CN1733825A - 具有摩擦改性纳米粒子层的摩擦材料 - Google Patents
具有摩擦改性纳米粒子层的摩擦材料 Download PDFInfo
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- CN1733825A CN1733825A CNA2005100980496A CN200510098049A CN1733825A CN 1733825 A CN1733825 A CN 1733825A CN A2005100980496 A CNA2005100980496 A CN A2005100980496A CN 200510098049 A CN200510098049 A CN 200510098049A CN 1733825 A CN1733825 A CN 1733825A
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Abstract
公开了一种摩擦材料,其包括多孔基材,至少一类树脂材料,和至少一类纳米粒子大小的摩擦改性颗粒。所述树脂材料和纳米粒子大小的摩擦改性颗粒基本上均匀分散在整个基材中。
Description
技术领域
本发明涉及一种包含多孔基材和至少一类纳米粒子大小的磨擦改性颗粒的多孔摩擦材料。本发明的摩擦材料具有高的磨擦特性系数、非常强的抗震颤特性,以及极其高的耐热性。所述摩擦材料也具有提高的强度、耐磨性和耐噪音性。
背景技术
汽车业研发了新的且先进的具有连续滑动转矩和变速离合系统的连续转矩传动系统。这些新的系统常常涉及高能量要求。因此,还必须研发摩擦材料技术以满足这些先进系统日益增长的能量要求。
特别地,需要新的高性能,可持久型摩擦材料。该新的高能量型摩擦材料必须能够承受其表面速度高达约65米/秒的高速度。而且,该摩擦材料必须能够承受高达约1500psi的高衬面压力(facing lining pressure)。所述摩擦材料要能够在有限的润滑条件下使用,这也是重要的。
所述摩擦材料必须是耐久的且具有高耐热性能以用于先进的系统中。该摩擦材料不仅要在高温下稳定,其还必须能够迅速地散逸操作过程中生成的高热量。
新型系统在啮合和脱离过程中产生的高速度意味着摩擦材料必须能够在整个啮合过程中保持较恒定的摩擦力。摩擦啮合要在宽的速度和温度范围内相对稳定以最小化制动或传动系统在将动力从一个齿轮向另一个转移时材料的震颤,这一点是重要的。该摩擦材料具有理想的转矩曲线形状,这样在该摩擦材料的摩擦啮合中无噪音或“刺耳声”,这也是重要的。
特别地,传动和需要转矩的系统引入了滑动式离合器,这主要是为了燃料效率和驾驶舒适性。这些系统中滑动式离合器的作用各不相同,从汽车发动装置如湿起动离合器,到液力变矩器离合器(torque converter clutch)。根据工作条件,滑动式离合器可分为三大类:(1)低压和高滑动速度离合器,如湿起动离合器;(2)高压和低滑动速度离合器,如变换器离合器(converter clutch);和(3)极低压和低滑动速度离合器如中速至怠速离合器(neutral to idle clutch)。
滑动式离合器所有用途涉及的主要性能是防止震颤并进行摩擦界面的能量控制。震颤的发生可归因于多种因素,包括摩擦材料的摩擦特性、啮合表面的硬度和粗糙度、油膜保持力、润滑剂化学性质和相互作用、离合器工作条件、动力传动系统组件和金属部件的同轴性(hardware alignment)以及动力传动系统的污染情况。摩擦界面的能量控制主要涉及界面温度的控制并受到泵送能力、油路和控制方式的影响。摩擦材料的表面设计也对界面能量控制的效率起作用。
以前,为获得温度稳定性将石棉纤维加入摩擦材料中。由于健康和环境的问题,不再使用石棉。更近期的摩擦材料试图通过用酚醛或酚醛改性的树脂来改性浸渍纸或纤维材料以解决摩擦材料中没有石棉带来的问题。然而,这些摩擦材料不能迅速散逸所产生的高热量且不具有必要的耐热性能和当今为用于正在研制的高速系统中所需的令人满意的高摩擦性能系数。
Kearsey的美国专利No.5,585,166描述了含有多孔基材层(纤维素和人造纤维,填料和热固性树脂)、多孔摩擦层(在热固性树脂中的无纺人造纤维)的多层摩擦衬里,其中所述摩擦层具有比基材层高的孔隙度。
