Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
  • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
  • F16D69/02—Composition of linings ; Methods of manufacturing
  • F16D69/025—Compositions based on an organic binder
  • F16D69/026—Compositions based on an organic binder containing fibres
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K7/00—Use of ingredients characterised by shape
  • C08K7/02—Fibres or whiskers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K9/00—Use of pretreated ingredients
  • C08K9/02—Ingredients treated with inorganic substances
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L21/00—Compositions of unspecified rubbers
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
  • F16D2200/00—Materials; Production methods therefor
  • F16D2200/006—Materials; Production methods therefor containing fibres or particles
  • F16D2200/0073—Materials; Production methods therefor containing fibres or particles having lubricating properties

Definitions

• the present invention relates to an aqueous impregnating cement, especially for the manufacture of friction material, a wire impregnated with said cement and a friction material comprising a wire impregnated with said cement.
• the field of the present invention is that of clutch friction discs, as well as friction rings.
• a friction ring is made from yarn based in particular on mineral fibers such as glass fibers, which provide resistance to centrifugal force, rubber for obtaining elastic properties and / or damping, various loads. and a binder, in practice a phenolic resin, to make the whole thing coherent.
• the Applicant has found that the known friction materials tend to have a drop in performance in attenuating hot vibrations, particularly at temperatures above 280 ° C.
• the object of the invention is to provide an aqueous impregnating cement which makes it possible to solve this problem.
• the subject of the present invention is an aqueous impregnating cement, in particular for the manufacture of friction material, comprising:
• the lubricating charge complexes comprising a mixture of lubricating fillers of different densities, the mass fraction ratio in the lubricant charge complexes between the least dense charge and the most dense charge being greater than or equal to 0.6 and less than or equal to at 4.
• the aqueous impregnating cement according to the invention makes it possible to balance and stabilize the performance of the friction material in hot lubrication, and thus to avoid vibratory phenomena at the origin of the discomfort.
• the aqueous impregnating cement according to the invention has the additional effect of providing the friction material with increased resistance to friction and wear compared with friction materials derived from aqueous impregnation cements of the state of the art. the technique.
• the mass fraction ratio in the lubricant charge complexes between the least dense charge and the most dense charge is greater than or equal to 1, preferably greater than or equal to 1.3, preferably less than or equal to 3 , preferably less than or equal to 2, preferably less than or equal to 1.8, preferably equal to 1.6.
• the aqueous impregnating cement according to the invention may also comprise one or more of the following characteristics, considered individually or in any technically possible combination: the density ratio in the lubricant charge complexes is greater than or equal to 1.2 and less than or equal to 4, preferably less than or equal to 3, preferably less than or equal to 2; and or
• the granulometry of the lubricating charge complexes is greater than or equal to 5 ⁇ m and less than or equal to 30 ⁇ m, preferably less than or equal to 20 ⁇ m; and or
• the lubricant charge complexes comprise mineral fillers; and or
• each mineral lubricating charge is a metal sulphide
• the lubricant charge complexes comprise mineral fillers of different densities, the density ratio in the lubricant charge complexes of the mineral fillers is greater than or equal to 1.2 and less than or equal to 2, preferably equal to 1.3; and or
• the lubricant charge complexes consist of mineral fillers; and or
• the lubricant charge complexes comprise mineral fillers and organic fillers; and or
• the lubricant charge complexes consist of mineral fillers and organic fillers; and or
• the mass fraction ratio in the lubricant charge complexes between the organic fillers and the mineral fillers is greater than or equal to 1 and less than or equal to 3;
• the mass fraction ratio in the lubricant charge complexes between the organic fillers and the densest mineral fillers is greater than or equal to 0.65 and less than or equal to 1, preferably equal to 0.8; and or
• the organic filler is graphite; and or
• the lubricant charge complexes comprise charges with a density greater than or equal to 2 and less than or equal to 8; and or
• the aqueous impregnating cement comprises a mass quantity of lubricating charge complexes greater than or equal to 3% and less than or equal to 10% relative to the total dry matter in the cement; and or
• the rubber is synthetic of the SBR or NBR type; and or
• the aqueous impregnating cement comprises a thermosetting resin
• thermosetting resin comprises a phenolic resin, for example a novolac phenolic resin, and / or a melamine formaldehyde resin; and or the aqueous impregnating cement comprises a total mass quantity of rubber and thermosetting resin greater than or equal to 60% and less than or equal to 70% of the total dry matter in the cement; and or
• the aqueous impregnating cement comprises a surfactant
• the aqueous impregnating cement comprises a thickener
• the aqueous impregnating cement comprises friction mineral fibers of different unit volume
• the unit volume ratio between the largest and the smallest fiber being greater than or equal to 10 and less than or equal to 1000;
• the aqueous impregnating cement comprises a dry matter mass percentage greater than or equal to 60% and less than or equal to 65% and / or
• the mineral fibers comprise potassium titanate and / or wollastonite and / or glass and / or slag and / or basalt and / or a ceramic; and or
• the mineral fibers have an identical composition; and or
• the mineral fibers have an identical density; and or
• the mass quantity of mineral friction fibers is greater than or equal to 1% of the total dry matter in the cement.
