CN1514152A - 密封用滑动元件及其制造方法 - Google Patents
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Abstract
本发明提供固体润滑性及流体润滑性两特性都优异的密封用滑动元件及其制造方法。该密封用滑动元件是以25-75重量%的碳骨材和20-50重量%的热固性合成树脂粘结料为主成分并有孔径1-100μm的球形气孔独立分散于其中。
Description
技术领域
本发明涉及用于机械密封等的密封用滑动元件及其制造方法,特别涉及润滑性优异的密封用滑动元件及其制造方法,该滑动元件能防止0密封流体时产生的粘附和发热胶着等引起的磨损和起泡之类的滑动面的表面损伤。
背景技术
碳滑动元件通常被广泛应用为密封流体的机械密封等的密封环。这种碳滑动元件除具有固体润滑性以外,在滑动面上还具有适度的凹凸,所以可在与配套滑动元件的密封滑动面之间保持密封流体形成的液膜并发挥优良的润滑性。
但在高负荷条件下使用机械密封时,碳滑动元件虽发挥了优异的固体润滑性,但密封滑动面成为边界润滑的状态,密封滑动面间部分固体接触后会产生粘附现象,摩擦系数明显升高,因磨损而使其寿命缩短。另外,滑动面镜面化并发生作为起泡现象的“表皮膨胀”,密封功能受到损害,有时会有密封流体泄漏。
针对上述问题,采用以碳化硅为代表的硬质材料作为高硬度、高强度材料来代替碳滑动元件,作为配套滑动的材料,也采用以碳化硅为代表的硬质材料并且是分散有气孔的材料,将它们相组合用于机械密封上。但这些机械密封存在如下问题。
首先,碳化硅非常硬且耐磨性好,但缺乏固体润滑性,将碳化硅元件间组合并放在高负荷条件下进行滑动时,滑动面马上镜面化,滑动停止时滑动面间的润滑膜被消耗掉的情况下,镜面化的密封滑动面间牢固附着,滑动启动时的摩擦系数异常升高,会产生发热粘结。
另外,通过分散气孔在碳化硅基体(matrix)中,使密封流体浸入到滑动面中,会产生集液效果和滑动时的流体动力效果,从而减少滑动转矩的异常和发热粘结。但是在因某种原因在短时间内出现密封滑动面附近无密封流体存在的状态的情况下、或在相对运动的密封滑动面不处在流体润滑状态而启动或停止时,滑动面彼此间处于固体接触状态,出现和上述相同的状态。
若产生如上所述的固体接触状态,滑动会引起急速发热,橡胶垫等二次密封部受到热损伤,不能维持密封功能的稳定性,或者在滑动面间有溶解于密封流体中的物质析出·堆积而不能维持密封功能的稳定性。
另一方面,还有将分散有气孔的碳化硅滑动材料和碳材料组合用作为机械密封的情况。该情况和碳化硅滑动元件间进行组合的情况相比,虽可利用碳滑动材料所具有的固体润滑性而使上述问题得到减轻,但此时,使软于有独立气孔和凹部的硬质材料的碳材料滑动,或者经滑动而使碳材料产生划痕都会使转矩上升,并引起碳滑动元件的磨损。另外,在碳化硅滑动面的气孔(凹部)中堵塞有碳磨损粉末而不能维持由存在于滑动面中的气孔所获得的稳定的流体润滑效果。
发明内容
本发明的目的是提供一种固体润滑性及流体润滑性都优异的密封用滑动元件及其制造方法。
为达到上述目的,本发明提供以25-75重量%的碳骨材和20-50重量%的热固性合成树脂粘结料为主成分,孔径1-100μm气孔独立分散于其中的密封用滑动元件。上述气孔较好为球形,其气孔径为2-100μm。另外,平均孔径较好为3-70μm,更好为5-70μm。
在本发明中,气孔的气孔面积率为1-20%,较好为2-20%,更好为3-15%。
本发明中的气孔分散型碳滑动元件的制造方法为:在以石墨、碳、中间相等碳骨材25-75重量%和合成树脂粘结料20-50重量%为主成分的原材料中,掺入1-30重量%的球形树脂,经混合,混炼和成形工序,于规定温度(800-3000℃)焙烧,挥发存在于碳基体中的球形树脂而使球形气孔独立分散于碳基体中而成。