Seiz的美国专利No.5,083,650涉及多步骤浸渍和固化工艺;即用涂料组合物浸渍纸张,将碳颗粒放在纸上,部分固化纸张中的涂料组合物,向部分固化的纸张上施用第二种涂料组合物,以及最后固化这两种涂料组合物。
已经开发出了各种用于摩擦材料的纸基纤维材料,它们归本发明的受让人,BorgWarner Inc.共有。这些参考文献全文在此引入作为参考。
特别地,Lam等人的美国专利No.5,998,307涉及一种摩擦材料,其具有浸渍了可固化树脂的第一多孔性基材,其中的多孔性基层包含至少一种纤维材料且第二层包含覆盖了至少约3%-约90%基层表面的碳颗粒。
Lam等人的美国专利No.5,858,883涉及一种基材,其具有原纤化较少的芳族聚酰胺纤维、合成石墨和填料的基层和在基层表面上包含碳颗粒的第二层。
Lam等人的美国专利No.5,856,224涉及包含浸渍了可固化树脂的基材的摩擦材料。其基层包含原纤化较少的芳族聚酰胺纤维、合成石墨和填料;第二层包含碳颗粒和助留剂。
Lam等人的美国专利No.5,958,507涉及生产摩擦材料的方法,其中含有原纤化较少的芳族聚酰胺纤维的纤维材料至少一个表面的约3-约90%涂覆有碳颗粒。
Lam的美国专利No.6,001,750涉及一种摩擦材料,其包含浸渍了可固化树脂的纤维状基材。多孔的基层包含原纤化较少的芳族聚酰胺纤维,碳颗粒、碳纤维、填料、酚醛novoloid纤维和任选的棉纤维。第二层包含覆盖了约3-约90%表面的碳颗粒。
还有另一项共有的专利申请,系列号为No.09/707,274涉及具有多孔纤维基层的纸型摩擦材料,其中摩擦改性颗粒覆盖所述基层表面积的约3-约90%。
此外,在BorgWarner Inc.,Lam等人共有的美国专利Nos.5,753,356和5,707,905(其描述了包含原纤化较少的芳族聚酰胺纤维、合成石墨和填料的基材)中描述了各种纸型纤维基材,将它们在此全文引入作为参考。
Lam的另一共有美国专利No.6,130,176涉及包含原纤化较少的芳族聚酰胺纤维、碳纤维、碳颗粒和填料的非金属纸型纤维基材。
对于所有类型的摩擦材料来说,为了使其能用于“湿法”应用,摩擦材料必须具有多种可接受的性能。该摩擦材料必须具有优良的抗震颤特性;高耐热性能并能够快速散逸热量;并且具有持久、稳定和一致的摩擦性能。如果任何这些特性不得到满足就不能获得摩擦材料的最佳性能。
同样重要的是要有合适的浸渍树脂用于摩擦材料以形成高能量用途的摩擦材料。该摩擦材料在使用中被制动液或传动润滑油(transmission oil)浸渍时必须具有良好的剪切强度。
因此,本发明的一个目的是提供与现有技术的摩擦材料相比具有可靠的和改进的性能的改进摩擦材料。
本发明的另一个目的是提供具有改进的“抗震颤”特性、耐“热点”性、高耐热性、高摩擦稳定性和持久性、以及高强度的摩擦材料。
附图说明
图1a是表明现有技术摩擦材料的示意图,其包含纤维基材和摩擦改性颗粒。
图1b-1d示意性地表明了颗粒的相对大小:
图1b-直径为10-15微米的典型纤维;
图1c-典型的平均尺寸为10-20微米的硅藻土颗粒;
图1d-尺寸为0.01微米的纳米粒子。
图2示意性地表明了在纤维上的纳米粒子大小的摩擦改性颗粒的层或局部涂层(一般来说,按规定比例表示)。
图3示意性地表明了在基材中的纤维上的纳米粒子大小的磨擦材料(一般来说,按规定比例表示)。
发明内容
本发明涉及一种摩擦材料,其包括多孔基材,在基材中含有至少一类摩擦改性颗粒,其中所述摩擦改性物质包括至少一类纳米粒子大小的磨擦改性颗粒。
在制备基材时,将所述纳米粒子大小的磨擦改性颗粒加入到多孔基材中。在基材制备过程中,所述纳米粒子大小的磨擦改性颗粒沉积在构成基材的独立的纤维和/或填料上。所述构成摩擦材料的独立的纤维和/或填料可以在这种独立的纤维和/或填料上具有厚度约为0-约250μm的纳米粒子大小的磨擦改性颗粒的层或局部涂层。所述纳米粒子大小的磨擦改性颗粒的平均粒径为约10nm-约150nm。在某些实施方案中,所述纳米粒子层或局部涂层,以面积计算,覆盖基材中独立的纤维和/或填料的约0~约99%,在其他实施方案中,所述纳米粒子覆盖为约3%-约20%面积。另外,在某些实施方案中,所述纳米粒子至少部分覆盖基材中独立的纤维和/或填料。
在某些优选实施方案中,所述摩擦改性颗粒包括二氧化硅纳米粒子。在某些其它的实施方案中,所述摩擦改性颗粒可以进一步包括二氧化硅颗粒和至少一种其他的纳米粒子大小的磨擦改性颗粒。