• the mass quantity of mineral friction fibers is less than or equal to 10% of the total dry matter in the cement.
• the MOHS hardness of each fiber is greater than or equal to 4, preferably greater than or equal to 6; and or
• the MOHS hardness of each fiber is less than or equal to 7; and or
• each mineral fiber is less than or equal to 3 mm;
• At least a portion of the mineral fibers are made from cut materials;
• At least a portion of the mineral fibers are made from crushed materials.
• the invention also relates to a yarn comprising mineral fibers impregnated with an aqueous impregnating cement according to the invention.
• the invention also relates to a friction material made from at least one thread impregnated with an aqueous impregnating cement according to the invention.
• FIG. 1 is a schematic representation of an impregnating cement according to the invention
• FIG. 2 is a diagrammatic representation of an impregnating cement according to one embodiment of the invention.
• FIG. 3 is a diagrammatic representation of a mineral fiber of a yarn impregnated with an impregnating cement according to the invention.
• FIG. 4 is a graph showing the result of chatter tests on two friction materials according to the invention and on a friction material known from the prior art.
• the invention relates to an aqueous impregnation cement, in particular for the manufacture of friction material, comprising an aqueous suspension of lubricant charge complexes 2, and a rubber emulsion 4.
• an aqueous impregnating cement is understood to mean a hydraulic binder composition, by aqueous suspension a dispersed phase, that is to say containing particles of size greater than 1 ⁇ m, and by emulsion a continuous phase. , that is to say, the particles that constitute it are less than 1 .mu.m in size.
• the aqueous impregnating cement according to the invention is a mixture of a dispersed phase and a continuous phase.
• the lubricant charge complexes 2 comprise a mixture of lubricant charges 6 of different densities, the mass fraction ratio in the lubricant charge complexes 2 between the least dense charge and the densest charge. being greater than or equal to 0.6 and less than or equal to 4.
• the ratio of the mass fraction between the least dense charge and the most dense charge is the quotient of the mass fraction of the least dense charge in the lubricant charge complexes 2 divided by the mass fraction. of the densest charge in the complexes 2 of lubricating charges.
• a ratio of the mass fraction in the lubricant charge complexes 2 between the least dense charge and the most dense charge lying in the range specified according to the invention has the effect of distributing the charges.
• lubricant 6 homogeneously in composition within the aqueous impregnating cement.
• each load is homogeneously distributed inside the impregnating cement.
• the impregnating cement makes it possible to produce a friction material capable of regulating vibrations in a balanced and stable manner in hot lubrication.
• a further effect of an aqueous impregnating cement according to the invention is that by virtue of the homogeneous distribution of the lubricating fillers 6 inside the impregnating cement, the mechanical properties of the friction material are uniform. In particular, the mechanical properties are identical to the surface of the material and in its volume. During the use of a friction material, friction causes surface wear. In this situation, the mechanical properties of a friction material produced from an aqueous impregnating cement according to the invention do not change. Thus a friction material produced from an aqueous impregnating cement according to the invention has a higher resistance to friction and wear compared to friction materials made from aqueous impregnating cements known from the skilled person.
• the mass fraction ratio between the least dense filler and the most dense filler is preferably greater than or equal to 1, preferably greater than or equal to 1.3, preferably less than or equal to 3, preferably less than or equal to 2, preferably less than or equal to 1.8, preferably equal to 1.6.
• the homogeneity in composition of the impregnating cement is obtained with a lower stirring speed, resulting in energy saving and costs for manufacturing, as well as better stability of the impregnating cement.
