CN109676944A - Peek基自润滑柔性轴承保持架及其制造方法 - Google Patents
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Abstract
本发明公开了一种PEEK基自润滑柔性轴承保持架及其制造方法，适用于谐波减速器领域的薄壁轴承。保持架材料采用PEEK基自润滑多元复合材料，其中主要包含聚四氟乙烯、多壁碳纳米管和PEEK树脂(聚醚醚酮)。聚四氟乙烯为固体润滑剂，多壁碳纳米管为增强体，通过真空热烧结工艺制备，PEEK基自润滑柔性轴承保持架表现出优异的力学性能和耐摩擦性能。
Description
技术领域
本发明属于谐波减速器领域，具体涉及一种用于谐波减速器领域的PEEK基自润滑柔性轴承保持架及其制备方法，该保持架采用PEEK基自润滑多元复合材料真空热烧结工艺制备。
背景技术
轴承保持架主要作用是使滚动体相互之间保持合适的距离，减少轴承的摩擦力矩和因摩擦产生的热量。本发明中的保持架主要用于谐波减速器领域的柔性轴承，柔性轴承作为凸轮波发生器的重要组成部分，与普通轴承的主要区别在于保持架以及内外圈的厚度均较小，凸轮会使轴承内圈产生强制变形，相对于普通轴承的保持架，柔性轴承保持架更容易与滚动体发生摩擦和产生局部应力，致使柔性轴承不能正常工作。目前，市场上柔性轴承保持架材料多采用尼龙，在滚珠和保持架摩擦磨损加剧的情况下，此部分接触区域润滑失效会导致导致柔性轴承径向游隙增大，旋转精度减低。本发明的特点是采用PEEK基复合材料制作保持架，此材料具有良好的自润滑性，可以满足谐波减速器中柔性轴承中保持架减摩和耐磨的要求。
发明内容
本发明的目的在于克服现有技术缺陷，并提供一种PEEK基自润滑柔性轴承保持架及其制造方法。该柔性轴承保持架适用于谐波减速器领域，材料选用PEEK基多元复合材料，基体材料为PEEK树脂，综合多壁碳纳米管优异的机械性能以及聚四氟乙烯的减摩性能。
本发明所采用的具体技术方案如下：
一种PEEK基自润滑柔性轴承保持架的制造方法，包括以下步骤：
1)将聚四氟乙烯置于钠-萘处理液中侵蚀，然后将其洗净干燥，得到改性聚四氟乙烯；
2)向羟基化多壁碳纳米管溶液中加入带水剂，然后在强碱催化下与4,4'-二氟二苯甲酮反应，制备得到表面含有氟酮基团的共价键修饰多壁碳纳米管；其中羟基化多壁碳纳米管溶液所用溶剂为环丁砜，强碱为NaOH或KOH，带水剂为甲苯或二甲苯，反应时间为8～10h；
3)将改性聚四氟乙烯、共价键修饰多壁碳纳米管溶于氯仿中，再加入PEEK树脂，混匀后得到分散液；然后将分散液倒入乙醇中，最后过滤干燥得到混合均匀的PEEK基多元复合材料粉末；
4)将PEEK基多元复合材料粉末挤压成PEEK基多元复合材料粒料；
5)将PEEK基多元复合材料粒料放入磨具中，采用真空热压烧结炉烧结制备得到保持架毛坯雏形；再通过机械加工及表面处理最终得到PEEK基自润滑柔性轴承保持架。
进一步优选，将步骤2)中的强碱优选为NaOH，带水剂优选为甲苯，反应时间优选为8h。
上述羟基化多壁碳纳米管，即为多壁碳纳米管的羟基化产物。
作为优选，所述的钠-萘处理液所用的溶剂为四氢呋喃，钠浓度为0.43mol/L，萘的浓度与钠相同。处理后聚四氟乙烯表面形成一层粗糙疏松的表面层，剪切强度测试可达0.51MPa，其粘结性能得到明显提升，后续与PEEK树脂可很好的结合，以起到润滑作用。
