CN114957867B - 一种载重货车合成闸瓦用摩擦体组合物及其制备的载重货车合成闸瓦 - Google Patents
一种载重货车合成闸瓦用摩擦体组合物及其制备的载重货车合成闸瓦 Download PDFInfo
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Abstract
本发明提供一种合成闸瓦用摩擦体组合物及其制备方法。所述合成闸瓦用摩擦体组合物按重量份计包括如下组分:三元乙丙橡胶100、氧化锌4‑6、硬脂酸1.5‑2.5、4,4'‑二硫代二吗啉(DTDM)2.0‑3.0、空心陶瓷微球190‑210、双季戊四醇20‑40和水滑石30‑70。本发明还提供该合成闸瓦用摩擦体组合物制备的摩擦体及含有该摩擦体的合成闸瓦。经实际测试,本发明提供的合成闸瓦性能优异,其在载重货车上的寿命达到16万公里以上,125km/h和35km/h制动初速度下的摩擦系数比值小于1.13。
Description
技术领域
本发明属于高分子材料领域,具体涉及一种载重货车合成闸瓦用摩擦体组合物及其制备的载重货车合成闸瓦。
背景技术
闸瓦是轨道车辆制动的主要零件;制动时,闸瓦抱紧车轮踏面,通过摩擦使车轮停止转动。目前轨道车辆所用的闸瓦大多数都是由瓦背和摩擦体组成的合成闸瓦,其中摩擦体又由粘结材料、增强材料和摩擦材料构成。不同的轨道车辆,要求摩擦体具有相应的性能。
如公开号CN102401052A(公开日2012年4月4日)的中国发明专利申请公开了一种专门用于大功率XHN5机车的高摩合成闸瓦及其制备方法和应用;用于摩擦体的组合物的组成为(重量份):酚醛树脂15~16,丁腈橡胶8~9,铁粉15~17,海泡石纤维10~13,硫酸钡13~20,钾长石14~17,硅灰石6~8,石墨6~8,氧化铝1~2;优选的,所述重量份数组成为:酚醛树脂15~16,丁腈橡胶8~9,铁粉15~16,海泡石纤维10~11,硫酸钡19~20,钾长石16~17,硅灰石6~7,石墨6~7,氧化铝1~2。公开号CN102643511A(公开日2012年8月22日)的中国发明专利申请公开了货车用的高摩合成闸瓦及其制备方法;其中,摩擦体的原料组成为酚醛树脂3-5份、丁腈橡胶1.5-3.5份、石墨1.5-3.5份、还原铁粉3.5-5.5份、钢纤维4.5-6.5份、硅灰石1.5-3.5份、海泡石2.5-4.5份、钾长石3.5-5.5份、氧化铝0.05-0.20份、硫磺0.15-0.40份和促进剂0.05-0.20份。公开号CN104725681A(公开日2015年6月24日)的中国发明专利申请公开了一种用于地铁合成闸瓦的摩擦体组合物,原料包括如下重量份的组分:丁腈橡胶3-7份,顺丁橡胶10-14份,酚醛树脂2-8份,石墨25-29份,玄武岩纤维21-25份,铝矾土20-26份,蛭石1-5份,氧化锌0.4-0.9份,硬脂酸0.1-0.6份,硫磺0.3-0.7份,促进剂0.3-0.7份;且丁腈橡胶、顺丁橡胶和酚醛树脂的总重量份不少于19重量份。
这些用于合成闸瓦摩擦体的组合物中都使用了硫黄-CZ(促进剂)硫化体系,导致摩擦体耐热性差、磨耗差;且粘合剂采用了丁腈橡胶和酚醛树脂,使摩擦体高速制动与低速制动下摩擦系数波动大,表现为高速(125km/h)制动初速度下摩擦系数/低速(35km/h)制动初速度下摩擦系数比值在1.15以上。
随着我国铁路的发展,重载运输发展迅速。除了改造和新建专用货运重载铁路外,随着“四纵四横”客运专线逐步建成,既有的客货混运铁路将逐步改造为重载铁路、以货运为主。按照2017年发布的《重载铁路设计规范》,重载铁路是指满足牵引质量8000t及以上、轴重为270kN及以上、在至少150km线路区段上年运量大于40Mt三项条件中两项的铁路。公开号CN102643511A披露的货车用的高摩合成闸瓦在普通货运列车上的运行里程可以达到20万公里以上,是按磨耗速率推算的预计寿命。但是重载条件下,闸瓦摩擦体因为摩擦生热大,磨耗会显著加快,寿命将急剧缩短。实际情况是,目前我国重载货车上配置的高摩合成闸瓦,平均使用寿命4-5个月,运行里程仅9-10万公里左右。而铁路货车修程修制改革的要求是延长各个配件的检修周期。显然,目前重载货车采用的合成闸瓦无法满足上述要求。这就造成在规定的大修期间内不得不增加一次货车返厂,以更换闸瓦。
