CN110715006A - 轻型机械制动盘用摩擦片及其制备方法 - Google Patents
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Abstract
本发明涉及一种摩擦片及其制备方法,特别涉及一种轻型机械制动盘用摩擦片及其制备方法。包括摩擦片本体,所述摩擦片本体由筒状纤维三维编织物与改性硼酚醛树脂浸润后经后处理成型,所述后处理包括干燥、模压、热处理和磨制。本项目将增强纤维(芳纶纤维和/或剑麻纤维)预先制成三维立体结构筒状的预制体,预制体属于一类具备多轴向取向的高度一体化的连贯纤维束编织集合体,各向同性的适应力好,克服了传统工艺胶条间分层的问题,具备优异的抗冲击韧性和抗疲劳特性,解决了原工艺存在的摩擦性能不稳定,产品压缩强度不均匀等缺陷;同时,基于一次成型萨三维加工技术,预制体的厚度可变范围大,成型性好,摩擦片生产效率提高40%以上。
Description
技术领域
本发明涉及一种摩擦片及其制备方法,特别涉及一种轻型机械制动盘用摩擦片及其制备方法。
背景技术
随着我国的飞速发展,带动各种轻型机械设备(包括各种割草机,手提式机械及电动葫芦起重机)类的市场需求也在大幅度的增长,年增长率超过30%以上,因此需要的摩擦片的增长率也在30%以上,也造成市场供应非常紧张局面,同时对现用的摩擦片的质量也提出了新的要求,也就是摩擦片要具有稳定的摩擦性、较好耐磨性和较长使用寿命,同时根据环保要求对摩擦片成分也规定了不准含有石棉、三价铬、铅、镉、汞等危害人体健康的成分。
目前轻型机械制动盘用摩擦片主要是采用铜丝和芳纶纤维等预先编织成纤维布再浸渍在改性酚醛树脂和丁腈橡胶溶液中,经胶条裁剪、盘绕和热压成型而成,生产工艺基本上都按照以下工序进行:增强纤维编织布→浸胶→干燥→裁剪胶条→按所需尺寸盘绕→模具内热压成型→热处理→磨制→检验→入库。
传统工艺生产工序长,特别是径向方向由多层胶条组成,热压成型时是沿轴向施压,通过胶条之间挤压粘结固化,层间粘结强度差,随着轻型机械载荷增加、电机等转速增大,摩擦片制动过程容易出现分层等缺陷,严重影响了摩擦片使用寿命。而且,金属铜在摩擦制动过程中会释放少量金属粉尘并积累在环境中造成危害。
另外,现有技术还有一种:沿周向连续铜丝确保了摩擦材料成型和使用过程的机械强度,但很难满足逐渐减少金属铜使用的要求。
发明内容
本发明的目的之一在于解决现有技术的不足,提供一种轻型机械制动盘用摩擦片。
本发明的目的之二在于解决现有技术的不足,提供一种轻型机械制动盘用摩擦片的制备方法。
本发明解决其技术问题所采用的技术方案是:
一种轻型机械制动盘用摩擦片,包括摩擦片本体,所述摩擦片本体由筒状纤维三维编织物与改性硼酚醛树脂浸润后经后处理成型,所述后处理包括干燥、模压、热处理和磨制。
优选的,所述纤维采用芳纶纤维和/或剑麻纤维。
优选的,所述纤维三维编织物形式为三维四向、三维五向、三维六向、三维七向以及其他三维多向不同编制结构的任意一种。
优选的,所述改性硼酚醛树脂为二氧化钛改性的硼酚醛树脂。
优选的,所述筒状纤维三维编织物的外径和宽度根据摩擦片本体的外径和宽度以及后处理时的形变量来确定,筒状纤维三维编织物的厚度基于摩擦片本体的厚度及后处理时的形变量来确定。
一种轻型机械制动盘用摩擦片的制备方法,所述方法包括如下步骤:
步骤S1:纤维采用三维编织机,经由立体编织工艺制备获得筒状的三维立体纤维预制体,筒状的三维立体纤维预制体的外径和宽度根据摩擦片本体的外径和宽度以及后处理时的形变量来确定;
