TW201733789A - Carbon fiber washer and bonding method thereof - Google Patents

Abstract

Present invention relates to a carbon fiber washer having a carbon fiber fabric woven by fibrous bundles. Each fibrous bundle is formed by multiple discontinuous fibers. The present invention has great stability to heat, fatigue and weather. Compared to element with continuous fibers, the entire construction of the carbon fiber washer in the present invention will not be damaged even partial of the discontinuous fibers being worn out. Thus, high durability and long life-time washer is disclosed in this invention.

Description

Carbon fiber gasket and bonding method thereof

A carbon fiber gasket, in particular a carbon fiber gasket containing discontinuous carbon fibers.

Gaskets are indispensable for many mechanical structures, such as metal gaskets for locking and fastening, preventing loosening, flat gaskets, and spring washers for tightness against leaks. The sheet, or a rotating spacer required to rotate the component, and the like are all. The rotating gasket in the fishing reel is one of the examples. The gasket used in the existing fishing reel has to withstand high high-speed rotational friction or even auxiliary braking due to the use of the gasket. The rotating gasket has extremely high requirements on wear resistance, self-lubricity and high temperature resistance. At present, the gaskets traditionally used for fishing reels or other similar applications are mainly metal-based or composite-based. Metal-based materials have the advantage of relatively superior heat conduction, but metal heat may be generated in cooperation with other parts. New problems such as expansion and contraction; composite-base rotating gaskets are formed by laminating multiple layers of continuous fiber woven fabrics. Please refer to Figure 8. Continuous fibers are easy to loosen due to local fiber breakage during use. Remove or delamination, resulting in reduced service life.

In order to solve the above problems, the present invention develops a carbon fiber gasket containing a carbon fiber gasket woven by discontinuous carbon fibers. When the discontinuous carbon fiber of the carbon fiber gasket is locally worn and fractured, it does not affect the structural looseness of other carbon fibers or Delaminate to increase the usefulness of use.

The present invention is a carbon fiber gasket comprising a carbon fiber cloth interwoven in a plurality of fiber bundles, each of which is formed of a plurality of discontinuous fibers.

Wherein two or more of the carbon fiber cloths are provided with a backing material partially infiltrated or impregnated between the fibers of the carbon fiber cloth, and the outer surface of the carbon fiber gasket is at least partially not impregnated or impregnated. material.

Among them, the carbon fiber cloth has a carbonization rate of between 10% and 95%.

Wherein, the impregnation rate of the adhesive material between the carbon fiber gaskets is between 40% and 80%.

The backing material is a thermoplastic resin or a thermosetting resin, and the discontinuous carbon fiber is formed by carbonization of a polyacrylonitrile fiber.

Among them, the thermoplastic resin is a polyester or a polyfluorene resin, and the thermosetting resin is an epoxy resin series or a phenolic resin.

Wherein, the two carbon fiber gaskets further form a laminated structure with a supporting material, and the two carbon fiber sheets are disposed on the outer side of the laminated structure.

Wherein, the support material is any one or a combination of the carbon fiber gasket, the thin fiber cloth, the basalt cloth or the glass fiber cloth.

The invention further provides a method for bonding carbon fiber gaskets, the steps comprising: (1) taking two or more carbon fiber cloths, which are interlaced by a plurality of fiber bundles, each of the fiber bundles Formed by a plurality of discontinuous fibers; (2) applying one of a specific thickness to the carbon fiber cloth and laminating; and (3) combining the carbon fiber cloth and the bonding material after lamination to form the carbon fiber gasket The backing material is partially infiltrated or impregnated between the fibers of the carbon fiber cloth, and the outer surface of the carbon fiber gasket is at least partially impregnated or impregnated with the binder.

The bonding method of the carbon fiber gasket further comprises: applying the bonding material to the carbon fiber gasket by lamination, coating or spraying; and laminating the carbon fiber cloth and the bonding material by hot pressing The method combines to form the carbon fiber gasket.

