CN112576663A - 重载高速货车用合成闸瓦 - Google Patents
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Abstract
重载高速货车用合成闸瓦,本发明所要解决的问题是传统工艺中以纯酚醛树脂为基体的摩擦材料所引起的模量过高、强度过低、噪音大、热分解温度低、摩擦层的分解残物性能不稳定的问题,本发明的技术方案是最高时速100km/h重载货车用合成闸瓦,其组成包括摩擦体和钢背,所述摩擦体材料组成丁腈橡胶、橡胶促进剂、橡胶硫化剂、防老剂、桐油改性树脂、丁腈胶粉、泡沫铁粉、氧化铝、碳化硅、硫酸钡、炭黑、硅灰石、焦炭粉、陶土、锆英粉、硅酸铝纤维、陶瓷纤维、复合矿物纤维、芳纶纤维、钢纤维;本发明的优点是:摩擦体材料粘接剂组成中采用桐油改性酚醛树脂,桐油改性酚醛树脂与其它材料融合后具有更好的粘接及耐热性能、制动更加舒适平稳。
Description
技术领域
本发明属于铁路制动装置,具体涉及一种重载高速货车用合成闸瓦。
背景技术
世界各国重载铁路借助于采用高新技术,促使重载列车牵引重量不断增加。重载运输技术在越来越多的国家推广应用。不仅在幅员辽阔的大陆性国家重载铁路上大量开行重载列车,而目前在欧洲传统以客运为主的客货混运干线铁路也开始开行重载列车;同时铁路重载运输已经带来了日益显著的经济效益;由此可见铁路发展重载运输的战略已定局。随着中国经济的发展,降低能耗,减少排放,提高安全性成为经济发展的主流,我国铁路技术的飞速发展,机车车辆的制动技术同样面临着重大的革新。为达到节能减排的目标,需要运用多种节能技术,其中采用多种复合型材料融合达到实际使用要求。通过此项设计,铁路车辆在提高安全性、延长使用寿命、降低噪声、改善乘车舒适性都有显著效果,使其能够适用于铁路重载列车上。
发明内容
本发明采用的技术方案是:最高时速100km/h重载货车用合成闸瓦,其组成包括摩擦体和钢背,所述摩擦体材料组成丁腈橡胶、橡胶促进剂、橡胶硫化剂、防老剂、桐油改性树脂、丁腈胶粉、泡沫铁粉、氧化铝、碳化硅、硫酸钡、炭黑、硅灰石、焦炭粉、陶土、锆英粉、硅酸铝纤维、陶瓷纤维、复合矿物纤维、芳纶纤维、钢纤维’;各组分的重量百分比为:丁腈橡胶5-7%、、橡胶促进剂0.5-1%、橡胶硫化剂0.5-1%、防老剂0.3-0.5%、桐油改性树脂7-10%、丁腈胶粉3-5%、泡沫铁粉3-5%、氧化铝1-2%、碳化硅1-2%、硫酸钡3-5%、炭黑2-3%、硅灰石3-5%、焦炭粉5-7%、陶土2-3%、锆英粉1-2%、硅酸铝纤维10-15%、陶瓷纤维5-8%、复合矿物纤维10-15%、芳纶纤维4-6%、钢纤维5-8%;
所述最高时速100km/h重载货车用合成闸瓦,其制备方法为:
1)丁腈橡胶分两段开炼,第一段辊温40℃-45℃,辊距2mm-3mm,先加生胶,再加入氧化锌、防老剂、炭黑,出片停放;第二段辊温35℃-40℃,辊距3mm-4mm,先加一段胶,割刀混均,加硫磺,待全部混入后割刀薄通;
2)将1)得到的胶和摩擦体其余组分都加入密炼机加压混合,温度控制在≤90℃,强力混合,停放降温至室温,得到混合料;
3)将2)制得的混合料用模具压制在特定钢背上,压机压力为20~24MPa,加温170-180℃热压成型,得到成型半成品;
4)将3)制得的压制成型半成品放到自制的专用夹具夹紧,施加大约10KN/m2的压力。
5)热压成型后的闸瓦在烘箱中采用热风循环电加热热处理28H,前18H温度逐渐升高,直至最高热处理温度达到250℃,后10H保持热处理温度250℃,让所有原材料充分反应,保证彻底熟透,制得合成闸瓦。热处理采用分段热处理的方式,温度逐渐升高,保证闸片表面与其内部温度一致,力保合成材料熟成度一致,采用热风循环电加热既能保证热处理的有效进行。
与现有技术相比,本发明具有的有益效果是:
1、我公司开发的有机合成闸片产品中不含石棉、铅等可能危害人体健康的物质,属于环保型产品;
2、本发明摩擦体的主要由高分子材料构成,在满足制动要求的基础同时,产品还具有比重轻,硬度适中,对制动对偶面无热伤害、制动平稳舒适、使用寿命长等特点;
3、 本发明摩擦体材料粘接剂组成中采用桐油改性酚醛树脂,桐油改性酚醛树脂与其它材料融合后具有更好的粘接及耐热性能、制动更加舒适平稳,避免了传统工艺中以纯酚醛树脂为基体的摩擦材料所引起的模量过高、强度过低、噪音大、热分解温度低、摩擦层的分解残物性能不稳定的问题,因此桐油改性树脂是适用该合成闸瓦的工艺要求的最优选择。