步骤S2:对步骤S1获得的筒状的三维立体纤维预制体进行裁切,获得一定厚度的筒状的三维立体纤维预制体,所述厚度基于摩擦片本体的厚度及后处理时的形变量来确定;
步骤S3:浸润改性硼酚醛树脂,浸润在真空的条件下进行,直至浸润充分;
步骤S4:干燥;
步骤S5:热压成型;
步骤S6:磨制,完毕后经检验合格,获得轻型机械制动盘用摩擦片。
优选的,所述纤维采用芳纶纤维和/或剑麻纤维,所述三维立体纤维预制体形式为三维四向、三维五向、三维六向、三维七向以及其他三维多向不同编制结构的任意一种。
优选的,所述改性硼酚醛树脂为二氧化钛改性的硼酚醛树脂,浸润温度为室温,浸润时间为1-24h。
优选的,浸润改性硼酚醛树脂液中添加质量分数1-3%的木质素磺酸钠,以及质量分数3-5%的氨基三元醇。实践中发现,木质素磺酸钠可以显著改善树脂液的粘度,氨基三元醇可以改善树脂液的润湿性,二者以特定的用量搭配使用,协同作用提高树脂液的吸附性能,便于树脂液深入三维织物的各个微小死角区,提高浸润的效果和效率。
优选的,热压成型的压力为:5-10Mpa,热压成型温度为120-135℃,热压成型的时间为6-10h。
本发明的工艺:增强纤维立体编制成筒状预制体→切断→真空浸胶→干燥→模具中热压成型→热处理→磨制→检验→入库。
本发明工艺采用芳纶纤维和/或剑麻纤维采用三维编制机,通过立体编制工艺制备获得三维立体增强纤维筒状的预制体,预制体外径和厚度根据摩擦片成品尺寸要求设定,然后预制体根据摩擦片厚度尺寸要求,径向切断成摩擦片毛坯,再经浸胶、干燥、热压成型,最后磨制得到摩擦片成品。
本项目将增强纤维(芳纶纤维和/或剑麻纤维)预先制成三维立体结构筒状的预制体,预制体属于一类具备多轴向取向的高度一体化的连贯纤维束编织集合体,各向同性的适应力好,克服了传统工艺胶条间分层的问题,具备优异的抗冲击韧性和抗疲劳特性,解决了原工艺存在的摩擦性能不稳定,产品压缩强度不均匀等缺陷;同时,基于一次成型萨三维加工技术,预制体的厚度可变范围大,成型性好,摩擦片生产效率提高40%以上。
为实现充分浸胶,采用真空浸胶工艺,采用筒状密闭容器,先将预制体放入容器,密闭后利用真空泵把预制体抽真空,然后逐步加入改性硼酚醛树脂溶液,浸胶充分、均匀,树脂中不会产生气泡,确保摩擦材料力学性能最佳。
本发明中,采用纳米二氧化硅粒子改性硼酚醛树脂,其中硼酚醛树脂有助于提高树脂耐热性,从而提高摩擦材料的高温耐腐蚀性能,但会导致材料脆性和硬度增加。本发明采用纳米二氧化硅进行填充改性,纳米粒子有利于提高硼酚醛树脂的韧性和初始分解温度;同时,纳米粒子表面含有大量羟基,可与硼酚醛树脂基体在固化过程发生反应,从而破坏酚醛分子的极性连接,减少交联点,削弱分子间作用力,提高树脂流动性,有利于预制体浸胶过程中,改性硼酚醛树脂在预制体三维结构中流动和增强纤维的浸润,提高浸胶均匀性。
附图说明
图1是本发明轻型机械制动盘用摩擦片的剖视图。
图中:1、摩擦片本体,2、纤维。
具体实施方式
下面通过具体实施例,并结合附图,对本发明的技术方案作进一步的具体说明。
如图1所示,一种轻型机械制动盘用摩擦片,包括摩擦片本体1,所述摩擦片本体1由纤维2三维编织物与改性硼酚醛树脂浸润后经后处理成型,所述后处理包括干燥、模压、热处理和磨制,所述纤维2采用芳纶纤维和/或剑麻纤维,所述筒状纤维三维织物形式为三维四向、三维五向、三维六向、三维七向以及其他三维多向不同编制结构的任意一种,所述改性硼酚醛树脂为二氧化钛改性的硼酚醛树脂,所述筒状纤维三维编织物的外径和宽度根据摩擦片本体的外径和宽度以及后处理时的形变量来确定,筒状纤维三维编织物的厚度基于摩擦片本体的厚度及后处理时的形变量来确定。