As can be seen from the above description, the present invention has the following advantages:

1. The carbon fiber gasket of the present invention has the advantages of high temperature resistance, fatigue resistance and high weather resistance, and the carbon fiber gasket disposed on the outermost layer maintains a pattern of short fibers and discontinuous fibers exposed, so that when the present invention is used, It can have better technical effects of self-lubrication and wear resistance compared to the prior art.

2. The invention is woven by using discontinuous carbon fiber. When the local carbon fiber breaks and wears, it does not affect other parts of the discontinuous fiber, and it is not easy to cause structural looseness or delamination, and the use efficiency and time are increased.

3. The carbon fiber gasket with different carbonization rate of the invention can be widely used in various fields, for example, the carbon fiber gasket with high carbonization rate can be applied to a mechanism that requires high-speed transmission for gears such as automobile gearboxes and fishing reels, and medium carbonization. The carbon fiber gasket can be used in machines with low gear speed requirements such as food-grade machinery, replacing the problem that lubricating oil is left in the general gear to cause the lubricating oil to remain in the food, and the carbon fiber gasket with lower carbonization rate is It can be applied to mechanical gear gaskets with lower speeds or general gaskets between screws.

The present invention comprises a carbon fiber cloth 11 interlaced by a plurality of fiber bundles 111, each of which is formed of a plurality of discontinuous fibers 1111. Preferably, the plurality of warp and weft interlaced fiber bundles 111 are interlaced in a warp and a weft direction, as shown in an electron microscope (SEM) observation chart of FIGS. 1 to 4.

A preferred embodiment of the method for manufacturing the carbon fiber cloth 11 is as follows:

(1) taking a plurality of non-carbonized non-continuous fibers to be twisted, bundled, and lined; the discontinuous fiber may be a polyacrylonitrile series fiber.

(2) The bundled non-carbonized discontinuous fibers are woven into a non-carbonized fiber cloth in various woven textures or forms, and the method of weaving the non-carbonized fiber cloth is not limited, but is preferably in the form of a shuttleless weave, such as plain weave. Therefore, the non-carbonized fiber cloth is reduced in the formation of the carbon fiber gasket 10, and the transverse shear force is blocked during use, and the problem of damage is greatly reduced.

(3) The non-carbonized fiber cloth is carbonized in a temperature range of 400 ^o C to 3500 ^o C to form a carbon fiber cloth 11, and preferably, the carbon fiber cloth 11 has a carbonization ratio of 10% to 95%.

Referring to FIG. 3 to FIG. 4, the first preferred embodiment of the present invention is a laminated structure formed by stacking the carbon fiber cloths 11 which are obtained by the above manufacturing method, and the two carbon fiber cloths 11 are made of a single material. 20, the bonding material 20 may be a thermoplastic resin such as polyester, polyfluorene or the like, or may be a thermosetting resin such as an epoxy resin, a phenol resin or the like. The facilities for the carbon fiber sheet member 11 and then the adhesive 20, followed by step, using a hot press may be a pressure of between 45 and 250 kg / cm2 and the temperature of ≦ 350 ^o C, and the carbon fiber sheet 11 After laminating with the sheet-shaped support material 20 of a specific thickness, it is heat-pressure bonded, and the adhesive material 20 is partially impregnated and infiltrated into the fibers of the carbon fiber cloth 11, as shown in FIGS. 3 to 4, and the adhesive material 20 is hardened ( After the heat curing and heat curing, the carbon fiber cloth 11 may be combined to have a certain structural rigidity, thereby reducing the problem of delamination; the so-called specific thickness of the sheet material 20, the specific thickness is The carbon fiber cloth 11 is controlled by the thickness, the volume percentage, and the desired impregnation rate. For example, if the secondary material 20 is to be semi-impregnated (40% to 80%) between the carbon fiber cloths, the carbon fiber cloth 40 can be applied. a binder of % to 80 vt% of thickness, which is semi-impregnated between the fibers of the carbon fiber cloth 11 by coating, spraying or film stacking. In order to make the carbon fiber cloth of the outermost layer of the embodiment 11 dimensional Short fibers, non-continuous patterns of the exposed fibers, when used, may have a better compared to the prior art self-lubricating, wear, durability of technical efficiency.