一方面,摩擦材料包括多孔基材,至少一类树脂材料,和至少一类纳米粒子大小的磨擦改性颗粒。
根据本发明,纳米粒子的层或局部涂层沉积在多孔摩擦基材上和沉积在多孔摩擦基材中。所述纳米粒子渗透到内部结构中并附着在基材的纤维和/或填料成分上。
虽然不希望受缚于理论,但是相信,所述纳米粒子,当附着到基材的纤维上时,会提供额外的机械强度并使摩擦材料的摩擦特性增强。所述纳米粒子之所以附着到基材中存在的纤维和/或填料的表面上,是由于它们极其小,且与所述纳米粒子相比,所述纤维/填料本身具有相对大的表面积。与基材中的纤维/填料相比,纳米粒子极其小的尺寸使得纳米粒子大小的磨擦改性物质基本上均匀地分布在整个基材上。
把纳米粒子加入到基材中并因此使其沉积到构成基材的独立纤维和/或填料的表面上的一个优点是,增强了摩擦性能(如具有较高的摩擦系数、较好的mu-v斜率等。
在某些实施方案中,所述纳米粒子的直径为约10nm-150nm。另外,在某些实施方案中,所述纳米粒子形成纳米粒子簇,它们以组或丛的形式沉积在构成基材的独立纤维和/或填料上。
根据本发明的另一方面,所述纳米粒子大小的磨擦改性颗粒使得可以形成开放的或基本上多孔的基材,其具有希望的高渗透性,同时又保持高性能摩擦材料的其他希望的特性。含有这种纳米粒子大小的磨擦改性颗粒的这种基材的较高渗透性使得所述摩擦材料在其中保留有所需量的流体,与此同时,使所述摩擦材料具有希望的流动和抗震颤特性。
在某些实施方案中,本发明涉及一种含有多孔或膨松且开放的基材的磨擦材料。所述摩擦材料具有希望的低密度,并具有允许使树脂材料渗入其中的纤维构造。所述摩擦材料具有极好的耐热性和摩擦特性系数,使得所述摩擦材料在热和机械应力下能很好地做出响应。
另一方面,本发明涉及一种“宏孔(macro porous)”纤维基材(如,纺织基材)。这种多孔基材中的大孔使得纳米粒子大小的摩擦改性物质留在多孔基材的孔隙或空隙中。在本发明的宏孔摩擦材料中,大孔使得流体中的杂质能很容易地通过所述摩擦材料。正如本领域技术人员所公知的,润滑会随着时间的推移变差并且会产生碎屑。本发明的磨擦材料在摩擦材料的整个使用寿命期间保持摩擦材料的摩擦性能恒定不变。
在本发明的一个方面,基材的平均空隙率为约40%-约85%。在某些实施方案中,所述多孔基材包括约70-85重量%的纤维和约10-30重量%的填料。在某些实施方案中,所述多孔基材可以包括约80%的纤维和约20%的填料。
在某些实施方案中,基材的平均孔/孔隙/空隙直径为约2-约10μm,平均直径为约5-约7μm。
另外,在某些实施方案中,所述摩擦改性颗粒包括二氧化硅纳米粒子。在其他实施方案中,所述纳米粒子可以是二氧化硅与其他摩擦改性颗粒的组合。
此外,在某些实施方案中,所述摩擦改性颗粒包括纳米粒子大小的材料与较大尺寸的摩擦改性颗粒的混合物。
处于基材中的纳米粒子大小的摩擦改性颗粒为所形成的摩擦材料提供改进的三维结构。
另一方面,本发明涉及一种制备摩擦材料的方法,其中多孔基材被饱和剂饱和。所述饱和剂可以包括至少一种树脂材料,和至少一类纳米粒子大小的摩擦改性颗粒,从而使得多个纳米粒子大小的摩擦改性颗粒在构成基材的独立纤维和/或填料上形成层或局部涂层。所述饱和的基材在预定的温度下固化预定的时间段。
另一方面,所述方法包括通过以下步骤制备摩擦材料,即,制备包括至少一种可固化树脂材料和至少一类纳米粒子大小的摩擦改性颗粒的混合物的饱和剂,制备具有多个贯穿分散的空隙的多孔基材,并用所述饱和剂饱和所述多孔基材从而使多个纳米粒子大小的摩擦改性颗粒至少部分沉积在构成基材的独立纤维上,和使所述树脂材料基本上均匀分散在整个基材中。
发明详述
为了满足上述要求,在类似于操作过程中所碰到的那些条件下,评价了许多摩擦材料的摩擦特性和耐热性。研究并证明,商品摩擦材料不适合用于高能应用场合。
根据本发明,摩擦材料中,可固化的树脂均匀分散在整个多孔基材中,并且在整个多孔基材中,纳米粒子大小的摩擦改性颗粒基本上以均匀的量分散。
在一个方面,所述基材包括高度多孔的材料,如长纤维纺织材料,在另外的方面,其包括高度多孔的无纺材料。在某些实施方案中,所述多孔基材具有,以基材的重量计,约75-约85重量%的高纤维含量,并且在某些实施方案中为约80重量%。所述基材的填料含量在,以基材的重量计,约15-约25重量%的范围内,并且在某些实施方案中为约20重量%。基材中填料较少会明显增加侧向渗透性。