本实施例的轻型机械制动盘用摩擦片的制备方法,所述方法包括如下步骤:
步骤S1:纤维采用三维编织机,经由立体编织工艺制备获得筒状的三维立体纤维预制体,筒状的三维立体纤维预制体的外径和宽度根据摩擦片本体的外径和宽度以及后处理时的形变量来确定;
步骤S2:对步骤S1获得的筒状的三维立体纤维预制体进行裁切,获得一定厚度的筒状的三维立体纤维预制体,所述厚度基于摩擦片本体的厚度及后处理时的形变量来确定;
步骤S3:浸润改性硼酚醛树脂,浸润在真空的条件下进行,直至浸润充分;
步骤S4:干燥;
步骤S5:热压成型;
步骤S6:磨制,完毕后经检验合格,获得轻型机械制动盘用摩擦片。
具体到本发明,所述改性硼酚醛树脂为二氧化钛改性的硼酚醛树脂,浸润温度为室温,浸润时间为1-24h,如1h,3h,6h,12h,18h,24h,实际操作中根据工况需要做适应性选择。
为了改善浸润效果,本发明还考虑加入一些助剂,浸润改性硼酚醛树脂液中添加质量分数1-3%的木质素磺酸钠,如1%,1.5%,2.0%,3.0%,以及质量分数3-5%的氨基三元醇,如3.0%,3.5%,4.5%,5.0%。实践中发现,木质素磺酸钠可以显著改善树脂液的粘度,氨基三元醇可以改善树脂液的润湿性,二者以特定的用量搭配使用,协同作用提高树脂液的吸附性能,便于树脂液深入三维织物的各个微小死角区,提高浸润的效果和效率。
具体到本发明中,热压成型的压力为:5-10Mpa,如5Mpa、7Mpa、8Mpa、9Mpa、10Mpa,热压成型温度为120-135℃,如120℃,125℃,130℃,135℃,热压成型的时间为6-10h,如6h,8h,9h,10h。
上述助剂的添加量、热压压力、热压温度和热压成型时间都可以根据生产工况的实际需要,在上述范围内做合理的选择、调整。
本发明的工艺:增强纤维立体编制成筒状预制体→切断→真空浸胶→干燥→模具中热压成型→热处理→磨制→检验→入库。
本发明工艺采用芳纶纤维和/或剑麻纤维采用三维编制机,通过立体编制工艺制备获得三维立体增强纤维筒状的预制体,预制体外径和厚度根据摩擦片成品尺寸要求设定,然后预制体根据摩擦片厚度尺寸要求,径向切断成摩擦片毛坯,再经浸胶、干燥、热压成型,最后磨制得到摩擦片成品。
本项目将增强纤维(芳纶纤维和/或剑麻纤维)预先制成三维立体结构筒状的预制体,预制体属于一类具备多轴向取向的高度一体化的连贯纤维束编织集合体,各向同性的适应力好,克服了传统工艺胶条间分层的问题,具备优异的抗冲击韧性和抗疲劳特性,解决了原工艺存在的摩擦性能不稳定,产品压缩强度不均匀等缺陷;同时,基于一次成型萨三维加工技术,预制体的厚度可变范围大,成型性好,摩擦片生产效率提高40%以上。
为实现充分浸胶,采用真空浸胶工艺,采用筒状密闭容器,先将预制体放入容器,密闭后利用真空泵把预制体抽真空,然后逐步加入改性硼酚醛树脂溶液,浸胶充分、均匀,树脂中不会产生气泡,确保摩擦材料力学性能最佳。
本发明中,采用纳米二氧化硅粒子改性硼酚醛树脂,其中硼酚醛树脂有助于提高树脂耐热性,从而提高摩擦材料的高温耐腐蚀性能,但会导致材料脆性和硬度增加。本发明采用纳米二氧化硅进行填充改性,纳米粒子有利于提高硼酚醛树脂的韧性和初始分解温度;同时,纳米粒子表面含有大量羟基,可与硼酚醛树脂基体在固化过程发生反应,从而破坏酚醛分子的极性连接,减少交联点,削弱分子间作用力,提高树脂流动性,有利于预制体浸胶过程中,改性硼酚醛树脂在预制体三维结构中流动和增强纤维的浸润,提高浸胶均匀性。
以上所述的实施例只是本发明的一种较佳的方案,并非对本发明作任何形式上的限制,在不超出权利要求所记载的技术方案的前提下还有其它的变体及改型。
