CN113214597A - 玄武岩纤维基高性能环保型摩擦材料及制备方法 - Google Patents
玄武岩纤维基高性能环保型摩擦材料及制备方法 Download PDFInfo
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- UNYSKUBLZGJSLV-UHFFFAOYSA-L calcium;1,3,5,2,4,6$l^{2}-trioxadisilaluminane 2,4-dioxide;dihydroxide;hexahydrate Chemical compound O.O.O.O.O.O.[OH-].[OH-].[Ca+2].O=[Si]1O[Al]O[Si](=O)O1.O=[Si]1O[Al]O[Si](=O)O1 UNYSKUBLZGJSLV-UHFFFAOYSA-L 0.000 claims abstract description 14
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Abstract
本发明提供一种玄武岩纤维基高性能环保型摩擦材料,按重量百分比计,包括以下组分:酚醛树脂5‑10%,钛酸盐片晶5‑15%,玄武岩纤维5‑15%,芳纶纤维2‑5%,人造石墨2‑10%,石油焦炭粉2‑8%,腰果壳油摩擦粉3‑6%,金属硫化物5‑15%,丁腈橡胶粉1‑5%,氧化锆5‑10%,水合硅酸钙3‑8%,菱沸石3~6%,云母粉3‑8%,氧化镁2‑5%,氢氧化钙2‑5%,轮胎粉1‑3%,硫酸钡15‑30%。本发明还提供一种玄武岩纤维基高性能环保型摩擦材料的制备方法,本发明应用于汽、车用摩擦材料领域,具有优异摩擦磨损性能,高温衰退小、寿命长、优秀的噪音表现,不伤对偶件,稳定的摩擦系数。
Description
技术领域
本发明涉及摩擦材料,具体涉及一种玄武岩纤维基高性能环保型摩擦材料及制备方法。
背景技术
国民经济得到快速增长,“科技创新,自主创新”已成为目前国内工业发展的主流,我国工业正逐步向集约型、节能减排、低碳的方向发展。随着人们生活水平的不断提高,汽车逐步成为人们的日常生活中最重要的交通工具。制动系统是汽车上最重要的安全系统,制动性能直接影响汽车的行驶安全性,而制动器又是制动系统中直接作用于汽车运动的一个关键装置,是汽车上最重要的安全件。汽车制动器是利用摩擦片在制动时产生的摩擦阻力来进行制动的。因此,摩擦片的工作寿命和可靠性分十分重要。它事关汽车制动器工作的安全性、可靠性和持久性。
目前,现有的汽车用摩擦材料由于一些矿物粉伴生矿含有不环保材料,如重金属和有毒有害物质,影响生态环境;且还存在高温衰退大、使用寿命短和摩擦系数稳定性差等问题。
因此,需要对现有技术进行改进。
发明内容
本发明要解决的技术问题是提供一种高效的玄武岩纤维基高性能环保型摩擦材料及制备方法。
为解决上述技术问题,本发明提供一种玄武岩纤维基高性能环保型摩擦材料,按重量百分比计,包括以下组分:酚醛树脂5-10%,钛酸盐片晶5-15%,玄武岩纤维5-15%,芳纶纤维2-5%,人造石墨2-10%,石油焦炭粉2-8%,腰果壳油摩擦粉3-6%,金属硫化物5-15%,丁腈橡胶粉1-5%,氧化锆5-10%,水合硅酸钙3-8%,菱沸石3~6%,云母粉3-8%,氧化镁 2-5%,氢氧化钙2-5%,轮胎粉1-3%,硫酸钡15-30%。
