CN114857192A - 一种碳纤维增强碳基摩擦片结构及其制备方法 - Google Patents

一种碳纤维增强碳基摩擦片结构及其制备方法 Download PDF

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CN114857192A
CN114857192A CN202210633464.0A CN202210633464A CN114857192A CN 114857192 A CN114857192 A CN 114857192A CN 202210633464 A CN202210633464 A CN 202210633464A CN 114857192 A CN114857192 A CN 114857192A
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杜建华
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Abstract

本发明提供了一种碳纤维增强碳基摩擦片结构及其制备方法，属于摩擦片的技术领域，缓解了现有技术容易发生高温树脂分解，导致连接失效的问题。该碳纤维增强碳基摩擦片结构包括摩擦层、连接层和支撑板，所述连接层连接于摩擦层与支撑板之间；所述摩擦层由经纱和纬纱编织而成，所述摩擦层的经纱和纬纱中至少一种为碳纤维，且所述摩擦层经过了浸渍树脂、树脂碳化和碳沉积处理；所述连接层由经纱和纬纱编织而成，所述连接层的经纱和纬纱中至少一种为金属纤维。

Description

一种碳纤维增强碳基摩擦片结构及其制备方法
技术领域
本发明涉及摩擦片技术领域，尤其是涉及一种碳纤维增强碳基摩擦片结构及其制备方法。
背景技术
目前，传统的碳纤维摩擦材料主要包括碳纤维增强树脂基摩擦材料和碳/碳摩擦材料，其中碳纤维增强树脂基摩擦材料是由碳纤维和树脂基体组成，其中树脂起基体和芯板的连接作用，但当摩擦材料的承载过大时，摩擦温度升高，会导致树脂发生碳化分解，从而引起摩擦材料剥落、引起粘结层碳化失效。因而，碳纤维增强树脂基摩擦材料适用于中、低载荷条件下。
传统的碳/碳摩擦材料，基体虽然为耐高温的碳，但使用过程中容易发生纤维的脱落、基体强度下降时，磨损严重，碳/碳摩擦材料与支撑板之间采用树脂粘接，会发生高温树脂分解，导致连接失效的问题。
发明内容
本发明的目的在于提供一种碳纤维增强碳基摩擦片结构及其制备方法，缓解了现有技术容易发生高温树脂分解，导致连接失效的问题。
第一方面，本发明提供一种碳纤维增强碳基摩擦片结构，包括摩擦层、连接层和支撑板，所述连接层连接于摩擦层与支撑板之间；
所述摩擦层由经纱和纬纱编织而成，所述摩擦层的经纱和纬纱中至少一种为碳纤维，且所述摩擦层经过了浸渍树脂、树脂碳化和碳沉积处理；
所述连接层由经纱和纬纱编织而成，所述连接层的经纱和纬纱中至少一种为金属纤维。
进一步的，所述摩擦层的编织方式为浅交直联、浅交弯联或深交联，所述连接层的编织方式为浅交直联、浅交弯联或深交联。
进一步的，所述金属纤维为铜纤维、钢纤维、铝纤维、钛纤维、镍纤维、银纤维中的一种或多种的合金纤维，所述金属纤维的直径为0.001-5.0mm。
进一步的，所述摩擦层和所述连接层均为多层；
位于最外层的摩擦层的经纱和纬纱均为碳纤维，与所述支撑板相接的连接层的经纱和纬纱中至少一种为金属纤维。
进一步的，所述摩擦层和所述连接层相接处的经纱与纬纱相互编织，所述连接层中的金属纤维与所述支撑板烧结固定。
进一步的，所述支撑板上设有金属镀层，所述金属镀层的材料与所述连接层的金属纤维具有互溶性。
进一步的，所述金属镀层为镀铜层、镀镍层或镀铜镀镍层。