Claims (10)
1.一种轻型机械制动盘用摩擦片,包括摩擦片本体,其特征在于:所述摩擦片本体由筒状纤维三维编织物与改性硼酚醛树脂浸润后经后处理成型,所述后处理包括干燥、模压、热处理和磨制。
2.根据权利要求1所述的轻型机械制动盘用摩擦片,其特征在于:所述纤维采用芳纶纤维和/或剑麻纤维。
3.根据权利要求1所述的轻型机械制动盘用摩擦片,其特征在于:所述纤维三维编织物形式为三维四向、三维五向、三维六向、三维七向以及其他三维多向不同编制结构的任意一种。
4.根据权利要求1所述的轻型机械制动盘用摩擦片,其特征在于:所述改性硼酚醛树脂为二氧化钛改性的硼酚醛树脂。
5.根据权利要求1所述的轻型机械制动盘用摩擦片,其特征在于:所述筒状纤维三维编织物的外径和宽度根据摩擦片本体的外径和宽度以及后处理时的形变量来确定,筒状纤维三维编织物的厚度基于摩擦片本体的厚度及后处理时的形变量来确定。
6.一种轻型机械制动盘用摩擦片的制备方法,其特征在于:所述方法包括如下步骤:
步骤S1:纤维采用三维编织机,经由立体编织工艺制备获得筒状的三维立体纤维预制体,筒状的三维立体纤维预制体的外径和宽度根据摩擦片本体的外径和宽度以及后处理时的形变量来确定;
步骤S2:对步骤S1获得的筒状的三维立体纤维预制体进行裁切,获得一定厚度的筒状的三维立体纤维预制体,所述厚度基于摩擦片本体的厚度及后处理时的形变量来确定;
步骤S3:浸润改性硼酚醛树脂,浸润在真空的条件下进行,直至浸润充分;
步骤S4:干燥;
步骤S5:热压成型;
步骤S6:磨制,完毕后经检验合格,获得轻型机械制动盘用摩擦片。
7.根据权利要求6所述的轻型机械制动盘用摩擦片的制备方法,其特征在于:所述纤维采用芳纶纤维和/或剑麻纤维,所述三维立体纤维预制体形式为三维四向、三维五向、三维六向、三维七向以及其他三维多向不同编制结构的任意一种。
8.根据权利要求1所述的轻型机械制动盘用摩擦片的制备方法,其特征在于:所述改性硼酚醛树脂为二氧化钛改性的硼酚醛树脂,浸润温度为室温,浸润时间为1-24h。
9.根据权利要求6所述的轻型机械制动盘用摩擦片的制备方法,其特征在于:浸润改性硼酚醛树脂液中添加质量分数1-3%的木质素磺酸钠,以及质量分数3-5%的氨基三元醇。
10.根据权利要求6所述的轻型机械制动盘用摩擦片的制备方法,其特征在于:热压成型的压力为:5-10Mpa,热压成型温度为120-135℃,热压成型的时间为6-10h。
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Address after: 310000 No. 19, songyun Road, Longgang Town, Lin'an District, Hangzhou City, Zhejiang Province Applicant after: Hangzhou hanleke New Material Technology Co.,Ltd. Address before: 310000 No. 19, songyun Road, Longgang Town, Lin'an District, Hangzhou City, Zhejiang Province Applicant before: Hangzhou Lin'an Hualong friction material Co.,Ltd. |
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CB02 | Change of applicant information |