CN101300297A - 碳摩擦材料 - Google Patents
碳摩擦材料 Download PDFInfo
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- CN101300297A CN101300297A CNA2006800411498A CN200680041149A CN101300297A CN 101300297 A CN101300297 A CN 101300297A CN A2006800411498 A CNA2006800411498 A CN A2006800411498A CN 200680041149 A CN200680041149 A CN 200680041149A CN 101300297 A CN101300297 A CN 101300297A
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- 239000002783 friction material Substances 0.000 title claims abstract description 90
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 title claims abstract description 15
- 229910052799 carbon Inorganic materials 0.000 title claims abstract description 13
- 239000000463 material Substances 0.000 claims abstract description 105
- 229920005989 resin Polymers 0.000 claims abstract description 33
- 239000011347 resin Substances 0.000 claims abstract description 33
- 238000005245 sintering Methods 0.000 claims abstract description 22
- 239000002657 fibrous material Substances 0.000 claims abstract 3
- 239000000835 fiber Substances 0.000 claims description 47
- CREMABGTGYGIQB-UHFFFAOYSA-N carbon carbon Chemical compound C.C CREMABGTGYGIQB-UHFFFAOYSA-N 0.000 claims description 30
- 239000011203 carbon fibre reinforced carbon Substances 0.000 claims description 30
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 25
- 239000002245 particle Substances 0.000 claims description 23
- 238000000034 method Methods 0.000 claims description 18
- 229920003987 resole Polymers 0.000 claims description 14
- 229920000271 Kevlar® Polymers 0.000 claims description 11
- 239000004761 kevlar Substances 0.000 claims description 11
- 239000000377 silicon dioxide Substances 0.000 claims description 10
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 9
- 239000004917 carbon fiber Substances 0.000 claims description 9
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 9
- 239000003795 chemical substances by application Substances 0.000 claims description 8
- 239000008187 granular material Substances 0.000 claims description 7
- 238000009941 weaving Methods 0.000 claims description 6
- 238000005470 impregnation Methods 0.000 claims description 5
- 244000226021 Anacardium occidentale Species 0.000 claims description 4
- 235000020226 cashew nut Nutrition 0.000 claims description 4
- 229920002972 Acrylic fiber Polymers 0.000 claims description 3
- 238000007598 dipping method Methods 0.000 claims description 3
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- 238000004519 manufacturing process Methods 0.000 claims description 3
- 239000011148 porous material Substances 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 2
- 229910052782 aluminium Inorganic materials 0.000 claims description 2