进一步优选，钠-萘处理液的制备方法为：
取500mL四氢呋喃于800mL三口瓶中，加入27.56g萘，开启搅拌器使之完全溶解，称取4.95g金属钠剪成小块，边搅拌边用镊子逐步加入到上述溶液中，开启回流冷凝器，通入氮气，控制反应体系温度在5～15℃，反应2h，最后反应产物为深绿色粘性液体钠-萘处理液。
作为优选，所述步骤2)反应制备得到的共价键修饰多壁碳纳米管中，F元素含量小于4wt％。进一步优选，共价键修饰多壁碳纳米管中F元素含量为1wt％。共价键修饰多壁纳米碳管可大幅度提高PEEK基复合材料的力学性能和摩擦性能以及与PEEK树脂的结合能力。其中F元素主要来自于4,4'-二氟二苯甲酮，通过控制4,4'-二氟二苯甲酮的加入量以控制共价键修饰多壁碳纳米管中F元素的含量。
作为优选，步骤3)得到的PEEK基多元复合材料粉末中，改性聚四氟乙烯的含量为10wt％，共价键修饰多壁碳纳米管的含量为0.5wt％。以此控制步骤3)中改性聚四氟乙烯、共价键修饰多壁碳纳米管及PEEK树脂的投料比例。
作为优选，所述的PEEK树脂为白色微粉，且粒度小于100um；所述聚四氟乙烯粒度为50um；所述羟基多壁碳纳米管直径为0.5～2um，长度为35～50um。
作为优选，所述步骤4)中的挤压采用双螺杆挤出机。
作为优选，所述步骤5)的烧结工艺为以升温速率5℃/min到240℃，在此温度下保温20min；再以相同的升温速率到320℃，保温30min，保压30Mpa，然后水冷至80℃，最后关闭水冷系统随炉冷却。
本发明还提供了一种由上述方法制造的PEEK基自润滑柔性轴承保持架。
本发明相对于现有技术而言，具有以下有益效果：
该PEEK基自润滑柔性轴承保持架通过真空热烧结工艺制造，其所用的复合材料由聚四氟乙烯、多壁碳纳米管和PEEK树脂基体组成。其中聚四氟乙烯起润滑作用，多壁碳纳米管用于增强基体。而且其表面采用钠-萘处理液进行了改性处理以增加剪切强度，多壁碳纳米管通过共价键修饰增强其力学性能和摩擦性能以及与PEEK树脂的结合能力。因此该PEEK基自润滑柔性轴承保持架具有自润滑特性，具有低的摩擦系数和低的磨损率，可减少滚动体对保持架的摩擦损耗，有效提高柔性轴承的使用寿命。
附图说明
图1为柔性轴承轴向示意图。
图2为PEEK基自润滑柔性轴承保持架的侧视图。
具体实施方式
下面结合附图和具体实施方式对本发明做进一步阐述和说明。本发明中各个实施方式的技术特征在没有相互冲突的前提下，均可进行相应组合。
PEEK基自润滑柔性轴承保持架的制作方法基本包含四个步骤：
1、聚四氟乙烯(PTFE)采用钠-萘处理液改性处理；
2、以NaOH为催化剂，利用4,4'-二氟二苯甲酮修饰羟基化多壁碳纳米管，制备共价键修饰多壁碳纳米管；
3、将改性聚四氟乙烯、共价键修饰多壁碳纳米管和PEEK树脂制成PEEK基多元复合材料粉末；
4、采用双螺杆挤出机制备PEEK基多元复合材料粒料；
5、以上述制备的材料采用真空热压烧结炉制备PEEK基自润滑柔性轴承保持架。
具体实施步骤如下：
实施例1：聚四氟乙烯(PTFE)的钠-萘处理液改性处理。