• the density ratio in the lubricant charge complexes 2 is greater than or equal to 1.2 and less than or equal to 4, preferably less than or equal to 3, preferably less than or equal to 2.
• the granulometry of the lubricant charges 6, defined by their median diameter is greater than or equal to 5 ⁇ m and less than or equal to 30 ⁇ m.
• each lubricating load 6 defined by its chemical composition consists of grains of variable diameter. The median diameter of the grains has a diameter greater than or equal to 5 ⁇ m and less than or equal to 30 ⁇ m.
• a fine particle size gives the friction material better abrasion resistance due to an increased contact surface between the grains and the rubber.
• the granulometry of the lubricating fillers 6 is less than or equal to 20 ⁇ m.
• the lubricant charge complexes 2 comprise charges with a density greater than or equal to 2 and less than or equal to 8, preferably the lubricating charge complexes 2 consist of charges of a higher density or equal to 2 and less than or equal to 8.
• the lubricant charge complexes 2 may comprise mineral fillers and / or organic fillers.
• the complexes 2 of lubricating fillers may consist of mineral fillers or mineral fillers and organic fillers.
• the aqueous impregnating cement may comprise an aqueous suspension of lubricating fillers, the lubricating fillers being constituted by mineral fillers or mineral fillers and organic fillers.
• Mineral lubricating fillers may include metal sulphides, for example sulphides of bismuth, copper, tin, molybdenum, iron or zinc.
• Organic lubricating fillers may include graphite.
• the density ratio of the mineral fillers i.e., the quotient of the density of the densest inorganic filler in the lubricant charge complexes 2 divided by the density of the least mineral filler dense in the complexes 2 of lubricating charges, is greater than or equal to 1.2 and less than or equal to 2, preferably equal to 1.3.
• the mass fraction ratio in the lubricant charge complexes 2 between organic and inorganic fillers is greater than or equal to 1 and less than or equal to 3.
• the mass fraction ratio in the lubricant charge complexes 2 between the organic feeds and the densest inorganic filler i.e., the quotient of the mass fraction of the organic feeds divided by the mass fraction of the feedstock. the densest mineral filler, is greater than or equal to 0.65 and less than or equal to 1, preferably equal to 0.8.
• the aqueous impregnating cement comprises a mass quantity of lubricant charge complexes 2 greater than or equal to 3% and less than or equal to 10% relative to the total solids content.
• the formulation of the impregnating cement which is a heterogeneous medium comprising a continuous phase such as water or an emulsion in water and a dispersed phase, requires controlling many physical and chemical interactions.
• the mass fractions of these various constituents must be adapted.
• the impregnating cement according to the invention comprises a rubber in the form of an aqueous emulsion 4, also called latex.
• the rubber comprises a synthetic rubber of styrene-butadiene (SBR), nitrile-butadiene (NBR) or carboxylated nitrile-butadiene (XNBR) type.
• SBR styrene-butadiene
• NBR nitrile-butadiene
• XNBR carboxylated nitrile-butadiene
• the rubber comprises a NBR latex.
• the aqueous impregnating cement comprises a thermosetting resin, which may comprise a phenolic resin, for example a novolac phenolic resin, and / or a melamine formaldehyde resin.
• a thermosetting resin which may comprise a phenolic resin, for example a novolac phenolic resin, and / or a melamine formaldehyde resin.
• the aqueous impregnating cement comprises a dry matter mass percentage greater than or equal to 60% and less than or equal to 65%.
• the complement consists of water.
• the dry matter of the aqueous impregnating cement comprises a total mass quantity of rubber and thermosetting resin greater than or equal to 60% and less than or equal to 70% of the total dry matter.
• the aqueous impregnating cement may include one or more additives.
• the aqueous impregnating cement may thus comprise alone or in combination, at least one surfactant, at least one thickener.
• a surfactant may be of the anionic type, for example a sodium, potassium or ammonium polyphosphate, or a sodium, potassium or ammonium sulfonate, or a sodium, potassium or ammonium sulfate.
• a surfactant may be of the nonionic type, for example a polyacrylate or a polyvinyl alcohol.
• a thickener may comprise cellulose or calcium silicate.
• the cellulose may be of the microcrystalline colloidal cellulose type.
• the cellulose is insoluble in water but the presence of hydroxyl group -OH gives it a hydrophilic nature, these bonds cause swelling of the cellulose or a thickening in the continuous phase.