进一步的，所述支撑板为圆环形，所述摩擦层和所述连接层构成多个弧形的摩擦片，相邻的所述摩擦片之间形成有油槽。
第二方面，本发明还提供一种碳纤维增强碳基摩擦片结构的制备方法，包括：
利用三维编织技术编织形成碳纤维编织预制体；
对所述碳纤维编织预制体进行树脂浸渍、树脂碳化和沉积碳工艺，形成碳纤维增强碳基摩擦材料；所述碳纤维增强碳基摩擦材料包括摩擦层和连接层，所述摩擦层的经纱和纬纱中至少一种为碳纤维，所述连接层的经纱和纬纱中至少一种为金属纤维；
通过压制烧结工艺，将所述连接层中的金属纤维与支撑板烧结固定。
进一步的，对所述碳纤维编织预制体进行树脂浸渍、树脂碳化和沉积碳工艺，形成碳纤维增强碳基摩擦材料的步骤，包括：
在真空环境中，利用树脂传递模塑装置对所述碳纤维编织预制体进行树脂浸渍处理；
树脂浸渍完成后进行热压固化成型，成型压力1-20MPa，成型温度100-300℃，成型工艺时长5-50h，形成树脂基体；
通过高温树脂碳化处理，使树脂基体生成碳基体，碳化处理温度600-2500℃，处理工艺时长5-120h；
利用化学气相沉积工艺，对碳基体进行碳沉积处理，形成碳纤维增强碳基摩擦材料。
本发明提供的碳纤维增强碳基摩擦片结构包括摩擦层、连接层和支撑板，连接层连接于摩擦层与支撑板之间，摩擦层的经纱和纬纱中至少一种为碳纤维，且摩擦层经过了浸渍树脂、树脂碳化和碳沉积处理，连接层的经纱和纬纱中至少一种为金属纤维。该碳纤维增强碳基摩擦片结构采用连续碳纤维作为增强相，碳材料作为摩擦材料基体，利用碳基体代替树脂基体，具有更高的耐热性能，缓解了现有技术容易发生高温树脂分解，导致连接失效的问题。同时，摩擦层与支撑板通过金属冶金结合，提高了二者之间的结合强度，能够承受更高的温度，实现摩擦层与支撑板之间的高强度连接。本发明的摩擦材料不易发生纤维的脱落，具有更高的连接强度和抗损伤容限，耐磨性高，与传统碳基摩擦材料相比，碳纤维碳基摩擦材料具备更高的耐热性能和摩擦性能稳定性。
相应地，本发明实施例提供的碳纤维增强碳基摩擦片结构的制备方法，也同样具有上述技术效果。
附图说明
为了更清楚地说明本发明具体实施方式或现有技术中的技术方案，下面将对具体实施方式或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图是本发明的一些实施方式，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本发明实施例1提供的碳纤维增强碳基摩擦片结构的平面示意图；
图2为本发明实施例1提供的碳纤维增强碳基摩擦片结构的截面示意图；
图3为本发明实施例1提供的碳纤维增强碳基摩擦片结构的编织方式示意图；
图4为本发明实施例2中提供的碳纤维增强碳基摩擦片结构的编织方式示意图；
图5为本发明实施例3提供的碳纤维增强碳基摩擦片结构的编织方式示意图；
图6为本发明实施例3提供的碳纤维增强碳基摩擦片结构的截面示意图。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合附图对本发明的技术方案进行清楚、完整地描述，显然，所描述的实施例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。
本发明实施例中所提到的术语“包括”和“具有”以及它们的任何变形，意图在于覆盖不排他的包含。例如包含了一系列步骤或单元的过程、方法、系统、产品或设备没有限定于已列出的步骤或单元，而是可选地还包括其他没有列出的步骤或单元，或可选地还包括对于这些过程、方法、产品或设备固有的其它步骤或单元。
随着车辆、船舶、工程机械等装备转速、载荷的增加，以及装置的小型化，装备的传动和制动系统的单位能量负荷大幅增加，传统的铜基粉末冶金摩擦片、纸基摩擦片难以满足装备高速、重载的使用要求。碳基摩擦片因具有优良的耐热性能，逐渐被使用。