作为对本发明玄武岩纤维基高性能环保型摩擦材料的改进,按重量百分比计,该材料包括以下组分:丁腈酚醛树脂7%,钛酸盐片晶10%,玄武岩纤维8%,芳纶纤维2.5%,人造石墨2.3%,石油焦炭粉3.3%,腰果壳油摩擦粉3.5%,金属硫化物8%,丁腈橡胶粉1.7%,氧化锆8.2%,水合硅酸钙3.8%,菱沸石3.5%,云母粉5.2%,氧化镁4.3%,氢氧化钙2.7%,轮胎粉1.3%,硫酸钡24.7%;
酚醛树脂采用丁腈改性树脂。
作为对本发明玄武岩纤维基高性能环保型摩擦材料的改进,按重量百分比计,该材料包括以下组分:丁腈酚醛树脂7%,钛酸盐片晶10%,玄武岩纤维15%,芳纶纤维2.5%,人造石墨2.3%,石油焦炭粉3.3%,腰果壳油摩擦粉3.5%,金属硫化物8%,丁腈橡胶粉1.7%,氧化锆8.2%,水合硅酸钙3.8%,菱沸石3.5%,云母粉5.2%,氧化镁4.3%,氢氧化钙2.7%,轮胎粉1.3%,硫酸钡17.7%;
酚醛树脂采用丁腈改性树脂。
作为对本发明玄武岩纤维基高性能环保型摩擦材料的改进,按重量百分比计,该材料包括以下组分:丁腈酚醛树脂7%,钛酸盐片晶10%,玄武岩纤维5%,芳纶纤维2.5%,人造石墨2.3%,石油焦炭粉3.3%,腰果壳油摩擦粉3.5%,金属硫化物8%,丁腈橡胶粉1.7%,氧化锆8.2%,水合硅酸钙3.8%,菱沸石3.5%,云母粉5.2%,氧化镁4.3%,氢氧化钙2.7%,轮胎粉1.3%,硫酸钡27.7%;
酚醛树脂采用丁腈改性树脂。
本发明还提供一种玄武岩纤维基高性能环保型摩擦材料的制备方法,包括以下步骤:
1)、配、混料:按配方配比配制混合料,在犁耙式混料机中进行搅拌混合,得到混合料;
混料工艺为:犁刀速度为12HZ,飞刀速度为50HZ,分两次投料,第一次投料后搅拌(600±60)s,第二次投料后搅拌(900±60)s后放料。
2)、热压成型:将混合料放入模腔按照一定温度、压力、时间热压成型,再自然冷却到室温,得到热压成型产品;
具体为压力35MPa和上模(160±5)℃,中、下模(145±5)℃条件下,热压成型时间为5~7min;
3)、热处理:将热压成型产品从室温到230℃,分阶段进行升温和恒温热处理,得到热处理后产品;其具体工艺图1所示。
4)尺寸加工:按照图纸要求对热处理后产品进行尺寸加工。
本发明玄武岩纤维基高性能环保型摩擦材料及制备方法的技术优势为:
本发明应用于汽、车用摩擦材料领域,具有优异摩擦磨损性能,高温衰退小、寿命长、优秀的噪音表现,不伤对偶件,稳定的摩擦系数。
本发明的摩擦材料是环保材料,符合欧盟立法ELV报废车辆指令、美国地方法规SB6557/SB346和GB/T30512-2014《汽车禁用物质》,不含重金属和有毒有害等有害物质有效保护生态环境;同时试验表明,本发明具有优异耐高温特性和耐磨性,热衰退小、使用寿命长,稳定的摩擦系数。应用试验表明:实车验证制动平稳、脚感舒适、低噪音、无震颤现象且与制动盘具有良好的匹配性。
附图说明
下面结合附图对本发明的具体实施方式作进一步详细说明。
图1是本发明实施例1-3热处理工艺的示意图。
具体实施方式
下面结合具体实施例对本发明进行进一步描述,但本发明的保护范围并不仅限于此。
实施例1、玄武岩纤维基高性能环保型摩擦材料,按重量百分比计,该材料包括以下组分:丁腈酚醛树脂7%,钛酸盐片晶10%,玄武岩纤维8%,芳纶纤维2.5%,人造石墨2.3%,石油焦炭粉3.3%,腰果壳油摩擦粉3.5%,金属硫化物8%,丁腈橡胶粉1.7%,氧化锆8.2%,水合硅酸钙3.8%,菱沸石3.5%,云母粉5.2%,氧化镁4.3%,氢氧化钙2.7%,轮胎粉1.3%,硫酸钡24.7%;
酚醛树脂采用丁腈改性树脂。