钠-萘处理液的制备过程如下：以金属钠和萘为主要原料，在四氢呋喃溶剂中、氮气的保护下合成钠-萘处理液。具体为：取500mL四氢呋喃于800mL三口瓶中，加入27.56g萘，开启搅拌器使之完全溶解，称取4.95g金属钠剪成小块，边搅拌边用镊子逐步加入到上述溶液中，开启回流冷凝器，通入氮气，控制反应体系温度在5～15℃，反应2h，最终得到深绿色的粘性液体，即为钠-萘处理液。
用丙酮清洗粒度为50um的聚四氟乙烯原料，待其干燥后在25℃、氮气的保护条件下，放入上述制取的浓度为0.43mol/L的钠-萘处理液中侵蚀2s。然后将其取出用丙酮清洗，再用蒸馏水冲洗，干燥后最终得到改性聚四氟乙烯。聚四氟乙烯改性后会形成一层粗糙疏松的表面层，并将其剪切强度提升至0.51MPa。同时，其粘结性能也还得到明显提升，使其后续与PEEK基体更好结合。改性聚四氟乙烯在本发明中的主要作用为润滑。
实施例2：多壁碳纳米管的共价键修饰。
本实施例所用的羟基多壁碳纳米管为南京先丰纳米材料科技公司提供的纯度为95wt％的工业级羟基多壁碳纳米管。
修饰原理如下：用强腐蚀性的强碱NaOH作为催化剂，将4,4'-二氟二苯甲酮修饰于多壁碳纳米管上。具体为：将投料质量比为81.5:16.5:2的4,4'-二氟二苯甲酮、氢氧化钠以及羟基化多壁碳纳米管(直径为0.5-2um，长度为35～50um)装入一个带机械搅拌、氮气通口、带水器的三口烧瓶中，然后加入500mL的反应溶剂环丁砜，再加入500mL的带水剂甲苯。在氮气保护下反应8小时后，将反应液倒入大量水中，然后过滤，将过滤得到的固体分别使用丙酮和蒸馏水洗涤5遍，最后置于真空烘箱中烘干，最终制备得到表面含有氟酮基团的共价键修饰多壁碳纳米管。经检测，共价键修饰多壁碳纳米管中F元素含量为1wt％。
实施例3：PEEK基多元复合材料粒料的制备。
称取0.5g共价键修饰多壁碳纳米管加入到500-3000mL氯仿中，超声1h至溶解完全。再加入10g改性聚四氟乙烯，超声1h至溶解完全。然后加入89.5gPEEK树脂，搅拌0.5h，得到分散液。最后将分散液出料于乙醇中(即倒入大量乙醇中)，抽滤，烘干，制得多PEEK基多元复合材料粉末。经检测，其中改性聚四氟乙烯的含量为10wt％，共价键修饰多壁碳纳米管的含量为0.5wt％。将PEEK基多元复合材料粉末加入到双螺杆挤出机中挤出，制得PEEK基多元复合材料粒料。
实施例4：PEEK基自润滑柔性轴承保持架的制造。
将PEEK基多元复合材料粒料平铺在干燥托盘上，保证厚度不超过25mm，使用干燥箱干燥5h。干燥后将其装入模具中，放入真空热压烧结炉烧结制备。烧结工艺为：以升温速率5℃/min到240℃，在此温度下保温20min；再以相同的升温速率到320℃，保温30min，保压30Mpa，然后水冷至80℃，最后关闭水冷系统随炉冷却。最终可制得PEEK基自润滑柔性轴承保持架毛坯雏形。
再经过粗磨外径面、细车两端面、细车内径面、细磨外径面、终车两端面、终磨外径面、终车内径面、钻铣兜孔、去毛刺机械加工工艺和机械抛光表面处理工艺可得最终的PEEK基自润滑柔性轴承保持架。