目前，传统的碳纤维摩擦材料主要包括碳纤维增强树脂基摩擦材料和碳/碳摩擦材料，其中碳纤维增强树脂基摩擦材料是由碳纤维和树脂基体组成，树脂作为基体以及摩擦材料支撑板(芯板)的连接剂，但当摩擦材料的承载过大时，摩擦温度升高，会导致树脂发生碳化分解，从而引起摩擦材料剥落、引起粘结层碳化失效。因而，碳纤维增强树脂基摩擦材料适用于中、低载荷条件下。
实施例1：
如图1和图2所示，本发明实施例提供一种碳纤维增强碳基摩擦片结构，包括摩擦层4、连接层5和支撑板(芯板)1，连接层5连接于摩擦层4与支撑板1之间。摩擦层4由经纱和纬纱编织而成，摩擦层4的经纱和纬纱中至少一种为碳纤维，且摩擦层4经过了浸渍树脂、树脂碳化和碳沉积处理。连接层5由经纱和纬纱编织而成，连接层5的经纱和纬纱中至少一种为金属纤维。
本实施例中，支撑板1为圆环形，摩擦层4和连接层5构成多个弧形的摩擦片3，摩擦片3的大小形状相同，相邻的摩擦片3之间形成有油槽2。在其他实施方式中，也可以不设置油槽，相邻摩擦片之间紧密贴合。
本发明实施例采用连续碳纤维作为增强相，碳材料作为摩擦材料基体，利用碳基体代替树脂基体，具有更高的耐热性能，缓解了现有技术容易发生高温树脂分解，导致连接失效的问题。
摩擦层4和连接层5可以是单层，也可以是多层，摩擦层4和连接层5的总层数通常可以为2-200层。摩擦层4的编织方式可以为浅交直联、浅交弯联或深交联，连接层5的编织方式也可以为浅交直联、浅交弯联或深交联。以上编织方式均为三维编织方式，能够使材料显示出较强的整体性，具有承载能力高耐冲击，不易破裂和剥离的特点。
本实施例中，摩擦层4和连接层5相接处的经纱与纬纱相互编织，实现稳定的连接。支撑板1上设有金属镀层8，金属镀层8的材料与连接层5的金属纤维具有互溶性，可以是镀铜层、镀镍层或镀铜镀镍层。连接层5中的金属纤维与金属镀层8通过400℃-1500℃的高温烧结固定，使摩擦层4与支撑板1通过连接层5相互连结固定。金属镀层8让连接层5与支撑板1的连接更为牢固，金属镀层8形成的界面好，连接力强，金属镀层8形成一个面连接，连接更牢固。
摩擦层4与支撑板1通过金属冶金结合，提高了二者之间的结合强度，能够承受更高的温度，实现摩擦层4与支撑板1之间的高强度连接。本发明实施例的摩擦材料不易发生纤维的脱落，具有更高的连接强度和抗损伤容限，耐磨性高，与传统碳基摩擦材料相比，碳纤维碳基摩擦材料具备更高的耐热性能和摩擦性能稳定性，保证摩擦片可以在高载荷情况下，稳定运转，提高摩擦片的使用寿命。
在其他实施方式中，也可以不设置金属镀层，将连接层5中的金属纤维直接与支撑板烧结固定。
如图3所示，本实施例中摩擦层以碳纤维作为经纱6和纬纱7，用浅交直联方式进行编织，摩擦层共有2层，碳纤维的基体是有热解炭和沉积碳混合组成的。
摩擦层的最下层与连接层的最上层也是采用浅交直联方式进行编织，从而实现摩擦层和连接层的一体性，保证整体结构的一致性。连接层共有2层，连接层的经纱和纬纱均为铜纤维，连接层也采用浅交直联方式进行编织。在其他实施方式中，金属纤维也可以采用铜纤维、钢纤维、铝纤维、钛纤维、镍纤维、银纤维中的一种或多种的合金纤维，金属纤维的直径可以为0.001-5.0mm。
本实施例中，位于最外层的摩擦层的经纱和纬纱均为碳纤维，与支撑板(金属镀层)相接的连接层的经纱和纬纱中至少一种为金属纤维。最上层的摩擦层承受主要的摩擦力，全部由碳纤维编织保证耐磨性；最下层的连接层主要是与支撑板相接，其中的金属纤维能够保证连接的牢固度。
实施例2：
本实施例与实施例1基本相同，其不同点在于，摩擦层和连接层均是采用浅交弯联方式进行编织，如图4所示，摩擦层为4层，摩擦层的经纱6和纬纱7均为碳纤维。连接层为3层，连接层的上面两层的经纱和纬纱分别采用碳纤维和钢纤维，连接层最下面一层的经纱和纬纱均采用钢纤维，支撑板上的金属镀层为镀镍层。