在另一些实施方案中,所述纳米粒子大小的摩擦改性颗粒也可以包括其他的摩擦改性颗粒,如金属氧化物、氮化物、碳化物和其混合物。在本发明所期待的范围内,这些实施方案可以包括,例如二氧化硅、氧化铁、氧化铝、氧化钛等;氮化硅、氮化铁、氮化铝、氮化钛等;和碳化硅、碳化铁、碳化铝、碳化钛等。
各种不同的基材都可用于本发明的摩擦材料中,其包括例如,非石棉纤维基材,包括例如织物材料、纺织和/或无纺材料。适当的纤维基材包括例如,纤维和填料。所述纤维可以是有机纤维、无机纤维和碳纤维。有机纤维可以是芳族聚酰胺纤维,如原纤化的和/或未原纤化的芳族聚酰胺纤维,丙烯酸纤维,聚酯纤维,尼龙纤维,聚酰胺纤维,棉/纤维素纤维等。所述填料可以是例如,二氧化硅,硅藻土,石墨,氧化铝,腰果树粉等。
在其他实施方案中,所述基材可以包括纤维纺织材料,纤维无纺材料和纸材料。另外,可用于本发明的各类纤维基材的实例参见以上引用的BorgWarner的美国专利,其全文在此引入作为参考。然而,应当理解,本发明的其他实施方案还可以包括不同的纤维基材。
在某些实施方案中,所述摩擦材料包括其中具有多个孔隙或空隙的基材。纤维基材中孔隙的大小可以是约0.5μm-约20μm。
在某些实施方案中,所述基材优选具有约60-约85%的孔隙率,这样,与“紧密的”纺织材料相比,所述纤维基材就被认为是“多孔的”。所述摩擦材料在径向和法向上具有基本上相同的渗透性。
本发明的一个方面,涉及具有新型微结构表面的摩擦材料。所述微结构表面摩擦材料具有较高的摩擦系数,甚至更强的抗震颤特性,和极其高的耐热性。
本发明的一个方面,涉及具有多孔或膨松且开放的基材的磨擦材料。这种材料具有密度低,并具有允许使树脂材料渗入基材当中的纤维构造。所述摩擦材料具有极好的耐热性和摩擦特性系数,使得所述摩擦材料在热和机械应力下能很好地做出响应。
另一方面,“宏孔”纤维基材具有局部未被摩擦改性物质覆盖的表面。大孔使得纳米粒子大小的摩擦改性物质留在基材的孔隙或空隙中。在本发明的宏孔摩擦材料中,大孔使得流体中的杂质能很容易地通过所述摩擦材料。当润滑随着时间的推移变差时,产生碎屑。本发明的磨擦材料会保持摩擦材料的摩擦性能恒定不变。
在某些实施方案中,摩擦材料还包括树脂材料,其至少部分填充纤维基材的孔隙。所述树脂材料基本上均匀分散在整个基材的厚度中。
在某些实施方案中,所述基材包括纤维基材,其中原纤化较少的纤维和碳纤维用于纤维基材中,用以向所述摩擦材料提供希望的孔结构。所述纤维的几何学不仅提供增加的耐热性,而且也提供耐层离性能和耐刺耳声或耐噪音性能。另外,在某些实施方案中,存在碳纤维和碳颗粒有助于纤维基材耐热性的提高,有助于保持稳定的摩擦系数,并增加耐刺耳声性能。在某些实施方案中,纤维基材中可以包括棉纤维,用来提高摩擦材料的离合“磨合”特性(clutchbreak-in characteristics)。
在纤维基材中使用原纤化较少的芳族聚酰胺纤维和碳纤维会提高摩擦材料耐受高温的能力。原纤化较少的芳族聚酰胺纤维通常有了了无几的原纤附着在核心纤维上。使用原纤化较少的芳族聚酰胺纤维会使摩擦材料具有更大程度的多孔结构,即,比起使用典型的原纤化的芳族聚酰胺纤维来,有更大的孔。所述多孔结构通常是由孔大小和液体渗透性定义的。
另外,在某些实施方案中,希望芳族聚酰胺纤维的长度在约0.5-约10mm的范围内,Canadian Standard Freeness(CSF)大于约300。在某些实施方案中,也希望使用CSF为约450-约550,优选约530或更大的原纤化较少的芳族聚酰胺纤维,并且,在其他实施方案中,所述CSF为约580-650和该值以上,优选约650和650以上。相反,原纤化程度较大的纤维,如芳族聚酰胺纸浆,其排水度则为约285-290。
“Canadian Standard Freeness”(T227 om-85)意思是指,纤维的原纤化程度可以用纤维的排水度量度来描述。所述CSF试验是经验方法,它给出的是一种任意的速率度量,是3克纤维在1升水中的悬浮液可以被排干的速率。因此,原纤化较少的芳族聚酰胺纤维具有较高的排水度,或者与原纤化较多的芳族聚酰胺纤维或纸浆相比,具有较高的从摩擦材料中排出流体的速率。含有CSF在约430-650(在某些实施方案中优选约580-640,或优选约620-640)范围内的芳族聚酰胺纤维的摩擦材料,与包含通用的原纤化较多的芳族聚酰胺纤维的摩擦材料相比,摩擦性能更好并且具有更好的材料性质。较长的纤维长度与高的Canadian排水度结合在一起,会使摩擦材料具有高强度、高孔隙度和优良的耐磨性。原纤化较少的芳族聚酰胺纤维(CSF约为530-约650)具有特别优良的长期耐受性和稳定的摩擦系数。