玄武岩纤维基高性能环保型摩擦材料的制备方法,包括以下步骤:
(1)配、混料:按配方配比配制混合料,在犁耙式混料机中进行搅拌混合,得到混合料;
混料工艺为:犁刀速度为12HZ,飞刀速度为50HZ,分两次投料,第一次投料后搅拌(600 ±60)s,第二次投料后搅拌(900±60)s后放料。
(2)热压成型:将混合料放入模腔按照一定温度、压力、时间热压成型,再自然冷却到室温,得到热压成型产品;
具体为压力35MPa和上模(160±5)℃,中、下模(145±5)℃条件下,热压成型时间总共为5~7min;
(3)热处理:将热压成型产品从室温到230℃,分阶段进行升温和恒温热处理,得到热处理后产品;
(4)尺寸加工:按照图纸要求对热处理后产品进行尺寸加工。
本实施例1所得的摩擦材料在台架实验台上按照AK-Master进行测试各个工况下摩擦系数如下表所示,衰退摩擦系数在0.3以上;
本实施例1所得的摩擦材料在汽车(名爵ZS11)上试装4万公里,总厚度磨损量为3mm,按照有效厚度折算使用寿命在10万公里以上,远远超过普通配方刹车片。对偶面光洁无划痕,无噪音等影响舒适性问题。
实施例2、玄武岩纤维基高性能环保型摩擦材料,按重量百分比计,该材料包括以下组分:丁腈酚醛树脂7%,钛酸盐片晶10%,玄武岩纤维15%,芳纶纤维2.5%,人造石墨2.3%,石油焦炭粉3.3%,腰果壳油摩擦粉3.5%,金属硫化物8%,丁腈橡胶粉1.7%,氧化锆8.2%,水合硅酸钙3.8%,菱沸石3.5%,云母粉5.2%,氧化镁4.3%,氢氧化钙2.7%,轮胎粉1.3%,硫酸钡17.7%;
酚醛树脂采用丁腈改性树脂。
玄武岩纤维基高性能环保型摩擦材料的制备方法,包括以下步骤:
(1)配、混料:按配方配比配制混合料,在犁耙式混料机中进行搅拌混合,得到混合料;
混料工艺为:犁刀速度为12HZ,飞刀速度为50HZ,分两次投料,第一次投料后搅拌(600 ±60)s,第二次投料后搅拌(900±60)s后放料。
(2)热压成型:将混合料放入模腔按照一定温度、压力、时间热压成型,再自然冷却到室温,得到热压成型产品;
具体为压力35MPa和上模(160±5)℃,中、下模(145±5)℃条件下,热压成型时间总共为5~7min;
(3)热处理:将热压成型产品从室温到230℃,分阶段进行升温和恒温热处理,得到热处理后产品;
(4)尺寸加工:按照图纸要求对热处理后产品进行尺寸加工。
实施例3、玄武岩纤维基高性能环保型摩擦材料,按重量百分比计,该材料包括以下组分:丁腈酚醛树脂7%,钛酸盐片晶10%,玄武岩纤维5%,芳纶纤维2.5%,人造石墨2.3%,石油焦炭粉3.3%,腰果壳油摩擦粉3.5%,金属硫化物8%,丁腈橡胶粉1.7%,氧化锆8.2%,水合硅酸钙3.8%,菱沸石3.5%,云母粉5.2%,氧化镁4.3%,氢氧化钙2.7%,轮胎粉1.3%,硫酸钡27.7%;
酚醛树脂采用丁腈改性树脂。
玄武岩纤维基高性能环保型摩擦材料的制备方法,包括以下步骤:
(1)配、混料:按配方配比配制混合料,在犁耙式混料机中进行搅拌混合,得到混合料;
混料工艺为:犁刀速度为12HZ,飞刀速度为50HZ,分两次投料,第一次投料后搅拌(600 ±60)s,第二次投料后搅拌(900±60)s后放料。
(2)热压成型:将混合料放入模腔按照一定温度、压力、时间热压成型,再自然冷却到室温,得到热压成型产品;
具体为压力35MPa和上模(160±5)℃,中、下模(145±5)℃条件下,热压成型时间总共为5~7min;
(3)热处理:将热压成型产品从室温到230℃,分阶段进行升温和恒温热处理,得到热处理后产品;