在本发明中,在碳基体中独立分散球形气孔可在碳滑动面上形成凹部。这样,本发明的气孔分散型碳滑动元件可在滑动面间同时具有固体润滑性和流体润滑性,即使在高负荷条件下,也能维持良好的滑动性能,是高性能机械密封用滑动材料。
即,本发明的密封用滑动元件具有如下特征:
(1)因密封流体浸入到碳基体中所分散的气孔部分中而使气孔部分的密封流体具有集的效果(密封流体浸入到气孔中并作为滑动面间的润滑液的效果)及流体动力效果(在密封的滑动面上存在有凹部,通过旋转,该凹部和流体压力一起产生润滑的效果)以保持液膜,所以可维持对滑动材料小负荷的流体润滑状态。
(2)通过碳滑动材料所具有的固体润滑性来减少无流体润滑状态的机械密封启动及停止时的摩擦系数。
(3)区别于分散有气孔的硬质材料,将气孔分散于软质碳滑动元件中的碳材料无明显磨损而能通过气孔部分来稳定维持流体润滑性。
由于有如上所述特征,可减少用碳化硅材料所产生的、无润滑状态下的粘附、滑动发热所产生的粘结等滑动面的损伤和密封流体溶解成分在滑动面析出·堆积的现象,还可抑制·防止碳滑动元件的异常磨损·起泡现象和防止因滑动发热所产生的橡皮垫等二次密封部位的损伤,从而防止密封流体的泄漏。
通过球形气孔独立分散于碳基体中可使表观比重在1.55以下从而使其轻量化,作为机械密封也可轻量化,可实现机械密封工作和移动的节能化。但要维持滑动材料的强度,必须控制气孔分散用的球形树脂的大小及掺入量使肖氏硬度在70以上。
若肖氏硬度过高,会存在和以往分散有气泡的碳化硅滑动元件相同的问题,所以肖氏硬度最好在130以下。
为满足上述内容,球形树脂的掺入比较好占整个原材料的1-30重量%。而球形树脂的平均粒径较好在3-50μm的范围内,粒度分布较好在1-100μm的范围内。若球形树脂的掺入比超过该范围时,或球形树脂的平均粒径及粒度分布超过该范围内时,会出现强度上的问题,和气孔相互连接引起流体的异常泄漏等,会影响滑动元件的密封性。若球形树脂的掺入比低于该范围内或球形树脂的平均粒径及粒度分布小于该范围内时,掺入球形树脂的效果减弱。
虽不特别苛求本发明球形树脂的组成,但其软化点、熔点和挥发的开始温度要高于成形工序时的成形温度,并且不因成形压力而使球形变形,球形树脂必须独立分散于成形体碳基体中。在烧成工序中,90重量%的球形树脂成分要因焙烧热负荷而挥发掉,并必须维持和存在于成形工序后的成形体碳基体中的球形树脂几乎相同的粒径和掺入比并使其独立分散。但因焙烧碳基体发生收缩时,即使因该收缩而使碳基体中的气孔也收缩的话也没关系。作为满足上述条件的树脂,可用聚甲基丙烯酸丁酯、聚甲基丙烯酸甲酯、聚苯乙烯、聚丙烯酸酯、聚乙烯、尼龙6等合成树脂,这些树脂也可以是交联型树脂。本发明中,可将这些树脂的1种或2种以上进行混合而使用。
虽对作为粘结料被掺入的合成树脂的组成无特别限制,但要求该合成树脂在混炼工序中,和碳骨材表面有良好的浸湿性,在成形工序中,有良好的流动于金属模具内的流动性。作为满足上述条件的树脂,可用酚醛树脂、环氧树脂、呋喃树脂、聚酯树脂、萘树脂等合成树脂。在本发明中,可选定其中的1种或2种以上的树脂进行掺入,于120-200℃温度下,模压成形。粘结料的掺入比较好占整个原材料的20-50重量%,少于该范围时,和骨材结合不足;而若多于该范围时,因烧成挥发而形成的气孔增多,很难通过所需球形树脂的掺入来控制气孔。
附图说明
图1为摩擦特性的评价结果的f-G线图。
图2显示比较例3的接合环表面的电子显微镜照片。
图3的上图为固体润滑性评价结果的发热图,下图为表示滑动面形状的曲线图。
图4为表示流体润滑性评价结果的滑动面形状的曲线图。
具体实施方式