4、本发明摩擦体材料组成中采用丁腈橡胶与胶粉共混使用,丁腈橡胶与天然橡胶和丁苯橡胶相比,具有弹性高、耐磨性好、耐寒性好、生热低、耐曲挠性和动态性能好等特点,硫化后其耐寒性、耐磨性和弹性特别优异,动负荷下发热少,耐老化性,且胶粉容易分散共混使用使其性能更加稳定等。丁腈橡胶良好耐候性,耐寒性可以很好地适应中国的铁路的区域气候差异大实际运行情况。
具体实施方式
实施例一:
本发明采用的技术方案是:最高时速100km/h重载货车用合成闸瓦,其组成包括摩擦体和钢背,所述摩擦体材料组成丁腈橡胶、橡胶促进剂、橡胶硫化剂、防老剂、桐油改性树脂、丁腈胶粉、泡沫铁粉、氧化铝、碳化硅、硫酸钡、炭黑、硅灰石、焦炭粉、陶土、锆英粉、硅酸铝纤维、陶瓷纤维、复合矿物纤维、芳纶纤维、钢纤维’;各组分的重量百分比为:丁腈橡胶6%、、橡胶促进剂0.8%、橡胶硫化剂0.75%、防老剂0.5%、桐油改性树脂9%、丁腈胶粉5%、泡沫铁粉5%、氧化铝1.5%、碳化硅1.5%、硫酸钡5%、炭黑3%、硅灰石4%、焦炭粉6%、陶土3%、锆英粉2%、硅酸铝纤维15%、陶瓷纤维8%、复合矿物纤维12%、芳纶纤维6%、钢纤维6%;
所述最高时速100km/h重载货车用合成闸瓦,其制备方法为:
1)丁腈橡胶分两段开炼,第一段辊温40℃-45℃,辊距2mm-3mm,先加生胶,再加入氧化锌、防老剂、炭黑,出片停放;第二段辊温35℃-40℃,辊距3mm-4mm,先加一段胶,割刀混均,加硫磺,待全部混入后割刀薄通;
2)将1)得到的胶和摩擦体其余组分都加入密炼机加压混合,温度控制在≤90℃,强力混合,停放降温至室温,得到混合料;
3)将2)制得的混合料用模具压制在特定钢背上,压机压力为20~24MPa,加温170-180℃热压成型,得到成型半成品;
4)将3)制得的压制成型半成品放到自制的专用夹具夹紧,施加大约10KN/m2的压力。
5)处理后的闸片在烘箱中采用热风循环电加热热处理28H,前18H温度逐渐升高,直至最高热处理温度达到250℃,后10H保持热处理温度250℃,让所有原材料充分反应,保证彻底熟透,制得合成闸瓦。热处理采用分段热处理的方式,温度逐渐升高,保证闸片表面与其内部温度一致,力保合成材料熟成度一致,采用热风循环电加热既能保证热处理的有效进行。
表1 热处理过程中温度与时间
温度(℃) | 室温~80 | 80 | 80~100 | 100 | 100~120 | 120 | 120~140 | 140 |
时间(min) | 30 | 60 | 10 | 60 | 10 | 120 | 10 | 120 |
温度(℃) | 140~160 | 160 | 160~180 | 180 | 180~200 | 200 | 200~220 | 220 |
时间(min) | 15 | 120 | 15 | 120 | 15 | 120 | 15 | 180 |
温度(℃) | 220~240 | 240 | 240~250 | 250 | ||||
时间(min) | 15 | 180 | 15 | 600 |
注:升温过程累计为18H,之后250℃恒温保持10小时,整个热处理过程28H。
Claims (3)
1.最高时速100km/h重载货车用合成闸瓦,是为适应重载运输日益增加及发展的需求,设计的一种耐磨性好的制动块,其组成包括摩擦体和钢背,其特征适用于轴重大于27t的重载货车中,耐磨耗性好,有效延长部件的使用寿命,降低铁路行业中的修理成本,所述摩擦体材料组成包括丁腈橡胶、橡胶促进剂、橡胶硫化剂、防老剂、桐油改性树脂、丁腈胶粉、泡沫铁粉、氧化铝、碳化硅、硫酸钡、炭黑、硅灰石、焦炭粉、陶土、锆英粉、硅酸铝纤维、陶瓷纤维、复合矿物纤维、芳纶纤维、钢纤维。
2.压制完成后的闸瓦放到自制的专用夹具中,施加大约10KN/m2的压力,之后送入烘箱热处理,加压热处理的方式可以有效的改善闸瓦在热处理过程中的变形等问题,增加产品在使用中的热稳定性。
3.根据权利要求1或2所述的最高时速100km/h重载货车用合成闸瓦,其制备方法为:
1)丁腈橡胶分两段开炼;
2)在温度控制不大于100℃密炼机中对所有原料强力混合;
3)闸瓦成型的压力为20-23MPa,加温热压成型;
4)压制完成后的闸瓦放到自制的专用夹具夹紧,施加大约10KN/m2的压力;
5)用热风循环电加热热处理28H。
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