(4)尺寸加工:按照图纸要求对热处理后产品进行尺寸加工。
本发明在具体的实施例中,选用如下的原料:
帝人公司3091牌号芳纶浆粕是一种新型高科技合成纤维,具有超高强度、高模量和耐高温、耐酸耐碱、重量轻、绝缘、抗老化、生命周期长等优良性能。其强度为钢丝的5~6倍,模量为钢丝或玻璃纤维的2~3倍,韧性为钢丝的2倍,而重量仅为钢丝的1/5左右,在560度的温度下,不分解,不融化。无金属刹车片采用芳纶为主增强纤维,其具有良好的耐温性和抗剪切性能,制成的产品具有稳定的摩擦系数和较小的磨损率。
玄武岩纤维是玄武岩石料在1450℃~1500℃熔融后,通过铂铑合金拉丝漏板高速拉制而成的连续纤维。纯天然玄武岩纤维的颜色一般为褐色,有金属光泽。玄武岩纤维是一种新型无机环保绿色高性能纤维材料,它是由二氧化硅、氧化铝、氧化钙、氧化镁、氧化铁和二氧化钛等氧化物组成。玄武岩连续纤维不仅强度高,而且还具有电绝缘、耐腐蚀、耐高温等多种优异性能。经过表面改性后,其表面增加纳米SiO2粒子,有效地提高纤维表面粗糙度,增加了纤维与树脂等粘结剂的相容性。使用在摩擦材料中具有稳定的摩擦系数,降低热衰退,低噪音等特点。以上实施使用的玄武岩纤维为浙江石金玄武岩纤维股份有限公司生产。
水合硅酸钙是一种具有中空结构的矿物粉,其性能非常稳定,耐高温,在650℃到750℃之间失去部分结晶水,但其物理性能没有明显的变化,具有较高的PH值,耐腐蚀性好,吸水率等特点。在无铜NAO摩擦材料中使用能提高、稳定摩擦系数,减少热衰退,增加气孔率及增加压缩比,减少制动盘与摩擦片的锈蚀粘连。加入适当的水合硅酸钙产品还能改变有机纤维(比如芳纶和丙烯晴纤维)的静电属性,提高了其对混料的亲和力。以上实施使用的水合硅酸钙为荷兰Lapinus公司代理。
钛酸钾片晶是由于钛酸钾晶须针状结构,人吸入体内不能分解而禁止使用后新出来的一种摩擦材料用鳞片状钛酸盐。其具有对摩擦过程中能量的反射和能量的缓慢传递,致使刹车片工作时温度上升缓慢,保持摩擦系数的稳定性,减少磨损增加摩擦片的使用寿命。本实施中使用的钛酸钾片晶为日本大冢化学公司的钛酸钾片晶PM,其使用在摩擦片中能有芳纶等有机纤维互补增强作用,能减小摩擦材料的高温衰退,在制动过程中保持摩擦系数的稳定性,降低刹车盘和刹车片的磨损,由于其本身具有的高温吸音特性能有效地降低制动噪音。具有较高的PH值可以减少制动盘与摩擦片的锈蚀粘连。
人造石墨具有完整的晶体结构和高气孔率,其导热性稳定,由于其层状结构具有较好的低温润滑性能,能减少磨损和降低制动噪音。以上实施选用的瑞典特密高人造石墨含碳量为 99%以上,气孔率为20%,就有较好的吸音作用。
硫化锑熔点较低,高温时分解后生成氧化锑,在还原剂存在时生成金属锑,能防止高温时材料的氧化燃烧。本实施中使用的湖北天森锑业的硫化锑含量92%以上的材料在摩擦材料中使用能保持摩擦系数的稳定性,提高材料的抗烧性能,降低有机粘结剂在高温时的分解速度,减少材料的高温磨损,起到了高温无机粘结剂和润滑摩擦调整剂的作用。
腰果壳油摩擦粉由腰果壳油加工而成的,可改善刹车片中无机纤维的、粉料的界面结合状况,在高温时能分解,防止摩擦界面的温度进一步升高。本实施中使用的卡德莱黑色腰果壳油摩擦粉分解温度高,稳定摩擦系数,降低磨损,减少制动噪音的特性。
菱沸石于沸石族,晶体呈假立方体和菱面体,常成双晶。旧称斜方沸石。成分 Ca[Al2Si4O12]·6H2O。三方晶系。晶体呈近于立方体的菱面体。常呈以c轴为双晶轴的贯穿双晶。白色、肉红或浅黄色。条痕无色。透明到半透明,玻璃光泽。硬度4~5。密度2.05~2.10g/cm3,在摩擦材料用可以有效降低金属镶嵌,降低热膨胀及稳定摩擦系数、降低热衰退,减少热压时摩擦材料的开裂。本实施中使用的菱沸石系上海先普贸易有限公司代理的意大利进口产品。