实施例4中所用的磨具制成的保持架适用于型号为SH-25的轴承。该轴承保持架为卡式保持架，一侧设有均匀分布的若干开口式卡槽，其侧视图如图2所示。卡槽呈圆弧形，用于放置滚体。SH-25轴承的示意图如图1所示，包括轴承保持架、内圈、外圈及滚体。其中轴承保持架位于内圈与外圈之间，内外圈上均设有供滚体滚动的内滚道。轴承保持架的所有卡槽均放置球状滚体，球状滚体分别与内圈及外圈接触用于滚动传力。此轴承的特点是利用柔性元件可控的弹性变形来传递运动和动力。该轴承广泛用于SHXB-CSF25-100机型谐波减速器中。此制造方法，也适用于其他轴承的保持架制造。图2为本发明制造的PEEK基自润滑柔性轴承保持架，可降低轴承运动过程中的保持架磨损问题，提高柔性轴承寿命。
以上所述的实施例只是本发明的一种较佳的方案，然其并非用以限制本发明。有关技术领域的普通技术人员，在不脱离本发明的精神和范围的情况下，还可以做出各种变化和变型。因此凡采取等同替换或等效变换的方式所获得的技术方案，均落在本发明的保护范围内。
Claims (8)
1.一种PEEK基自润滑柔性轴承保持架的制造方法，其特征在于，包括以下步骤：
1)将聚四氟乙烯置于钠-萘处理液中侵蚀，然后将其洗净干燥，得到改性聚四氟乙烯；
2)向羟基化多壁碳纳米管溶液中加入带水剂，然后在强碱催化下与4,4'-二氟二苯甲酮反应，制备得到表面含有氟酮基团的共价键修饰多壁碳纳米管；其中羟基化多壁碳纳米管溶液所用溶剂为环丁砜，强碱为NaOH或KOH，带水剂为甲苯或二甲苯，反应时间为8～10h；
3)将改性聚四氟乙烯、共价键修饰多壁碳纳米管溶于氯仿中，再加入PEEK树脂，混匀后得到分散液；然后将分散液倒入乙醇中，最后过滤干燥得到混合均匀的PEEK基多元复合材料粉末；
4)将PEEK基多元复合材料粉末挤压成PEEK基多元复合材料粒料；
5)将PEEK基多元复合材料粒料放入磨具中，采用真空热压烧结炉烧结制备得到保持架毛坯雏形；再通过机械加工及表面处理最终得到PEEK基自润滑柔性轴承保持架。
2.如权利要求1所述的PEEK基自润滑柔性轴承保持架的制造方法，其特征在于，所述的钠-萘处理液所用的溶剂为四氢呋喃，钠浓度为0.43mol/L，萘的浓度与钠相同。
3.如权利要求1所述的PEEK基自润滑柔性轴承保持架的制造方法，其特征在于，所述步骤2)反应制备得到的共价键修饰多壁碳纳米管中，F元素含量小于4wt％。
4.如权利要求1所述的PEEK基自润滑柔性轴承保持架的制造方法，其特征在于，所述步骤3)得到的PEEK基多元复合材料粉末中，改性聚四氟乙烯的含量为10wt％，共价键修饰多壁碳纳米管的含量为0.5wt％。
5.如权利要求1所述的PEEK基自润滑柔性轴承保持架的制造方法，其特征在于，所述的PEEK树脂为白色微粉，且粒度小于100um；所述聚四氟乙烯粒度为50um；所述羟基多壁碳纳米管直径为0.5～2um，长度为35～50um。
6.如权利要求1所述的PEEK基自润滑柔性轴承保持架的制造方法，其特征在于，所述步骤4)中的挤压采用双螺杆挤出机。
7.如权利要求1所述的PEEK基自润滑柔性轴承保持架的制造方法，其特征在于，所述步骤5)的烧结工艺为以升温速率5℃/min到240℃，在此温度下保温20min；再以相同的升温速率到320℃，保温30min，保压30Mpa，然后水冷至80℃，最后关闭水冷系统随炉冷却。
8.一种PEEK基自润滑柔性轴承保持架，其特征在于，所述保持架通过权利要求1～7任一所述方法制造。
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