• the cellulose is introduced in low concentrations, of the order of 0.3% to 1% by mass fraction of the total dry matter.
• the viscosity of the impregnating cement is sufficiently low to facilitate impregnation with the cement.
• the calcium silicate becomes the hydrated calcium silicate in the aqueous dispersion.
• the hydrated calcium silicate hydrates gradually join and form a gel, which makes it possible to keep the charges in suspension in the dispersion.
• the concentration of calcium silicate may be higher than that of cellulose.
• the viscosity of the mixture is more favorable to impregnation.
• the calcium silicate is introduced into the cement in concentrations of less than or equal to 5% of the total dry matter.
• the aqueous impregnating cement comprises cellulose and calcium silicate in combination with at least one surfactant.
• the aqueous impregnating cement comprises cellulose in a concentration of greater than or equal to 0.3% and less than or equal to 1% of the total dry matter, calcium silicate in a concentration of greater than or equal to 0% and below or equal to 5% of the total dry matter, and a surfactant, preferably of the anionic or nonionic type.
• cellulose in a concentration of greater than or equal to 0.3% and less than or equal to 1% of the total dry matter
• calcium silicate in a concentration of greater than or equal to 0% and below or equal to 5% of the total dry matter
• a surfactant preferably of the anionic or nonionic type.
• the homogeneity of the mineral fibers 2 in the cement is more easily maintained with moderate agitation.
• the aqueous impregnating cement may comprise mineral fibers 12 of friction of different unit volume.
• These mineral friction fibers have the effect of increasing the frictional resistance of a friction material from the aqueous impregnating cement.
• the unit volume ratio between the largest and the smallest fiber is greater than or equal to 10 and less than or equal to 1000.
• a ratio of unit volume between the largest and the smallest fiber lying in the range specified according to the invention has the effect of distributing the fibers 12 homogeneously in volume within the aqueous impregnating cement.
• the performance of the fibers 12 acting in different temperature ranges overlap.
• the mineral fibers 12 are homogeneously distributed in volume inside the impregnating cement.
• the impregnating cement makes it possible to produce a friction material having a better resistance to friction.
• a further effect is that due to the homogeneous distribution of the fibers 12 inside the impregnating cement, the mechanical properties of the friction material are uniform. In particular, the mechanical properties are identical to the surface of the material and in its volume. During the use of a friction material, friction causes surface wear. In this situation, the mechanical properties of a friction material produced from an aqueous impregnating cement according to the invention do not change. Thus, a friction material produced from an aqueous impregnating cement according to the invention has an increased resistance to wear compared to friction materials made from aqueous impregnating cements known to those skilled in the art. .
• the unit length of each mineral fiber is less than or equal to 3 mm.
• a fine particle size gives the friction material better resistance to abrasion because of an increased contact surface between the fibers and the rubber.
• the MOHS hardness of each fiber is greater than or equal to 4, preferably greater than or equal to 6. According to one embodiment of the invention, the MOHS hardness of each fiber is lower or equal to 7.
• the MOHS hardness value of the fibers is directly related to the abrasion resistance of the friction material.
• the mineral fibers 12 have a composition and / or an identical density.
• the unit volume ratio between the largest fiber, that is to say of greater volume and the smaller fiber that is to say smaller volume, greater or equal at 10 and less than or equal to 1000 allows a homogeneous distribution of the fibers in the cement.
• the performance of the friction material in terms of resistance to friction and wear is uniform. Indeed, if all the mineral fibers 12 have the same composition, then they have the same MOHS hardness.
• all the mineral fibers are distributed homogeneously in the friction material.
• the mineral fibers may be synthetic and / or natural and may include glass, ceramic material, basalt, slag, wollastonite and / or potassium titanate. Those skilled in the art can freely choose to use mineral fibers made of other materials that are exemplified and having characteristics, in particular mechanical and thermal, adapted to an aqueous impregnating cement.
• the mass quantity of mineral fibers 12 is greater than or equal to 1% of the total dry matter. According to one embodiment of the invention, the mass quantity of mineral fibers 12 is less than or equal to 10% of the total dry matter.
• the mineral fibers 12 comprise cut fibers.
• the mineral fibers 12 comprise crushed fibers.
• the invention also relates to a yarn 8 comprising mineral fibers 10 impregnated with an aqueous impregnating cement.
