处理，即可得到离合器片面的半成品；
S6、磨加工、检验包装：将制得的离合器片面的半成品进行机床的打磨精磨加工，检验、打标包装后得到高性能汽车无石棉离合器面片成品。
2.根据权利要求1所述的一种高耐磨碳纤维复合汽车离合器面片的制备方法，其特征在于：所述步骤S1中所述碳纤维包芯纱由高碳纤维长丝和纺织组成，所述高碳纤维长丝为6Ｋ高碳纤维长丝，皮纱由粘胶纤维和腈纶纤维按质量百分比40％与60％组成，将得到碳纤维包芯纱。
3.根据权利要求1所述的一种高耐磨碳纤维复合汽车离合器面片的制备方法，其特征在于：所述步骤S1中无金属碳纤维复合线的线密度为2100tex、捻度为S260TPM、含水率不大于1.5％、烧失量为22％以及抗拉强度不小于350N。
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| CN109537117A (zh) * | 2018-11-09 | 2019-03-29 | 东台市华阳玻纤有限责任公司 | 一种应用于离合器面片包胶工艺的玻璃纤维复合纱 |
| CN112123631A (zh) * | 2020-09-14 | 2020-12-25 | 来安县隆华摩擦材料有限公司 | 一种低磨损碳纤维汽车离合器摩擦片生产用浸渍方法 |
| CN112460163A (zh) * | 2020-12-15 | 2021-03-09 | 东台市华阳玻纤有限责任公司 | 无石棉离合器面片制作工艺 |
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