摩擦层承受主要的摩擦力，全部由碳纤维编织保证耐磨性；最下层的连接层主要是与金属镀层相接，全部采用金属纤维，能够进一步保证连接的牢固度。
实施例3：
本实施例与实施例1基本相同，其不同点在于，摩擦层和连接层均采用深交联方式进行编织，如图5和图6所示，本实施例中支撑板1的两面都设置有摩擦层4、连接层5和金属镀层8。摩擦层为10层，摩擦层的最上面5层的经纱6和纬纱7均为碳纤维，摩擦层的下面5层的经纱和纬纱分别采用碳纤维和银纤维。连接层为5层，连接层的经纱和纬纱均采用银纤维。
靠近上面摩擦层承受主要的摩擦力，全部由碳纤维编织保证耐磨性；靠近下面的连接层主要是与支撑板(金属镀层)相接，全部采用金属纤维，能够进一步保证连接的牢固度。
实施例4：
本发明实施例提供一种碳纤维增强碳基摩擦片结构的制备方法，包括以下步骤：
S1：利用三维编织技术编织形成碳纤维编织预制体。
具体的，由碳纤维以浅交直联、浅交弯联或深交联等三维编织方式，编织预制体增强碳基体(CF/C)摩擦材料构成摩擦层，连续碳纤维的丝束可选择1K、3K、6K、12K。
S2：对碳纤维编织预制体进行树脂浸渍、树脂碳化和沉积碳工艺，形成碳纤维增强碳基摩擦材料。
其中，碳纤维增强碳基摩擦材料包括摩擦层和连接层，摩擦层的经纱和纬纱中至少一种为碳纤维，连接层的经纱和纬纱中至少一种为金属纤维。连接层可以是由预埋在碳纤维编织物中的金属丝组成，金属纤维可以是直径0.001-5.0mm的钢纤维、铜纤维、镍纤维和铝纤维及其合金纤维等。
本步骤具体包括以下几个子步骤：
树脂浸渍：
在真空环境中，利用树脂传递模塑(Resin Transfer Molding，RTM)装置对碳纤维编织预制体进行树脂浸渍处理。全程保持抽真空，以保证树脂对碳纤维预制体的充分浸渍。在其他实施方式中，也可以在常温常压下进行树脂浸渍处理。
树脂浸渍完成后进行热压固化成型，成型压力1-20MPa成型温度100-300℃，成型工艺时长5-50h，形成树脂基体。压力、温度、时长等具体工艺参数，可根据所采用的材料进行针对性选择。
树脂碳化：
通过高温树脂碳化处理，使树脂基体生成碳基体，碳化处理温度600-2500℃，处理工艺时长5-120h。为避免材料因受热发生变形，在高温碳化处理过程中，对CF/C材料采取平面层叠布置，并利用石墨压板加压。
沉积碳：
利用化学气相沉积(Chemical Vapor Deposition，CVD)工艺，对碳基体进行碳沉积处理，形成碳纤维增强碳基摩擦材料。
S3：通过压制烧结工艺，将连接层中的金属纤维与支撑板烧结固定。
在此之后，可以对成品进行超声清洗、烘干、试验，试验前需对摩擦片进行超声清洗并烘干，去除机加工过程中产生的碎屑。
应注意到：相似的标号和字母在下面的附图中表示类似项，因此，一旦某一项在一个附图中被定义，则在随后的附图中不需要对其进行进一步定义和解释。
在本发明的描述中，需要说明的是，术语“中心”、“上”、“下”、“左”、“右”、“竖直”、“水平”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，或者是该发明产品使用时惯常摆放的方位或位置关系，仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。此外，术语“第一”、“第二”、“第三”等仅用于区分描述，而不能理解为指示或暗示相对重要性。
在本发明的描述中，还需要说明的是，除非另有明确的规定和限定，术语“设置”、“安装”、“相连”、“连接”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或一体地连接；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通。对于本领域的普通技术人员而言，可以具体情况理解上述术语在本发明中的具体含义。