各种不同的填料也可以用于本发明的纤维基材中。特别是,可以使用二氧化硅填料,如硅藻土。但是,我们认为其他类型的填料也适合用于本发明中,并且填料的选择取决于摩擦材料的具体要求。
在某些实施方案中,棉纤维被加入到本发明的纤维基材中,以使所述纤维材料具有较高的摩擦系数。在某些实施方案中,也可以向纤维基材中加入约10-约20%的棉,且在某些实施方案中,加入约10%的棉。
所述纤维基材组成的一个实例包括约15-约25%的棉,约40-约50%的芳族聚酰胺纤维,约10-约20%的碳纤维,约5-约15%的碳颗粒,约5-约15%的C盐(celite),和任选约1-约3%的胶乳添加剂。
当所述纤维基材具有较高的平均孔径和流体渗透性时,所述摩擦材料更容易较冷运行,或者说由于有更好的自动传输流体流动通过摩擦材料的多孔结构,因此,在传输过程中产生的热较少。在传输系统的操作过程中,随着时间的推移,流体会倾向于裂解并形成“油渣”,特别是在高温下时。这种“油渣”会降低孔的开放程度,因此,当摩擦材料最初有较大的孔时,在摩擦材料的使用期限内,会有较多的开放孔保留下来。
纤维基材的摩擦改性颗粒为所得到的摩擦材料提供改进的三维结构。
所述摩擦改性颗粒将流体润滑剂保留在基材中,并增加所述摩擦材料保留油的能力。因此,本发明的摩擦材料允许油膜保留在其表面上。这也会提供优良的摩擦特性系数和优良的滑移耐受特性。
纤维基材中纳米粒子大小的摩擦改性颗粒的量充分随机,使得沉积在基材的独立纤维和/或填料上的纳米粒子大小的摩擦改性颗粒为基材提供三维结构。这种三维结构由独立纤维和/或填料上的和在基材的独立纤维之间的孔隙或空隙中的独立的摩擦改性物质颗粒组成。
在基材中沉积的纳米粒子大小的摩擦改性颗粒的均匀性是通过使用一定尺寸的摩擦改性颗粒实现的,这种摩擦改性颗粒的主要粒径可以在直径约为10-约150nm范围内,优选约10-约50nm。在某些实施方案中,所述颗粒具有约15nm-约30nm的平均纳米粒子直径的主要纳米粒子尺寸。
各种类型的纳米粒子大小的摩擦改性颗粒均可用于所述摩擦材料。在一个实施方案中,可用的摩擦改性颗粒包括二氧化硅颗粒。其他实施方案可以包括以下纳米粒子大小的摩擦改性颗粒,比如树脂粉末如酚醛树脂、硅酮树脂、环氧树脂和其混合物。还有其他的实施方案可以包括部分和/或完全碳化的纳米粒子大小的碳粉和/或碳粒和其混合物;以及这种纳米粒子大小的摩擦改性颗粒的混合物。在某些实施方案中,纳米粒子大小的二氧化硅颗粒,如硅藻土,Celite、Celatom和/或二氧化硅是特别有用的。所述纳米粒子大小的二氧化硅颗粒是强有力的键连到基材上的无机材料。所述纳米粒子大小的二氧化硅颗粒使摩擦材料具有高的摩擦系数。所述纳米粒子大小的二氧化硅颗粒也为基材提供平滑的摩擦表面,并使摩擦材料具有优良的“移动感(shift feel)”和摩擦特性,从而将任何的“震颤”减到最低程度。
在某些实施方案中,所述摩擦材料可以用不同的树脂系统浸渍。在某些实施方案中,可使用至少一种酚醛树脂,至少一种改性的酚醛基树脂,至少一种硅酮树脂,至少一种改性的硅酮树脂,至少一种环氧树脂,至少一种改性的环氧树脂,和/或上述树脂的组合。在某些实施方案中,可使用与酚醛树脂在相容溶剂中共混或混合的硅酮树脂。
各种各样的树脂都可用于本发明中。在某些实施方案中,所述树脂包括酚醛或酚醛基树脂,优选使得饱和剂,以每100重量份摩擦材料计,占约45-约65重量份。在树脂混合物已经施加到基材上且所述基材已经用树脂混合物浸渍过之后,将浸渍后的基材加热到所需的温度下,加热预定的时间段,以形成摩擦材料。在某些实施方案中,加热使饱和剂中存在的酚醛树脂在约300°F温度下固化。当饱和剂中存在其他的树脂如硅酮树脂时,在约400°F温度下加热使硅酮树脂固化。之后,固化的摩擦材料通过适当的方式附着在所需要基材上。
