JP2001151983A - Phenolic resin molding material and molded pulley prepared therefrom - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a phenolic resin molding material which gives a molded pulley having an excellent wear resistance and less belt attacking properties, and a molded article prepared from the molding material. SOLUTION: There are provided a phenolic resin molding material comprising a phenolic resin and an inorganic fiber, which further comprises an organic filler composed of a cured product of a melamin resin in an amount of 5-25 wt.% based on the total amount of the phenolic resin molding material, the phenolic resin molding material wherein the organic filler composed of a cured product of a melamine resin is a powder formed by grinding a waste material generated in the molding step of a melamine resin molding material, and a molded pulley obtained by molding the phenolic resin molding material by a hot press.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a phenolic resin molding material, and more particularly to a phenolic resin molding material suitable for manufacturing resin pulleys used for automobile engine parts and the like.

[0002]

2. Description of the Related Art Conventionally, pulleys are mainly made of metal. However, with the recent reduction in size and weight of automobile parts and reduction in cost, the use of resin is progressing. A resin pulley usually has a structure in which an annular pulley molded product (resin pulley body) is fitted to the outside of a metal boss. As the pulley molded product, phenolic resin is made of inorganic fiber such as glass fiber. A material composed of a blended phenolic resin molding material is often used.

[0003]

A pulley molded product made of a phenolic resin molding material containing the above-mentioned inorganic fiber such as glass fiber has a severe surface wear when used in a dusty environment such as dust and is inferior in durability. And the problem that the partner material such as a belt is easily worn.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and it is an object of the present invention to provide a phenolic resin molding material capable of obtaining a pulley molded product having good wear resistance and low belt attack. It is an object of the present invention to provide a pulley molded product using the molding material.

[0005]

The phenolic resin molding material according to the first aspect of the present invention is a phenolic resin molding material containing a phenolic resin and an inorganic fiber. A phenolic resin molding material containing 5 to 25% by weight of an organic filler composed of a cured product of the above.

The phenolic resin molding material according to the first aspect of the present invention contains an organic filler composed of a cured melamine resin, and the melamine resin as a base thereof has the highest hardness among various resins. Being at a high level,
It has the effect of modifying the surface state of the molded article.

The phenolic resin molding material of the invention according to claim 2 is characterized in that an organic filler comprising a cured product of melamine resin comprises:
The phenolic resin molding material according to claim 1, which is a powder obtained by pulverizing a loss material generated in a molding step of the melamine resin molding material. As the loss material generated in the molding process of the melamine resin molding material, there are culls, runners, defective molding products, etc.
Since these are usually disposed of, the use of this lost material as a raw material contributes to effective utilization of resources.

[0008] The phenolic resin molding material of the invention according to claim 3 is the phenolic resin molding material according to claim 1, wherein the particle size of the organic filler composed of a cured melamine resin is 100 µm or less. When the particle size of the organic filler is 100 μm or less, the dispersibility during kneading of the materials is improved.

According to a fourth aspect of the present invention, there is provided a pulley molded product,
A pulley molded product obtained by molding the phenolic resin molding material according to any one of claims 1 to 3 by a hot press.

[0010]

Embodiments of the present invention will be described below.

The phenolic resin used in the phenolic resin molding material of the present invention may be either a novolak type or a resol type, and a curing agent, a wax, a coloring agent and the like may be added together with the phenolic resin, if necessary. it can.

As the inorganic fibers used in the phenolic resin molding material of the present invention, glass fibers can be used, but carbon fibers and the like can also be used in addition to glass fibers. As for the content ratio of the inorganic fiber, the content is preferably 25 to 60% by weight based on the total amount of the phenolic resin molding material. If the content is less than 25% by weight, the strength of the obtained molded product is low. However, it is not preferable because aggression against the partner material becomes large.

The phenolic resin molding material of the present invention contains 5 to 25% by weight of an organic filler composed of a cured melamine resin, based on the total amount of the phenolic resin molding material.
The cured product of the melamine resin as used herein refers to a cured product containing more than 50% by weight of the melamine resin component, and may be a cured product of only the melamine resin component, It may be a cured product of a melamine resin composition containing a filler such as pulp.

As an organic filler composed of a cured product of the melamine resin, a powder obtained by pulverizing a loss material such as a cal, a runner, and a defective product generated in a molding process of a melamine resin molding material is conventionally used. Has been disposed of, which contributes to the effective use of resources.

If the content of the organic filler composed of a cured melamine resin is less than 5% by weight with respect to the total amount of the phenolic resin molding material, the effect of modifying the surface condition of the molded product is poor. If the effect of improving wear resistance is insufficient and exceeds 25% by weight, the effect of improvement is saturated, so the range is limited to 5 to 25% by weight.

The melamine resin, which is the base of the organic filler composed of a cured product of the melamine resin, has the highest hardness among various resins and has a function of modifying the surface condition of a molded article. When an inorganic filler such as silica powder having a higher hardness than the melamine resin is used instead of the organic filler to make a pulley molded product, the surface hardness of the molded product increases, but the surface of the molded product during abrasion increases. Since the separated inorganic filler intervenes on the sliding surface and acts as an abrasive to attack the surface of the molded product and a mating material such as a belt, the wear resistance of the molded product is deteriorated. On the other hand, an organic filler made of a cured melamine resin has a lower hardness than an inorganic filler such as silica powder, separates from the surface of a molded product when worn, and is used as an abrasive even when interposed on a sliding surface. It does not work and has very low aggressiveness on the surface of the molded product and on the opponent material such as a belt. Therefore, when an organic filler made of a cured product of a melamine resin is used, the wear resistance of a molded product is not impaired. And in the case of a pulley molded product,
Substances that cause wear such as dust are mainly silica-based substances, and the dust and the like selectively wear the resin portion between the inorganic fibers, so that the inorganic fibers are exposed, and as a result, belts and the like are consequently exposed. Although the property of attacking the opponent material becomes remarkable, in the case of the present invention, the abrasion resistance of the resin portion between the inorganic fibers is improved by the action of the organic filler, so that the inorganic fibers are exposed by abrasion due to dust and the like. As a result, the property of attacking a partner material such as a belt is reduced.