发明内容
为了克服现有技术的不足,本发明提供一种适应我国载重货车修程修规的合成闸瓦用摩擦体组合物。该组合物制备的摩擦体,耐热性好,寿命长,摩擦系数高且高低速下制动的摩擦系数波动小,摩擦系数稳定。经试验,由本发明的摩擦体组合物制备的合成闸瓦在重载下使用寿命达到16万公里以上。
为实现上述技术效果,本发明采用了如下的技术方案:
一种合成闸瓦用摩擦体组合物,按重量份计,包括如下组分:
三元乙丙橡胶100、氧化锌4-6、硬脂酸1.5-2.5、4,4'-二硫代二吗啉(DTDM)2.0-3.0、空心陶瓷微球190-210、双季戊四醇20-40和水滑石30-70。
优选地,所述合成闸瓦用摩擦体组合物,按重量份计,包括如下组分:
三元乙丙橡胶100、氧化锌4.5-5.5、硬脂酸1.8-2.2、4,4'-二硫代二吗啉(DTDM)2.2-2.8、空心陶瓷微球195-205、双季戊四醇45-55和水滑石40-60。
优选地,所述空心陶瓷微球的粒径为10-30μm。
优选地,所述水滑石为二元镁铝碳酸根型水滑石。
本发明还提供上述组合物的制备方法,包括如下步骤:
I.按照重量份准备各组分;
II.将各组分投入密炼机,混炼14-16分钟,出料,即得。
本发明还有一个目的,在于提供一种合成闸瓦用摩擦体,由上述合成闸瓦用摩擦体组合物按照本领域常规方法制备得到。
此外,本发明还提供一种合成闸瓦,包括瓦背和上述合成闸瓦用摩擦体。
本发明还提供上述合成闸瓦的制备方法,包括:
称取本发明所述合成闸瓦用摩擦体组合物,装填入在硫化机上已经预热的模具中,表面放置钢制瓦背,155℃-165℃和13-17MPa下硫化35-45分钟,卸模,自然冷却,即得。
本发明还提供上述合成闸瓦作为制动零件在载重货车中的应用。
本发明提供的合成闸瓦用摩擦体组合物中,使用三元乙丙橡胶做粘合剂。相比较现有技术中以丁腈橡胶、酚醛树脂为粘合剂制成的闸瓦摩擦体,摩擦系更稳定,不同速度下不同温度下摩擦系数波动更小。而且三元乙丙橡胶本身饱和度高,耐高温性好,从而可以显著延长闸瓦寿命。
本发明提供的合成闸瓦用摩擦体组合物中,采用硫载体——4,4'-二硫代二吗啉(DTDM)作硫化剂。与采用硫磺-CZ促进剂作为硫化剂的现有闸瓦相比,本发明的摩擦体耐热性显著提高,延长了闸瓦的寿命。
合成闸瓦制造技术的难点在于高速度下摩擦系数容易偏小,低速度下容易偏大。而实际使用过程中则要求两个速度下的摩擦系数越接近越好。闸瓦在长时间制动时表面瞬时温度会超过350℃,例如实验室模拟制动以及现场经常看到刹车时有大量火花出现即是明证。本发明的组合物中的双季戊四醇,高温时发生碳化,在摩擦面形成稳定碳层,减小了磨耗,稳定了摩擦系数。
本发明提供的合成闸瓦用摩擦体组合物中,加入空心陶瓷微球作为填料。相比较无机填料,空心玻璃微球具有更高的耐热性、抗冲击性等物理机械性能,隔热效果好,防止摩擦中产生的热量往闸瓦内部传递,有效防止闸瓦里橡胶过份降解,从而提高闸瓦摩擦体的耐热、耐磨性,使得摩擦系数稳定。
总之,本发明提供的合成闸瓦用摩擦体组合物制备的合成闸瓦,125km/h制动初速度下摩擦系数/35km/h制动初速度下摩擦系数比值小于1.13,表现出优异的摩擦系数稳定性。
具体实施方式
以下参照具体的实施例来说明本发明。本领域技术人员能够理解,这些实施例仅用于说明本发明,其不以任何方式限制本发明的范围。
下述实施例中的实验方法,如无特殊说明,均为常规方法。下述实施例中所用的原料、试剂材料等,如无特殊说明,均为市售购买产品。其中,部分原料购买情况如下:
三元乙丙橡胶,常州阿朗新科高性能弹性体有限公司;
氧化锌,淄博海顺锌业有限公司;
4,4'-二硫代二吗啉(DTDM),濮阳蔚林化工股份有限公司;
空心陶瓷微球,粒径10-30微米,广州兆通玻塑科技有限公司;
双季戊四醇,山东丰泰化工科技有限公司;
二元镁铝碳酸根型水滑石,东莞市诺佳塑化有限公司;
实施例1-3一种合成闸瓦用摩擦体组合物和包括该摩擦体组合物的合成闸瓦
实施例1-3所述的合成闸瓦用摩擦体组合物的组成,见表1,其中1份=0.1kg。
所述的合成闸瓦用摩擦体组合物通过如下方法制备:
将各组分称量好后,投入密炼机,混炼14-16分钟,出料,即得。
通过如下方法制备合成闸瓦:
称取上述制备的合成闸瓦用摩擦体组合物,装填入在流化剂中预热的模具中,表面放置钢制瓦背,155℃-165℃和13-17MPa下硫化35-45分钟,卸模,即得。
对比例1-7一种合成闸瓦用摩擦体组合物和包括该摩擦体的合成闸瓦
对比例1-7所述的合成闸瓦用摩擦体组合物的组成,见表1,其中1份=0.1kg。
按照实施例1-3相同的方法制备各对比例的合成闸瓦用摩擦体组合物。
按照实施例1-3中所述相同的方法和步骤制备相应的合成闸瓦。
表1实施例1-3和对比例1-7的摩擦体组合物组成
对比例9一种合成闸瓦
按照CN102401052A记载的实施例1,制备得到本对比例的合成闸瓦。
对比例10一种合成闸瓦
按照CN102643511A记载的实施例2,制备得到本对比例的合成闸瓦。测试例:实施例1-3和对比例1-10的合成闸瓦性能测定
将各合成闸瓦装配在轴重27吨的载重货车上,在大秦线进行实地行车,测定其使用寿命,结果见表2。
按照行业标准《TB/T 3104.1-2020机车车辆闸瓦第1部分:合成闸瓦》中记载的方法对各合成闸瓦分别测定125km/h和35km/h制动初速度下的摩擦系数(以下简称“高低制动速度下摩擦系数比”),计算两者的比值,结果见表2。
表2各实施例和对比例制备的合成闸瓦的性能测定结果
从表2示出的测定结果可以看出:
含有本发明的摩擦体的合成闸瓦,在载重货车上的使用寿命显著长于各对比例的合成闸瓦(包括现有技术CN102401052A和CN102643511A中披露的合成闸瓦),其高低制动速度下摩擦系数比均小于1.13,说明其在高低速下制动的摩擦系数稳定,波动小。因此本发明的载重货车用合成闸瓦性能优异,寿命长。
Claims (7)
1.一种合成闸瓦用摩擦体组合物,按重量份计,原料包括如下组分:
三元乙丙橡胶100、氧化锌4-6、硬脂酸1.5-2.5、4,4'-二硫代二吗啉2.0-3.0、空心陶瓷微球190-210、双季戊四醇20-40和水滑石30-70。
2.根据权利要求1所述的合成闸瓦用摩擦体组合物,其特征在于,所述空心陶瓷微球的粒径为10-30μm。
3.根据权利要求1所述的合成闸瓦用摩擦体组合物,其特征在于,所述水滑石为二元镁铝碳酸根型水滑石。
4.权利要求1至3中任一项所述的合成闸瓦用摩擦体组合物的制备方法,包括如下步骤:
I. 按照重量份准备各组分;
II. 将各组分投入密炼机,混炼14-16分钟,出料,即得。
5.一种合成闸瓦,包括瓦背和权利要求1至3中任一项所述的合成闸瓦用摩擦体组合物或根据权利要求4所述的制备方法制备得到的所述合成闸瓦用摩擦体组合物。
6.权利要求5所述的合成闸瓦的制备方法,包括:
称取权利要求1至3中任一项所述的合成闸瓦用摩擦体组合物或根据权利要求4所述的制备方法制备得到的所述合成闸瓦用摩擦体组合物,装填入在硫化机上已经预热的模具中,表面放置钢制瓦背,155℃-165℃和13-17MPa下硫化35-45分钟,卸模,自然冷却,即得。
7.权利要求5所述的合成闸瓦或根据权利要求6所述的制备方法制备得到的合成闸瓦作为制动零件在载重货车中的应用。
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