各种可用的树脂包括酚醛和酚醛基树脂。应当理解,树脂共混物中包括其他的改性成分,如环氧、丁二烯、硅酮、酮油、苯、腰果壳油等的各种酚醛基树脂均被认为可用于本发明中。在改性的酚醛树脂中,所述酚醛树脂通常占树脂共混物的约50重量%或以上(不包括存在的任何溶剂)。但是,已经发现,在某些实施方案中,当混合物包括含有约5-约80重量%,且为了某些目的,为约15-约55%,和在某些实施方案中为约15-25重量%的硅酮树脂的树脂共混物时,摩擦材料可以得到改善(以上均以硅酮-酚醛树脂混合物的重量为基础计,不包括溶剂和其他加工助剂)。
可用于本发明的有用的酚醛类和酚醛-硅酮树脂的实例全部在以上引用的BrogWarner的美国专利中公开,其在此全文引用作为参考。可用于本发明的硅酮树脂包括,例如热固性硅酮密封剂和硅酮橡胶。各种硅酮树脂均可用于本发明。特别是,一种树脂包括二甲苯和乙酰丙酮(2,4-戊二酮)。所述硅酮树脂的沸点为约362°F(183℃),在68°F下的蒸汽压为21mmHg。蒸汽密度为4.8(空气=1),在水中的溶解度忽略不计,比重约为1.09,挥发百分比,以重量计为5%,蒸发速率(醚=1)低于0.1,使用Pensky-Martens法测定,闪点在149°F(65℃)。应当理解,其他的硅酮树脂也可用于本发明。其他有用的树脂共混物包括,例如适当的酚醛树脂,其包括(以重量%计):约55-约60%的酚醛树脂;约20-约25%的乙醇;约10-约14%的苯酚;约3-约4%的甲醇;约0.3-约0.8%的甲醛;和约10-约20%的水。另一种适当的酚醛树脂包括(以重量%计):约50-约55%的酚/甲醛树脂;约0.5%的甲醛;约11%的苯酚;约30-约35%的异丙醇;和约1-约5%的水。
还已经发现,另一种有用的树脂是环氧改性的酚醛树脂,其包含约5-约25重量%,优选约10-约15%的环氧化合物,其余部分(不包括溶剂和其他加工助剂)是酚醛树脂。环氧-酚醛树脂化合物,在某些实施方案中,为所述摩擦材料提供比单独用酚醛树脂更高的耐热性。
在某些实施方案中,优选树脂混合物包括所需量的树脂和纳米粒子大小的摩擦改性颗粒,从而使得树脂被基材吸收的目标吸收率为,以硅酮-酚醛树脂的总重量计,约25-约70%,在其他实施方案中,为约40-约65%,且在某些实施方案中,为约60到至少65%。在基材被树脂饱和之后,将基材在300-400℃的温度下固化一段时间(在某些实施方案中为约1/2小时),以将树脂粘合剂固化并形成摩擦材料。所述摩擦材料最终的厚度取决于基材的起始厚度。
另外还认为,可用于制备树脂共混物和制备基材的已知的其他成分和加工助剂也可以包括在内,并且都在本发明预期的范围之内。
在某些实施方案中,所述树脂混合物可以同时包括硅酮树脂和酚醛树脂,它们存在于与彼此相容的溶剂中。这些树脂混合在一起(在优选实施方案中),形成均一的共混物,然后用于使纤维基材饱和。在某些实施方案中,如果基材先用酚醛树脂浸渍,然后再加入硅酮树脂,将会产生不同的效果,反之亦然。在硅酮-酚醛树脂溶液和硅酮树脂粉末和/或酚醛树脂粉末的乳液之间也有差别。当硅酮树脂和酚醛树脂处于溶液中时,它们根本不固化。相反,硅酮树脂和酚醛树脂的粉末颗粒则会部分固化。硅酮树脂和酚醛树脂的部分固化会抑制基材进行良好的饱和。
在本发明的某些实施方案中,所述基材用一种处于与酚醛树脂及其溶剂相容的溶剂中的硅酮树脂的共混物浸渍。在一个实施方案中,异丙醇被发现是特别适合的溶剂。然而,应当理解,各种不同的其他适当的溶剂,如乙醇、甲乙酮、丁醇、异丙醇、甲苯等均可用于本发明的实践中。当与酚醛树脂共混并用于饱和基材时,硅酮树脂的存在会使所得到的摩擦材料比起只用酚醛树脂浸渍的基材来更有弹性。当在本发明的硅酮-酚醛树脂共混浸渍的摩擦材料上施加压力时,压力可以更均匀地分布,这随后会降低不均匀衬层磨损的可能性。在硅酮树脂和酚醛树脂与摩擦改性颗粒混合在一起之后,混合物用于浸渍所述基材。
本发明的摩擦材料包括在基材中随机分散的纳米粒子大小的摩擦改性颗粒,这会使摩擦材料具有优良的抗震颤特性、高耐受性、高摩擦系数、高耐久性、优良的耐磨性以及提高的“磨合(break in)”特性。
图1a是表明现有技术摩擦材料10的示意图,其包含纤维基材12和硅藻土摩擦改性颗粒14。图1b、1c和1d示意性地表明了纤维(图1b)、通用的二氧化硅颗粒(图1c),和本发明中使用的纳米粒子(图1d)大小的对比。图2示意性地表明了在纤维表面上具有纳米粒子的纤维。图3示意性地表明纤维基材20,其在纤维22上具有纳米粒子大小的摩擦物质24。
在某些实施方案中,已经发现,当摩擦改性颗粒的尺寸极其小时,会获得所需的最佳三维结构,因此,所得摩擦材料的热逸散和抗震颤特性也得到优化。