- 239000004411 aluminium Substances 0.000 claims description 2
- 230000008878 coupling Effects 0.000 claims description 2
- 238000010168 coupling process Methods 0.000 claims description 2
- 238000005859 coupling reaction Methods 0.000 claims description 2
- 239000010439 graphite Substances 0.000 claims description 2
- 229910002804 graphite Inorganic materials 0.000 claims description 2
- 239000010466 nut oil Substances 0.000 claims description 2
- 229920001169 thermoplastic Polymers 0.000 claims description 2
- 239000004416 thermosoftening plastic Substances 0.000 claims description 2
- 239000011800 void material Substances 0.000 claims 3
- 239000004809 Teflon Substances 0.000 claims 1
- 229920006362 Teflon® Polymers 0.000 claims 1
- 125000003118 aryl group Chemical group 0.000 claims 1
- 239000003365 glass fiber Substances 0.000 claims 1
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 claims 1
- 150000002825 nitriles Chemical class 0.000 claims 1
- 239000007787 solid Substances 0.000 claims 1
- 239000002344 surface layer Substances 0.000 claims 1
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 abstract description 2
- 229920001568 phenolic resin Polymers 0.000 abstract description 2
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- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 6
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- -1 phenolic aldehyde Chemical class 0.000 description 6
- 230000008569 process Effects 0.000 description 6
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- 238000002474 experimental method Methods 0.000 description 4
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- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- 239000004593 Epoxy Substances 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 229910052757 nitrogen Inorganic materials 0.000 description 3
- 150000003839 salts Chemical class 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical group C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 229910002091 carbon monoxide Inorganic materials 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 2
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- 238000011160 research Methods 0.000 description 2
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- 229920002050 silicone resin Polymers 0.000 description 2
- 229920004935 Trevira® Polymers 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
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- 230000002085 persistent effect Effects 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 229960001866 silicon dioxide Drugs 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 239000002383 tung oil Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 230000004580 weight loss Effects 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