最后应说明的是：以上所述实施例，仅为本发明的具体实施方式，用以说明本发明的技术方案，而非对其限制，本发明的保护范围并不局限于此，尽管参照前述实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，其依然可以对前述实施例所记载的技术方案进行修改或可轻易想到变化，或者对其中部分技术特征进行等同替换；而这些修改、变化或者替换，并不使相应技术方案的本质脱离本发明实施例技术方案的范围。都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应以权利要求的保护范围为准。

Claims (10)

1.一种碳纤维增强碳基摩擦片结构，其特征在于，包括摩擦层、连接层和支撑板，所述连接层连接于摩擦层与支撑板之间；
所述摩擦层由经纱和纬纱编织而成，所述摩擦层的经纱和纬纱中至少一种为碳纤维，且所述摩擦层经过了浸渍树脂、树脂碳化和碳沉积处理；
所述连接层由经纱和纬纱编织而成，所述连接层的经纱和纬纱中至少一种为金属纤维。
2.根据权利要求1所述的碳纤维增强碳基摩擦片结构，其特征在于，所述摩擦层的编织方式为浅交直联、浅交弯联或深交联，所述连接层的编织方式为浅交直联、浅交弯联或深交联。
3.根据权利要求1所述的碳纤维增强碳基摩擦片结构，其特征在于，所述金属纤维为铜纤维、钢纤维、铝纤维、钛纤维、镍纤维、银纤维中的一种或多种的合金纤维，所述金属纤维的直径为0.001-5.0mm。
4.根据权利要求1所述的碳纤维增强碳基摩擦片结构，其特征在于，所述摩擦层和所述连接层均为多层；
位于最外层的摩擦层的经纱和纬纱均为碳纤维，与所述支撑板相接的连接层的经纱和纬纱中至少一种为金属纤维。
5.根据权利要求1所述的碳纤维增强碳基摩擦片结构，其特征在于，所述摩擦层和所述连接层相接处的经纱与纬纱相互编织，所述连接层中的金属纤维与所述支撑板烧结固定。
6.根据权利要求1所述的碳纤维增强碳基摩擦片结构，其特征在于，所述支撑板上设有金属镀层，所述金属镀层的材料与所述连接层的金属纤维具有互溶性。
7.根据权利要求6所述的碳纤维增强碳基摩擦片结构，其特征在于，所述金属镀层为镀铜层、镀镍层或镀铜镀镍层。
8.根据权利要求1所述的碳纤维增强碳基摩擦片结构，其特征在于，所述支撑板为圆环形，所述摩擦层和所述连接层构成多个弧形的摩擦片，相邻的所述摩擦片之间形成有油槽。
9.一种碳纤维增强碳基摩擦片结构的制备方法，其特征在于，包括：
利用三维编织技术编织形成碳纤维编织预制体；
对所述碳纤维编织预制体进行树脂浸渍、树脂碳化和沉积碳工艺，形成碳纤维增强碳基摩擦材料；所述碳纤维增强碳基摩擦材料包括摩擦层和连接层，所述摩擦层的经纱和纬纱中至少一种为碳纤维，所述连接层的经纱和纬纱中至少一种为金属纤维；
通过压制烧结工艺，将所述连接层中的金属纤维与支撑板烧结固定。
10.根据权利要求1所述的制备方法，其特征在于，对所述碳纤维编织预制体进行树脂浸渍、树脂碳化和沉积碳工艺，形成碳纤维增强碳基摩擦材料的步骤，包括：
在真空环境中，利用树脂传递模塑装置对所述碳纤维编织预制体进行树脂浸渍处理；
树脂浸渍完成后进行热压固化成型，成型压力1-20MPa，成型温度100-300℃，成型工艺时长5-50h，形成树脂基体；
通过高温树脂碳化处理，使树脂基体生成碳基体，碳化处理温度600-2500℃，处理工艺时长5-120h；
利用化学气相沉积工艺，对碳基体进行碳沉积处理，形成碳纤维增强碳基摩擦材料。
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