最后,还需要注意的是,以上列举的仅是本发明的若干个具体实施例。显然,本发明不限于以上实施例,还可以有许多变形。本领域的普通技术人员能从本发明公开的内容直接导出或联想到的所有变形,均应认为是本发明的保护范围。
Claims (5)
1.一种玄武岩纤维基高性能环保型摩擦材料,其特征在于:按重量百分比计,包括以下组分:
酚醛树脂5-10%,钛酸盐片晶5-15%,玄武岩纤维5-15%,芳纶纤维2-5%,人造石墨2-10%,石油焦炭粉2-8%,腰果壳油摩擦粉3-6%,金属硫化物5-15%,丁腈橡胶粉1-5%,氧化锆5-10%,水合硅酸钙3-8%,菱沸石3~6%,云母粉3-8%,氧化镁2-5%,氢氧化钙2-5%,轮胎粉1-3%,硫酸钡15-30%。
2.根据权利要求1所述的一种玄武岩纤维基高性能环保型摩擦材料,其特征在于:按重量百分比计,包括以下组分:
丁腈酚醛树脂7%,钛酸盐片晶10%,玄武岩纤维8%,芳纶纤维2.5%,人造石墨2.3%,石油焦炭粉3.3%,腰果壳油摩擦粉3.5%,金属硫化物8%,丁腈橡胶粉1.7%,氧化锆8.2%,水合硅酸钙3.8%,菱沸石3.5%,云母粉5.2%,氧化镁4.3%,氢氧化钙2.7%,轮胎粉1.3%,硫酸钡24.7%;
酚醛树脂采用丁腈改性树脂。
3.根据权利要求1所述的一种玄武岩纤维基高性能环保型摩擦材料,其特征在于:按重量百分比计,包括以下组分:
丁腈酚醛树脂7%,钛酸盐片晶10%,玄武岩纤维15%,芳纶纤维2.5%,人造石墨2.3%,石油焦炭粉3.3%,腰果壳油摩擦粉3.5%,金属硫化物8%,丁腈橡胶粉1.7%,氧化锆8.2%,水合硅酸钙3.8%,菱沸石3.5%,云母粉5.2%,氧化镁4.3%,氢氧化钙2.7%,轮胎粉1.3%,硫酸钡17.7%;
酚醛树脂采用丁腈改性树脂。
4.根据权利要求1所述的一种玄武岩纤维基高性能环保型摩擦材料,其特征在于:按重量百分比计,包括以下组分:
丁腈酚醛树脂7%,钛酸盐片晶10%,玄武岩纤维5%,芳纶纤维2.5%,人造石墨2.3%,石油焦炭粉3.3%,腰果壳油摩擦粉3.5%,金属硫化物8%,丁腈橡胶粉1.7%,氧化锆8.2%,水合硅酸钙3.8%,菱沸石3.5%,云母粉5.2%,氧化镁4.3%,氢氧化钙2.7%,轮胎粉1.3%,硫酸钡27.7%;
酚醛树脂采用丁腈改性树脂。
5.应用于权利要求1-4任一所述一种玄武岩纤维基高性能环保型摩擦材料的一种玄武岩纤维基高性能环保型摩擦材料的制备方法,其特征在于:包括以下步骤:
1)、配、混料:按配方配比配制混合料,在犁耙式混料机中进行搅拌混合,得到混合料;
混料工艺为:犁刀速度为12HZ,飞刀速度为50HZ,分两次投料,第一次投料后搅拌(600±60)s,第二次投料后搅拌(900±60)s后放料;
2)、热压成型:将混合料放入模腔按照一定温度、压力、时间热压成型,再自然冷却到室温,得到热压成型产品;
具体为压力35MPa和上模(160±5)℃,中、下模(145±5)℃条件下,热压成型时间为5~7min;
3)、热处理:将热压成型产品从室温到230℃,分阶段进行升温和恒温热处理,得到热处理后产品;
4)尺寸加工:按照图纸要求对热处理后产品进行尺寸加工。
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