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- 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
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- 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
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/04—Carbon
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- 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
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- C08K7/00—Use of ingredients characterised by shape
- C08K7/22—Expanded, porous or hollow particles
- C08K7/24—Expanded, porous or hollow particles inorganic
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- 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
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Abstract
由在烧结前用树脂浸渍的纤维材料制成的烧结的碳摩擦材料。优选地,将非纺织纤维材料使用酚醛树脂进行浸渍并且在从400到8000℃进行烧结。所产生的材料具有按体积计高于百分之50的孔隙度。
Description
交叉引述
本申请要求2005年12月2日提交的美国临时专利申请序列号60/732,765的权益。
技术领域
本发明涉及通过烧结制成的碳摩擦材料。更确切地说,该烧结的碳摩擦材料是通过将树脂浸渍的纤维材料进行烧结而制成。
发明背景
汽车工业正在开发具有连续的滑动变矩器和换档离合器***的新颖并且先进的连续转矩传输***。这些新***通常涉及高的能量要求。因此,也必须开发摩擦材料技术以满足这些先进***不断增长的能量要求。
具体地说,需要一种新的高性能的、持久的摩擦材料。这一新摩擦材料必须能够承受高速度,其中表面速度是高达65m/秒。该摩擦材料还必须能够承受高达1500psi的表面衬层的压力。同样重要的是该摩擦材料在有限润滑条件下是有用的。
该摩擦材料必须是耐用的并且具有高耐热性以便有用于这些先进的***。该摩擦材料不仅必须在高温下保持稳定,它还必须能够迅速地将在运行条件下产生的高热量分散掉。
在这些新***接合和脱离接合过程中产生的高速度意味着一种摩擦材料必须能够在整个接合过程中保持一种相对恒定的摩擦。重要的是该摩擦接合必须在一个宽的速度和温度范围内是相对恒定的以便在制动过程中或在传送***在从一个档位到另一个档位的动力换档过程中使材料的“抖动”最小化。同样重要的是该摩擦材料具有一种希望的转矩曲线形状,这样在摩擦接合过程中该摩擦材料是无噪音或无“尖叫声”。
尽管酚醛树脂常规地用作湿摩擦材料中的一种浸渍剂用于湿式离合器应用,这些酚醛树脂具有不同的限制。这些酚醛树脂摩擦材料不具有与高能传输***一同使用所必须的高耐热性。特别是,这些酚醛树脂在大约300℃的温度下会分解,该温度太低而不能用于高能量应用中。此外,酚醛树脂是刚性材料并且当酚醛树脂用在摩擦材料中时,如果没有获得均匀的接触,就更有可能造成不均匀的衬层磨损,以及分离片“热点”。
鉴于对一种更好的摩擦材料的需求而进行的广泛研究的结果,本发明发展了一种具有改进特征的摩擦材料。该湿性摩擦材料在“湿”应用中是有用的,其中该摩擦材料在使用过程中是用一种液体(例如制动流体或自动传输流体)进行“湿润”或浸渍。在该“湿性”摩擦材料的使用过程中,流体最终从该摩擦材料中挤出或浸渍到该摩擦材料中。湿性摩擦材料在它们的组成和物理特征上均极大地不同于“干性”摩擦材料。
存在一种需要来继续研究“湿性”摩擦材料的增大的孔隙率。由造纸工艺制成的现有的“湿性”摩擦材料的开放的孔是按体积计大约百分之50。其他“湿性”摩擦材料(例如那些用挤压模制而制成的材料)的孔隙率按体积计低于百分之50。
发明内容
将纤维材料于400℃到800℃的温度范围进行烧结而制得独特的摩擦材料。这些纤维材料可以包含具有或没有填充剂和颗粒的不同纤维。这些材料在烧结之前首先使用树脂进行浸渍。所产生的材料是一种烧结的多孔碳体。这些纤维材料优选是纸和非纺织的纤维材料并且树脂优选是一种酚醛树脂。
本发明的烧结的碳摩擦材料具有按体积计实质上高于百分之50的开放孔隙率。当纤维/填充剂型的摩擦材料在低于550℃进行处理时,材料保持了足够的柔性和强度。孔的大小随着处理温度的增高而增大;表面也变得更加开放。摩擦系数随着处理温度的增加而增大;摩擦力-速度曲线变得更加有益/可取。
对于本领域的技术人员来说通过阅读以下这些优选实施方案以及附图的详细说明即可更加了解本发明的其他目的和优点。
附图简要说明
图1是根据本发明的碳化样品的一个侧视图。
图2是一个图表,示出本发明的碳化增强了压缩性。
图3是一个图表,示出了增强的碳化作用对孔大小的影响。
图4是一个图表,示出了增强的碳化作用对耐热性的影响。
本发明的详细说明
对于本发明有用的不同树脂包括酚醛树脂和酚醛基的树脂。应当理解被认为对本发明有用的不同的酚醛基树脂包括在树脂混合物中的其他的改性成分,例如环氧、丁二烯、有机硅、桐油、苯、腰果油、等。在酚醛改性的树脂中,该酚醛树脂大体上按重量计占树脂混合物(任何存在的溶剂除外)的50%或更大而存在。然而,已经发现,在某些实施方案中,当浸渍树脂混合物包含的有机硅树脂按重量计大约5%到大约80%,以及为了某些目的,按重量计大约15%到大约55%,以及在某些实施方案中按重量计大约15%到25%时,摩擦材料可以得到改进,这是基于有机硅-酚醛树脂混合物的重量(溶剂和其他处理酸除外)。
大体上,烧结的多孔体具有一个相当大的比表面积。此外,烧结的多孔体具有孔隙并且具有一个相当大的孔隙体积。这提供了具有一种开放孔结构的独特的烧结多孔体。