以下利用实施例对本发明进行具体说明。
实施例1
将71重量%的非石墨性碳、25重量%的酚醛树脂粘合剂、4重量%的交联型聚甲基丙烯酸甲酯微珠(平均粒径为40μm)配合、混合、捏合机混炼及粉碎后,利用压制工序,于160℃成形为水泵用机械密封的密封环的形状,再在氮气气氛中,于最高温度约为1200℃下焙烧,制得密封环。测定该密封环的气孔面积率、表观比重及肖氏硬度,如表1所示。
在实施例1中,测定气孔孔径时发现该孔径在5-70μm的范围。再算出其平均孔径,为30μm。气孔被确认几乎全为球形。
气孔孔径是对在所拍摄的密封环截面照片中的500μm×500μm范围内的全部气孔进行测定得到的结果。而气孔面积率是由截面照片中的500μm×500μm范围内的气孔的面积比率算出的。
实施例2
除了用平均粒径为20μm的交联型聚甲基丙烯酸甲酯微珠以外,其余均与实施例1相同来制得密封环。测定该密封环的气孔面积率、表观比重及肖氏硬度。如表1所示。
在实施例2中,测定气孔孔径时发现该孔径在3-25μm的范围内。算出该气孔的平均孔径为15μm。气孔被确认几乎全为球形。
比较例1
不掺入本发明的球形树脂,即混合75重量%的非石墨性碳、25重量%酚醛树脂粘合剂,混合、捏合机混炼及粉碎后,利用压制工序,用水泵于160℃成形为机械密封的密封环的形状,再在氮气气氛中,于最高温度约为1200℃下焙烧,制得密封环。测定该密封环的气孔面积率、表观比重及肖氏硬度,如表1所示。
在比较例1中,测定气孔孔径时发现该孔径在2μm以下。算出该气孔的平均孔径为0.3μm。
表1
比较例1 | 实施例1 | 实施例2 | |
非石墨性碳 | 75重量% | 71重量% | 71重量% |
酚醛树脂 | 25重量% | 25重量% | 25重量% |
交联型聚甲基丙烯酸甲酯平均粒径40μm | - | 4重量% | - |
交联型聚甲基丙烯酸甲酯平均粒径20μm | - | - | 4重量% |
气孔面积率 | 1% | 12% | 9% |
肖氏硬度(HSD) | 114 | 100 | 103 |
表观比重 | 1.56 | 1.45 | 1.45 |
摩擦特性的评价
作为材料的摩擦特性的评价,用水泵用机械密封并变化负荷和旋转速度,测定滑动转矩,其结果如图1所示。图1中,纵轴为摩擦系数f,横轴为轴承的特性数G(=zvb/w;z=滑动面附近的温度,v=滑动部分的平均周速度、b=滑动幅宽、w=全部负荷)。
作为配套的滑动材料的接合环,可用常压烧结的组织致密的碳化硅A和在该基材中分散有气孔孔径为1-150μm、平均孔径为35-65μm、气孔率为4-6体积%的气孔的碳化硅B。碳化硅A及碳化硅B的肖氏硬度分别为125及123。
摩擦特性的评价是在以下条件下进行的:采用摩擦磨损试验机,用80℃的自来水作为密封流体,将旋转速度调整到500-8000分-1,将流体密封压力设定为大气压(开放),在滑动面间的流体液膜容易消失而得到气液边界润滑的环境下进行。
滑动元件的组合如表2所示,作为评价结果的f-G线图如图1所示。将上述的实施例1的密封环和由碳化硅A构成的接合环的组合作为实施例3,将实施例2的密封环和碳化硅A制的接合环的组合作为实施例4,将比较例1的密封环和碳化硅A制的接合环的组合作为比较例2,将比较例1的密封环和碳化硅B制的接合环的组合作为比较例3。
表2
密封环 | 接合环 | |
比较例2 | 比较例1(气孔面积率1%) | 碳化硅A(无气孔) |
实施例3 | 实施例1(气孔面积率12%) | 碳化硅A(无气孔) |
实施例4 | 实施例2(气孔面积率9%) | 碳化硅A(无气孔) |
比较例3 | 比较例1(气孔面积率1%) | 碳化硅B(有气孔) |
由图1的f-G线图中可知:
(1)在比较例2中,因是无气孔分散的碳滑动元件和同样无气孔的碳化硅的组合,所以摩擦系数f整体较高,另外随着轴承特性数G变小,即随着气液边界润滑环境增强,摩擦系数f存在变高的趋势(参考图的记号◆)。
(2)在比较例3中,因是具有分散气孔的碳化硅和无气孔的碳滑动元件的组合,所以摩擦系数f整体较高,另外,随着轴承特性数G变小,即随着气液相界润滑环境的增强,摩擦系数f存在增高的趋势(参考图1的记号□)。另外,如图2所示,确认了碳化硅元件气孔中存在碳滑动元件的磨损粉的地方。
这被认为碳化硅元件气孔的液膜保持效果被软质碳滑动元件的变形抵销,结果是不能使摩擦系数降低。
(3)在实施例3和实施例4中,因是具有分散球形气孔的碳滑动材料和无气孔的碳化硅组合,轴承特性数G即使变小,摩擦系数f的上升也不显著(参考图1的记号△、▲)。这是因为,即使气液边界润滑环境变强,还存在留在碳基体中气孔内的流体的液膜保持效果和碳滑动元件所具有的固体润滑性。
(4)从实施例3、4及比较例3的结果可知:气液边界润滑条件下的密封滑动时,与使气孔分散于硬质的碳化硅材料中相比,使气孔分散于具有固体润滑性的软质碳材料中可降低摩擦系数f,防止缺乏固体润滑性的碳化硅所产生的镜面化、滑动发热所引起的上述粘附、烧结和橡胶垫的损伤等。
固体润滑性的评价
材料固体润滑性的评价是用水泵用机械密封并将旋转速度恒定时测定滑动面附近的发热温度来进行的。作为评价试样,采用了用于上述摩擦特性评价的材料。用于评价的材料组合的内容如表3所示。将上述实施例2的密封环和由碳化硅A构成的接合环的组合作为实施例5,将碳化硅B制的密封环和碳化硅A制的接合环的组合作为比较例4。
表3
密封环 | 接合环 | |
比较例4 | 碳化硅B(有气孔) | 碳化硅A(无气孔) |
实施例5 | 实施例2(气孔面积率9%) | 碳化硅A(无气孔) |
固体润滑性的评价是在如下条件下进行的:采用机械密封试验机,将旋转速度调整到5000分-1,将密封压力设定为大气压(开放),在干燥环境下(机械密封的周围不存在流体的状态)滑动1小时。作为评价结果,在密封环附近装上热电偶,测定发热温度,同时计测评价后的试样滑动面的形状。发热图及评价后的试样滑动面的形状如图3所示。从图3的发热图及评价后的试样滑动面的形状可知:
(1)用比较例4的具有分散气孔的碳化硅的滑动元件,开始滑动后马上达到约为380℃的最高温度,与此相反,用实施例5的具有分散气孔的碳滑动元件,在1小时滑动快要结束时的最高温度止于200℃左右。
(2)比较例4中,认定具有分散气孔的碳化硅滑动元件的滑动面上有粘附磨损,而与此相对实施例5的具有分散气孔的碳滑动元件无粘附磨损,维持了良好的滑动面状态。
(3)用比较例4的具有分散气孔的碳化硅滑动元件,橡胶垫部分产生滑动发热引起的烧结。
(4)从上可知,即使都具有气孔分散,机械密封的滑动状态在干燥环境下,有固体润滑性的碳材料比缺乏固体润滑性的碳化硅优异。
流体润滑性的评价
近似于流体润滑环境下的材料滑动特性的评价是通过用水泵用机械密封并将旋转速度恒定的条件下测定泄漏量来进行的。使用的滑动材料和上述评价固体润滑性一样,用于评价的滑动材料的组合如表4所示。上述实施例2的密封环和碳化硅A制的接合环的组合作为实施例6,碳化硅B制的密封环和碳化硅A制的接合环的组合作为比较例5。
表4
密封环 | 接合环 | |
比较例5 | 碳化硅B(有气孔) | 碳化硅A(无气孔) |
实施例6 | 实施例2(气孔面积率9%) | 碳化硅A(无气孔) |
流体润滑性的评价是在如下条件进行的:用机械密封试验机,用LIC(长效防冻液long life coolant)的90℃的50%水溶液作为密封流体,将旋转速度定为4000分-1,将流体密封压力设定为0.2MPa,试验时间为1000小时的条件下进行密封性能的评价。作为评价结果,1000小时(试验时间)的总泄漏量及评价后的滑动面形状如图4所示。