In a large number of continuous manufacturing, the carbon fiber cloth 11 and the support material 20 and the other carbon fiber cloth 11 which are taken up in a roll are produced in a roll-to-roll manner to produce the carbon fiber of the multi-layer structure. The gasket, wherein the binder 20 is appropriately selected as described above depending on the surface characteristics of the bonding object. The laminating process is preferably combined with the application of high temperature and high pressure to further improve the structural properties of the carbon fiber cloth of the multi-layer structure. In this step, the carbon fiber cloth or the continuous sheet material of the multi-layer structure of the roll is completed, and the carbon fiber gasket 10 can be further formed by cutting, cutting or the like.

According to a second preferred embodiment of the present invention, between the two carbon fiber cloths 11 , in addition to the adhesive material 20 , a support material 30 is further laminated in the order of carbon fiber cloth, an adhesive material, a support material, a back material and a carbon fiber cloth. Since the thickness of the single carbon fiber cloth 11 is thin, it is mainly used for lubrication and friction with other mechanical components, and the support material 20 can be used to increase the thickness and strength of the carbon fiber cloth 11. The support member 30 may be basalt, fiberglass cloth, carbon fiber cloth or the like. When the carbon fiber gasket structure of the present invention is formed into three or more layers, the carbon fiber cloth 11 is laminated on the outermost layer, and the other support members 30 (not limited to one layer, which can be laminated) are laminated or coated. The inner layer forms the structure of the sandwich.

The following is a verification of the effectiveness of the invention in terms of wear resistance, self-lubrication, excellent heat conduction and rapid heat dissipation. Please refer to Table 1 below and Table 2, which are representative of the samples prepared by the above manufacturing method of the present invention. 【Table 1】 【Table 2】

Each of the samples of the present invention has a heat transfer coefficient of about 5 (W/cm ∙ ^o C), and it can be seen that each sample can have a rapid heat dissipation performance at a high temperature generated by friction, thereby avoiding mechanical or fiber generated by excessively high temperature accumulation. loss. Please refer to FIG. 6 to FIG. 7, which is based in Table and Table 2 thermogravimetric analysis (TGA Q500) of each sample at 400 ^oC and 500 ^oC measured test results 1 and, at a temperature of 400 ^o C measured in each sample the weight loss rate (% / h) is less than 3%, while the rate of weight loss of each sample in the temperature 500 ^o C (% / h) is less than 18%, the present invention is confirmed each sample at a high temperature stable quality and easy to produce structure Or the problem of fiber damage.

Please refer to Table 3 below. The static and dynamic friction coefficient, wear resistance test and heat-resistant deformation temperature test results of each sample of the present invention measured by ASTM D1894, ASTM D3884 and ASTM D648 test standards are determined by static and dynamic friction coefficient results. The discontinuous carbon fiber woven structure of the present invention can have a self-lubricating effect. Further, from the test results of the abrasion resistance and the heat distortion temperature, the carbon fiber gasket 10 produced by the discontinuous fiber of the present invention has excellent excellent performance against high temperature and abrasion resistance. 【table 3】

It can be seen from the above test results that the structure woven by the discontinuous carbon fiber of the present invention has the characteristics of self-lubrication, friction resistance, high temperature resistance and wear resistance, and the broken carbon fiber does not break when the local carbon fiber breaks and wears. The fiber woven structure that affects other parts is not easy to cause the problem that the overall structure of the carbon fiber gasket is loose or delaminated, and the effect of increasing the use efficiency and time is achieved.