在某些实施方案中,相信纳米粒子大小的摩擦改性物质在独立的构成基材外表面的纤维和填料上形成纳米粒子簇、或聚集体。在某些实施方案中,所述簇的平均直径低于约30-100nm。
用于本发明多孔摩擦材料的纳米粒子大小的摩擦改性物质为所述摩擦材料提供优良的抗震颤特性。在所示的实施方案中,高温合成纤维和基材的孔隙度提供改进的耐热性。
另外,所述多孔摩擦材料具有相对大的孔,这使得流体中的杂质能很容易地通过。这种降解产物的吸附使得所述摩擦材料具有甚至更恒定的摩擦性能。
以下实施例进一步证明,纳米粒子大小的摩擦改性颗粒在本发明摩擦材料中的随机分散能改进通用的摩擦材料。这种摩擦材料具有希望的摩擦系数、耐热性和耐久性。在以下实施例中描述了各种不同的优选实施方案,但它们并不旨在限定本发明的范围。
具体实施方式
实施例
实施例I-A
在有槽的材料中倾斜与滑动时间的比较,其表明,所述材料允许油在所需的条件范围内流动,并允许优良的热逸散。
实施例II
纳米粒子大小的摩擦改性颗粒在基材内的沉积不会明显降低基材的渗透性。基材的渗透性使得流体或润滑剂流到基材中,并且不保留在摩擦材料的表面上。
工业实用性
本发明可用作用于离合器片、传动带、刹车片、同步器闭锁环、摩擦片或系统盘中的高能摩擦材料。
以上对本发明的优选和可选实施方案的描述旨在进行说明而不是用来限制以下权利要求的范围和内容。
Claims (25)
1.一种摩擦材料,其包括多孔基材,至少一类树脂材料和至少一类分散在所述多孔基材中的纳米粒子大小的摩擦改性颗粒,其中所述纳米粒子大小的摩擦改性颗粒随机分散在所述摩擦材料中。
2.权利要求1的摩擦材料,其中所述纳米粒子大小的摩擦改性颗粒以厚度为约0-约85μm沉积在构成所述多孔基材的独立的纤维和填料上。
3.权利要求1的摩擦材料,其中所述摩擦材料在径向和法向上具有基本上相同的渗透性。
4.权利要求1的摩擦材料,其中所述纳米粒子大小的摩擦改性颗粒的平均粒径为约10nm-约150nm。
5.权利要求1的摩擦材料,其中所述摩擦改性颗粒的大小为约1-约20nm。
6.权利要求1的摩擦材料,其中所述多孔基材的平均孔隙度为约65%-约85%。
7.权利要求1的摩擦材料,其中所述纳米粒子大小的摩擦改性颗粒包括二氧化硅颗粒。
8.权利要求7的摩擦材料,其中所述纳米粒子大小的摩擦改性颗粒包括C盐颗粒。
9.权利要求7的摩擦材料,其中所述纳米粒子大小的摩擦改性颗粒包括硅藻土。
10.权利要求1的摩擦材料,其中所述纳米粒子大小的摩擦改性颗粒包括碳颗粒和二氧化硅颗粒的混合物。
11.权利要求7的摩擦材料,其中所述C盐具有不规则的形状。
12.权利要求8的摩擦材料,其中所述C盐颗粒的大小为约2-约20nm。
13.权利要求1的摩擦材料,其中所述纳米粒子大小的摩擦改性颗粒包括金属氧化物。
14.权利要求1的摩擦材料,其中所述纳米粒子大小的摩擦改性颗粒包括氮化物。
15.权利要求1的摩擦材料,其中所述纳米粒子大小的摩擦改性颗粒包括碳化物。
16.权利要求1的摩擦材料,其中所述基材包括纤维基材。
17.权利要求1的摩擦材料,其中所述基材是无纺纤维基材。
18.权利要求1的摩擦材料,其中所述基材是纺织的纤维基材。
19.权利要求17的摩擦材料,其中所述纤维基材包括约15-约25%的棉,约40-约50%的芳族聚酰胺纤维,约10-约20%的碳纤维,约5-约15%的碳颗粒,约10-约15%的C盐,和任选约1-约3%的胶乳添加剂。
20.权利要求19的摩擦材料,其中所述摩擦材料包括沉积在无纺纤维材料的纤维上和沉积在纤维基材中的填料上的纳米粒子大小的二氧化硅摩擦材料颗粒。
21.权利要求17的摩擦材料,其中所述纤维基材的平均孔径为约5μm。
22.权利要求1的摩擦材料,其中所述树脂包括至少一种酚醛树脂或至少一种改性的酚醛树脂。
23.权利要求1的摩擦材料,其中所述树脂包括至少一种酚醛树脂和至少一种硅酮树脂的混合物,其中树脂混合物中硅酮树脂的量为,以树脂混合物的重量计,约5-约80重量%。
24.一种制备摩擦材料的方法,其包括:
用饱和剂饱和多孔基材,其中所述饱和剂包括至少一种树脂材料,和至少一类纳米粒子大小的摩擦改性颗粒,从而使得多个摩擦改性颗粒沉积在构成基材的独立纤维和填料上,其中,纳米粒子大小的摩擦改性颗粒在独立的纤维或填料上的平均厚度为约0-200μm,
将所述饱和的基材在预定的温度下固化预定的时间段。