从图中的泄漏量及评价后的滑动面形状可知:
(1)用比较例5的具有分散气孔的碳化硅滑动元件,密封泄漏量少,滑动面状态也良好。
(2)即使用实施例6的具有分散气孔的碳滑动元件,密封泄漏量也少,滑动面状态也良好。
(3)在近似于流体润滑的环境下,只要是具有分散气孔的滑动元件,无论使用碳化硅材料还是碳材料,密封性能无显著差异。
本发明的效果如下所述:
根据本发明,可提供固体润滑性及流体润滑性都优异的密封用滑动元件及其制造方法。
以上说明的实施例是为了便于理解本发明而记载的,不是为了限制本发明的,因此,实施例所公开的上述各要素在本发明技术的范围内都可以进行变化并也包含同等物。
Claims (11)
1.密封用滑动元件,它以25-75重量%的碳骨材和20-50重量%的热固性合成树脂粘结料为主成分,其特征在于,有孔径为1-100μm的气孔独立分散于其中。
2.根据权利要求1所述的密封用滑动元件,其特征在于,上述气孔为球形,平均孔径为2-100μm。
3.根据权利要求1所述的密封用滑动元件,其特征在于,上述气孔的气孔面积率为1-20%。
4.根据权利要求1所述的密封用滑动元件,其特征在于,肖氏硬度在70以上、表观比重在1.55以下。
5.根据权利要求4所述的密封用滑动元件,其特征在于,肖氏硬度在130以下。
6.密封组件,其特征在于,由权利要求1所述的密封用滑动元件和由硬于上述密封用滑动元件的材料构成的配套滑动元件组成。
7.根据权利要求6所述的密封组件,其特征在于,上述配套滑动元件由碳化硅构成。
8.密封用滑动元件的制造方法,其特征在于,在主要含有25-75重量%的碳骨材和20-50重量%的热固性合成树脂粘结料的原材料中,掺入1-30重量%的球形树脂并将其混合、混炼及成形后,以规定温度焙烧而成。
9.根据权利要求8所述的密封用滑动元件的制造方法,其特征在于,上述球形树脂的粒径为1-100μm。
10.根据权利要求8所述的密封用滑动元件的制造方法,其特征在于,上述球形树脂由选自聚甲基丙烯酸丁酯、聚甲基丙烯酸甲酯、聚苯乙烯、聚丙烯酸酯、聚乙烯或尼龙6中的1种或2种以上的树脂构成,该树脂的软化点、熔点及挥发开始温度高于上述成形温度。
11.根据权利要求8所述的密封用滑动元件的制造方法,其特征在于,上述热固性合成树脂粘结料由选自酚醛树脂、环氧树脂、呋喃树脂、聚酯树脂及萘树脂中的1种或2种以上的树脂构成,上述成形温度为120-200℃,上述焙烧温度为800-3000℃。
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JPS6090882A (ja) * | 1983-10-21 | 1985-05-22 | 日本メクトロン株式会社 | 多孔質カ−ボン成形品の処理方法 |
JPH0781587B2 (ja) * | 1986-12-24 | 1995-08-30 | 大豊工業株式会社 | 炭素系摺動材料 |
JPH0255273A (ja) * | 1988-08-18 | 1990-02-23 | Showa Denko Kk | メカニカルシール用炭化珪素焼結体およびそれを用いたメカニカルシール |
JPH02106876A (ja) * | 1988-10-14 | 1990-04-18 | Kureha Chem Ind Co Ltd | 燃料電池用多孔性炭素電極基板の製造方法 |