Referring to Table 4 below, the sample number CF-1001-Z of the present invention achieves an elemental analysis table of different carbonization rates at different carbonization temperatures. The carbon fiber gasket which is carbonized at a lower temperature in the present invention can have more functional groups to bond with a resin material such as the binder, and achieve excellent results in that delamination is difficult. 【Table 4】

The carbon fiber gasket with different carbonization rate of the invention has wide application fields, for example, a carbon fiber gasket with a high carbonization rate (60% to 90%) can be applied to a mechanism in which a mechanical gear such as an automobile gearbox or a fishing reel requires high-speed rotation. The medium carbonization rate (30% to 60%) of the carbon fiber gasket can be applied to machines with low gear speed requirements such as food-grade machinery, instead of the problem of lubricating oil remaining in the food, and lower. Carbon fiber gaskets with a carbonization rate (10% to 30%), in addition to reducing the cost of carbonization, can be applied to mechanical gear gaskets with lower rotational speeds or general gaskets between screws.

10‧‧‧Carbon fiber gasket
11‧‧‧Carbon cloth
111‧‧‧Fiber bundle
1111‧‧‧Discontinuous fiber
20‧‧‧Next material
30‧‧‧Support materials

Figure 1 is an SEM image of a carbon fiber gasket. Figure 2 is an SEM image of a carbon fiber gasket. Figure 3 is an SEM image of a carbon fiber gasket cross section. Figure 4 is an SEM image of a carbon fiber gasket cross section. Figure 5 is a schematic illustration of a second preferred embodiment of the present invention. Figure 6 is a TGA test result of each sample of the present invention measured at 400 ^oC . Figure 7 is a TGA test result of each sample of the present invention measured at 500 ^°C . Figure 8 is a schematic view of a carbon fiber gasket woven from continuous carbon fibers.

111‧‧‧Fiber bundle

1111‧‧‧Discontinuous fiber

Claims (10)

A carbon fiber gasket comprising a carbon fiber cloth interwoven in a plurality of fiber bundles, each fiber bundle being formed of a plurality of discontinuous fibers. According to the carbon fiber gasket of claim 1, the two or more of the carbon fiber cloths are provided with a backing material partially infiltrated or impregnated between the fibers of the carbon fiber cloth, and the outer surface of the carbon fiber gasket The backing material is at least partially impregnated or not impregnated. For example, in the carbon fiber gasket of claim 1 or 2, the carbon fiber cloth has a carbonization rate of between 10% and 95%. The carbon fiber gasket according to claim 1 or 2, wherein the impregnation rate of the binder between the carbon fiber gaskets is between 40% and 80%. A carbon fiber gasket according to claim 4, wherein the binder is a thermoplastic resin or a thermosetting resin, and the discontinuous carbon fiber is formed by carbonization of a polyacrylonitrile fiber. A carbon fiber gasket according to claim 5, wherein the thermoplastic resin is a polyester or a polyfluorene resin, and the thermosetting resin is an epoxy resin series or a phenolic resin. According to the carbon fiber gasket of claim 2, the carbon fiber gaskets further form a laminated structure with a support material, and the carbon fiber sheets are disposed on the outer side of the laminated structure. For example, in the carbon fiber gasket of claim 7, the support material is any one or a combination of the carbon fiber gasket, the thin fiber cloth, the basalt cloth or the glass fiber cloth. A method for bonding carbon fiber gaskets, the steps comprising: (1) taking two or more carbon fiber cloths, which are interwoven by a plurality of fiber bundles, each of which is composed of a plurality of non-woven fibers Continuous fiber formation; (2) applying one of a specific thickness to the carbon fiber cloth and laminating; and (3) combining the carbon fiber cloth and the bonding material after lamination to form the carbon fiber gasket, the bonding material Partially infiltrated or impregnated between the fibers of the carbon fiber cloth, the outer surface of the carbon fiber gasket is at least partially impregnated or impregnated with the binder. The bonding method of the carbon fiber gasket according to claim 9 , wherein the bonding material is applied to the carbon fiber gasket by lamination, coating or spraying; the carbon fiber cloth after the lamination and the subsequent bonding The material is combined by heat pressing to form the carbon fiber gasket.