25.一种制备摩擦材料的方法,其包括:
制备包括至少一种可固化树脂材料和至少一类纳米粒子大小的摩擦改性颗粒的混合物的饱和剂,
制备具有多个贯穿分散的空隙的多孔基材,和
用所述饱和剂饱和所述多孔基材从而使多个纳米粒子大小的摩擦改性颗粒至少部分沉积在构成基材的独立纤维上,和使所述树脂材料和纳米粒子大小的颗粒基本上均匀分散在整个基材中。
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US10/899508 | 2004-07-26 |
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EP (1) | EP1621791A1 (zh) |
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-
2004
- 2004-07-26 US US10/899,508 patent/US7429418B2/en active Active
-
2005
- 2005-07-18 EP EP20050254475 patent/EP1621791A1/en not_active Ceased
- 2005-07-22 JP JP2005212562A patent/JP2006038226A/ja active Pending
- 2005-07-25 CN CNA2005100980496A patent/CN1733825A/zh active Pending
- 2005-07-26 KR KR1020050067756A patent/KR20060046781A/ko not_active Application Discontinuation
-
2008
- 2008-06-12 US US12/157,901 patent/US7749562B1/en not_active Expired - Lifetime
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
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CN102264859A (zh) * | 2009-01-09 | 2011-11-30 | 博格华纳公司 | 包括在其上结合有摩擦改性颗粒的多个粘合剂颗粒的摩擦材料 |
CN102264859B (zh) * | 2009-01-09 | 2014-08-20 | 博格华纳公司 | 包括在其上结合有摩擦改性颗粒的多个粘合剂颗粒的摩擦材料 |
US9657798B2 (en) | 2009-01-09 | 2017-05-23 | Borgwarner Inc. | Friction material including a plurality of binder particles with friction modifying particles bound thereto |
CN103881295A (zh) * | 2014-03-31 | 2014-06-25 | 陕西科技大学 | 一种纳米颗粒改性碳布增强湿式摩擦材料的制备方法 |
CN103881295B (zh) * | 2014-03-31 | 2016-04-06 | 陕西科技大学 | 一种纳米颗粒改性碳布增强湿式摩擦材料的制备方法 |
CN107620773A (zh) * | 2016-07-15 | 2018-01-23 | 博格华纳公司 | 摩擦材料 |
Also Published As
Publication number | Publication date |
---|---|
US7749562B1 (en) | 2010-07-06 |
JP2006038226A (ja) | 2006-02-09 |
US7429418B2 (en) | 2008-09-30 |
EP1621791A1 (en) | 2006-02-01 |
US20060019085A1 (en) | 2006-01-26 |
KR20060046781A (ko) | 2006-05-17 |
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