US5538649A (en) * | 1995-09-28 | 1996-07-23 | John Crane Inc. | Carbon composite mateiral for tribological applications |
US5990222A (en) * | 1996-12-27 | 1999-11-23 | Kyocera Corporation | Resin-Filler composite and production method thereof |
JPH11130876A (ja) * | 1997-10-29 | 1999-05-18 | Kyocera Corp | 摺動部材 |
JP2002106720A (ja) * | 2000-09-28 | 2002-04-10 | Tanken Seal Seiko Co Ltd | 熱水用メカニカルシール |
JP3517711B2 (ja) * | 2000-11-09 | 2004-04-12 | 日本ピラー工業株式会社 | メカニカルシール用密封環及びこれを使用したメカニカルシール |
-
2002
- 2002-12-27 JP JP2002381684A patent/JP4030426B2/ja not_active Expired - Lifetime
-
2003
- 2003-12-24 US US10/744,008 patent/US7090919B2/en active Active
- 2003-12-26 KR KR1020030097412A patent/KR100968672B1/ko active IP Right Grant
- 2003-12-26 CN CNB200310123951XA patent/CN100412424C/zh not_active Expired - Lifetime
- 2003-12-29 EP EP03029936.6A patent/EP1433766B1/en not_active Expired - Lifetime
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN113677902A (zh) * | 2019-04-11 | 2021-11-19 | 伊格尔工业股份有限公司 | 滑动部件 |
CN117447204A (zh) * | 2023-12-22 | 2024-01-26 | 成都中超碳素科技有限公司 | 一种机械用碳材料的制备方法 |
CN117447204B (zh) * | 2023-12-22 | 2024-03-15 | 成都中超碳素科技有限公司 | 一种机械用碳材料的制备方法 |
Also Published As
Publication number | Publication date |
---|---|
EP1433766B1 (en) | 2017-03-29 |
JP2004211792A (ja) | 2004-07-29 |
EP1433766A3 (en) | 2007-11-07 |
KR100968672B1 (ko) | 2010-07-06 |
US7090919B2 (en) | 2006-08-15 |
CN100412424C (zh) | 2008-08-20 |
US20040137217A1 (en) | 2004-07-15 |
EP1433766A2 (en) | 2004-06-30 |
JP4030426B2 (ja) | 2008-01-09 |
KR20040060802A (ko) | 2004-07-06 |
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