It is preferable that the particle size of the organic filler composed of a cured product of the melamine resin used in the present invention is 100 μm or less, since the dispersibility during kneading of the materials becomes good. The lower limit of the particle size is not particularly limited, and can be selected within a range that does not impair the wear resistance.

Further, by blending an elastomer with the phenolic resin molding material of the present invention, it is possible to lower the Young's modulus of the molded article and improve the thermal shock resistance.

The pulley molded product of the present invention is a pulley molded product obtained by molding the above-mentioned phenolic resin molding material of the present invention by a hot press, and the molding method may be a direct pressure molding method or the like. it can. Since the molded product of the pulley of the present invention is manufactured using a molding material containing an organic filler composed of a cured product of a melamine resin together with inorganic fibers, it has good wear resistance and low belt attack. It becomes a pulley molded product.

[0020]

The present invention will be described below in detail with reference to examples.

After uniformly blending the blends having the blend compositions shown in Tables 1 and 2 (for 1 minute), using a twin-screw kneader, the temperature was:
The mixture was heated and kneaded under conditions of 90 to 100 ° C. and kneading time: 3 minutes, then solidified by cooling, pulverized, and granulated to obtain a phenol resin molding material.

The obtained molding material was subjected to direct pressure molding to obtain a molded product for a wear resistance test and a molded product for a belt attack test.
For each of the obtained molded products, a wear resistance test and a belt attack test were performed under the following measurement conditions, and the results are shown in Tables 1 and 2.

Abrasion resistance test: Based on JIS K6735 (taper abrasion test), type of worn wheel: CS-1
7, test piece rotation speed: 10 under the condition of 60 rpm
The wear amount (mg) of the molded article after 00 rotation is measured.

Belt aggression test: As a molded product for abrasion resistance test, a disk-shaped molded product of 100φ × 3 mm was prepared.
The molded product is rotated at 60 rpm, and a test is performed for 24 hours in a state where the belt is pressed against the outer peripheral surface thereof with a load of 2 kg, and the abrasion amount (mg) of the belt is measured.

The following materials were used for the raw materials shown in Tables 1 and 2. Phenol resin is a phenol novolak resin (molecular weight: 2,000 to 4,000), glass fiber is an average fiber diameter: 13 μm, fiber length: 3 mm, and silica is spherical silica having an average particle diameter of 5 μm. Filler A has an average particle diameter of about 30 obtained by pulverizing cal and runner produced in a molding process of a melamine resin molding material (melamine resin component 70% by weight, pulp component 30% by weight).
μm powder (120 mesh or less, maximum length 10
0 μm or less), and the organic filler B is a cured product of only the melamine resin component. The average particle size of about 40 μm melamine filler (maximum length 100 μm or less) manufactured by Nissan Chemical Industries, Ltd. is used. Used hexamethylenetetramine.

[0026]

[Table 1]

[0027]

[Table 2]

As shown in Comparative Example 1 shown in Table 2, a molding material containing phenol resin and glass fiber as main raw materials and a molding material containing phenol resin, glass fiber and spherical silica as main raw materials as in Comparative Example 2 were used. In the molded article used, both the abrasion resistance and the belt aggressiveness are both large. On the other hand, the molded articles using the molding materials of Examples 1 to 5, in which the organic filler composed of the cured product of the melamine resin is contained together with the glass fiber, have higher abrasion resistance than the results of Comparative Examples 1 and 2. It was confirmed that both characteristics of the belt aggressiveness were good.

[0029]

The phenolic resin molding material according to any one of the first to third aspects of the present invention contains an organic filler composed of a cured product of a melamine resin at a specific compounding ratio, so that the abrasion resistance is good. And a phenolic resin molding material from which a pulley molded article having low belt attack is obtained.

The phenolic resin molding material according to the second aspect of the present invention is a phenolic resin molding material having good abrasion resistance and a low pulley molded product with low belt attack. Since it is used, it contributes to effective use of resources.

The phenolic resin molding material according to the third aspect of the present invention is a phenolic resin molding material having a good abrasion resistance and a small pulley molded article having a low belt attack, and a dispersibility during kneading of the materials. And the quality of the molded article is stabilized.

The molded product of the pulley of the invention according to claim 4 is:
A pulley molded product having good wear resistance and low belt attack is obtained.

Claims (4)

[Claims] 1. A phenolic resin molding material comprising a phenolic resin and inorganic fibers, wherein the organic filler comprising a cured melamine resin is contained in an amount of 5 to 25% by weight based on the total amount of the phenolic resin molding material. A phenolic resin molding material. 2. The phenolic resin molding material according to claim 1, wherein the organic filler composed of a cured product of the melamine resin is a powder obtained by crushing a loss material generated in a molding step of the melamine resin molding material. 3. The phenolic resin molding material according to claim 1, wherein the organic filler composed of a cured melamine resin has a particle size of 100 μm or less. 4. A pulley molding obtained by molding the phenolic resin molding material according to claim 1 by a hot press.