• impregnated is understood to include the impregnating cement which penetrates the gap between the mineral fibers of a yarn, around the mineral fibers 10, around the mineral fiber strand 10 and / or the core mineral fibers 10.
• the aqueous impregnating cement coats the mineral fibers 10, so that the lubricant charge complexes 2 and the lubricating fillers 6 are distributed homogeneously along the mineral fibers 10.
• the invention also relates to a friction material made from at least one thread 8 impregnated with an aqueous impregnating cement according to the invention.
• the friction material results from the drying of impregnated threads 8, the space between the mineral fibers 10 of each thread 8, and possibly the space between the threads, being filled with a solid material comprising the impregnating cement according to the invention. dried invention.
• an aqueous impregnating cement is an aqueous dispersion comprising:
• polymers 60 to 70% of polymers, of which: NBR latex, phenolic resin and melamine resin,
• a first complex of lubricating fillers based on metal and graphite sulphides comprising 20 to 50% by weight of medium density metal sulphides 4.3 and 40 to
• a second complex of metal sulphide-based lubricant fillers comprising 20 to 60% by mass of denser metal sulphides, of average density 6.2 and 40 to 80% by mass of metal sulphides minus dense, average density 4.7,
• the quotient of the mass fraction of the least dense lubricant load divided by the mass fraction of the densest lubricating charge is 0.8.
• the density quotient of the densest lubricating load divided by the density of the least dense lubricant load is 2.8.
• an aqueous impregnating cement is an aqueous dispersion comprising:
• polymers 60 to 70% of polymers, of which: NBR latex, phenolic resin and melamine resin,
• metal sulphide lubricant fillers comprising 20 to 60% by mass of denser metal sulphides, of average density 6.2 and 40 to 80% by mass of less dense metal sulphides , average density 4.7, - 3% calcium silicate,
• the quotient of the mass fraction of the least dense lubricant load divided by the mass fraction of the densest lubricating charge is 1, 4.
• the density quotient of the densest lubricating load divided by the density of the least dense lubricating load is 1.3.
• aqueous impregnating cements according to the first and second examples are diluted with water up to 35% water by mass, then homogenized by stirring and then left to stand.
• the aqueous impregnating cements according to the first and second examples are left standing for several hours. No settling occurs. The viscosity is high and remains at a constant level.
• the lubricating fillers are distributed homogeneously in the friction materials resulting from the drying of the first and second impregnating cement without phase separation.
• Chatter tests were carried out on friction materials resulting from the impregnation of yarns with aqueous impregnating cements according to the first and second examples.
• friction material known to those skilled in the art was also subjected to the same test.
• This friction material known to those skilled in the art is derived from an impregnating cement not comprising lubricating charge complexes.
• a grazing test consists of subjecting a manual transmission clutch equipped with two identical friction linings to cycles representing sloped starts at an energy of 50 kJ. The test is repeated for each friction material at different temperatures from 50 ° C to 320 ° C.
• the measurement points represented by squares show the response of the friction material according to example 1.
• the measuring points represented by crosses show the response of the friction material according to Example 2.
• the friction material according to Example 1 has the best average performance between 50 and 230 ° C with the lowest excitation coefficient of the three materials tested in this temperature range.
• the material according to Example 2 is the one with the best performance, with the lowest excitation coefficient of the three materials tested in this temperature range.
• a monolithic block made of a friction material is produced from an aqueous impregnating cement including in particular:
• a complex of lubricating fillers expressed as a mass fraction of the dry matter in the cement
• the complex of lubricating fillers comprising, expressed in mass fraction, 47.5% of graphite and 29.1% of sulphides of metals, the metal sulphides being a mixture of tin and zinc disulfides of average density 4.2.
• the quotient RI of the mass fraction of the graphite divided by the mass fraction of the metal sulfides is 1.63.
• the ash from the second calcination is analyzed by X-ray fluorescence to determine their metal sulfide composition.
• the absence of segregation of the charges is also verified by means of a scanning electron microscope coupled to an EDS (energy scanning X-ray spectroscopy) probe.
• EDS energy scanning X-ray spectroscopy
• the analyzes of the samples of the friction material produced from an impregnating cement according to the third example confirm, on the one hand, that the lubricant charge complexes are distributed homogeneously in the friction material, and on the other hand This is because graphite and metal sulphides are homogeneously distributed in the friction material, respectively.

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• 2017
  • 2017-09-29 FR FR1759084A patent/FR3071891B1/fr active Active
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