根据本发明,一种摩擦材料具有树脂在基体材料中的一种均匀的分散。在某些实施方案中,按重量计每100份的摩擦材料中该树脂材料包含大约按重量计45到大约65份。
在某些实施方案中,在树脂材料已被应用到基体材料,并且基体材料已经使用树脂混合物进行浸渍后,在一个预定的时间长度将该浸渍的基体材料加热到一个希望的温度以形成一种摩擦材料。然后,将固化的摩擦材料通过适当的手段粘连到一个希望的基质上。
图1是根据本发明的碳化样品的侧视图。该图示出了碳化前后的样品。
图2是一个图表,示出了本发明的碳化改进了压缩性。该碳化的纤维基体材料具有一种增加的压缩性,这改进了热点耐受性以及摩擦特征。
图3是一个图表,示出了增强的碳化作用对孔大小的影响。该图示出碳化作用增加了孔的大小。该图还示出碳化的温度越高,结构就越开放。
图4是一个图表,示出改进的碳化作用对耐热性的影响。该碳化的材料比原始的未碳化的材料具有更高的能量容量。
在某些实施方案中,优选的是由基体材料汲取树脂的目标值是按重量计在从大约25%到大约120%范围的总酚醛树脂材料,在其他实施方案中是在从大约40%到大约60%,并且在某些实施方案中则是在从大约60%到至少80%。在用树脂使基体材料饱和之后,将该基体材料在一段时间内(在某些实施方案中大约1/2小时)于范围在160-250℃之间的温度下进行固化以便使树脂材料固化并且形成摩擦材料。该摩擦材料的最终厚度取决于初始的基体材料的厚度。
进一步考虑到可以包含已知的在制备树脂混合物以及制备纤维基体材料中有用的其他成分和处理酸,并且它们是在本发明考虑的范围之内。
典型地是在一个惰性或还原气氛中进行烧结,例如氮气和氢气的一个混合物或还可以是包含一氧化碳(CO)的一个气体混合物。于是烧结部件经受一个加热相,在此过程中可能发生微观结构的转变。烧结可以在一种还原气体中进行,该气体自身不包括碳化合物,例如氮气与按体积计10%的氢气的混合物。
本发明的方法可以用于自身支持的烧结体的生产,例如具有自身支持骨架的烧结体。
基体材料
在本发明的摩擦材料中多种基体材料是有用的,包括,例如,非石棉的纤维基体材料包含(例如)纤维材料、纺织和/或非纺织材料。适当的纤维基体材料包括,例如,纤维和填充剂。这些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,聚酯纤维、尼龙纤维、聚酰胺纤维、棉/纤维素纤维等等。这些填充剂可以是,例如,硅石、硅藻土、石墨、铝、腰果树灰等等。
在其他实施方案中,基体材料可以包括纤维纺织材料,纤维非纺织材料和纸材料。此外,在本发明中有用的不同类型的纤维基体材料的多个实例披露在很多博格华纳的美国专利中。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体材料。
例如,在某些实施方案中,纤维基体材料包括一种纤维基体材料,其中较少的有原纤维组织的纤维和碳纤维被用在该纤维基体材料中以便为摩擦材料提供一种希望的孔结构。纤维的几何形状不仅提供了增加的耐热性,还提供了抗层离作用以及抗鸣响音或噪音作用。并且,在某些实施方案中,碳纤维以及碳纤维颗粒在纤维基体材料中的存在有助于增加耐热性、保持稳定的摩擦系数并且增加抗鸣响音作用。在纤维基体材料中可以包含一个相对低量的棉纤维以便改进摩擦材料的离合器“磨合(breake-in)”特性。
在本发明的纤维基体材料的主体层中不同的填充剂是有用的。特别是硅石填充剂,例如硅藻土是有用的。然而,考虑到其他类型的填充剂适合用于本发明并且填充剂的选择取决于摩擦材料的具体要求。
在优选的实施方案中,烧结的摩擦材料由芳族聚酰胺纤维制成。然而,烧结的纤维还可以是单独的丙烯酸纤维或与芳族聚酰胺纤维的组合。
在某些实施方案中,将棉纤维加入到本发明的纤维基体材料中以便使纤维材料有更高的摩擦系数。在某些实施方案中,大约5%到大约20%,而在某些实施方案中大约10%的棉纤维也可以加入到纤维基体材料中。
一种纤维基体材料的主体层配方的实例包括按重量计大约75%到大约85%的一种较少原纤维组织化的芳族聚酰胺纤维,以及按重量计大约15%到大约25%的一种填充剂材料。
在一些其他实施方案中,已经发现一个有用的具体的配方包括按重量计大约35%到大约45%的较少原纤维组织化的芳族聚酰胺纤维,大约5%到大约15%的绵纤维,按重量计大约2%到大约20%的碳纤维,以及按重量计大约25%到大约35%的填充剂。
在另外一些其他的实施方案中,该基体材料包括从大约15%到大约25%的绵纤维,大约40%到大约50%的芳族聚酰胺纤维,大约10%到大约20%的碳纤维,并且摩擦改性颗粒包括大约5%到大约15%的c盐,并且任选大约1%到大约3%的乳胶附加物。
当该纤维基体材料具有一个较高的平均孔径和流体通透性时,由于更好的自动传输流体流过该摩擦材料的多孔结构,该摩擦材料更加有可能更凉地运行或在一次传输中产生更少的热量。在传输***运行过程中,流体经过一段时间倾向于分解并且形成“油沉积物”,尤其是在较高的温度下。这些“油沉积物”降低了孔的开口。因此,当摩擦材料初始时以更大的孔开始运作,在摩擦材料的有用寿命中仍然还有更多开放的孔。
在纤维基体材料表面上的摩擦改性颗粒为所产生的摩擦材料提供了一种改进的三维结构。
在顶部的摩擦改性颗粒层上的油层或流体层在表面上保持了该油膜,因此使油或流体更难在初始时渗透到摩擦材料之中。该顶部的摩擦改性材料层保持了表面上的流体润滑剂并且增加了摩擦材料的保持油的能力。因此本发明的摩擦材料允许一个油膜保留在其表面。这还提供了良好的摩擦系数特性以及良好的滑动耐久特性。
在某些实施方案中,形成顶层的摩擦改性颗粒平均覆盖面积是在表面积的从大约80%到大约100%的范围。在某些实施方案中,平均覆盖面积的范围是从大约90%到大约100%。摩擦改性的颗粒实质上以一个优选的从大约35到200μm的平均厚度保留在基体材料的顶部表面上。在某些实施方案中,顶层具有一个优选的从大约60到大约100微米的平均厚度。
在纤维基体材料表面上摩擦改性颗粒沉淀层的均匀性是通过使用一个大小可以在范围从大约1到大约80微米直径的颗粒来实现的,并且在某些实施方案中从大约1到大约50微米,并且在其他一些实施方案中是从大约1到大约20微米。在某些实施方案中,这些颗粒具有大约12μm的平均颗粒直径。在某些实施方案中已经发现如果摩擦改性的颗粒尺寸太大或太小,就不能达到所希望的一种最佳三维结构,并且因此热分散和抗抖动特性就不是最佳的。
纤维基体材料上摩擦改性的颗粒的覆盖量是足够的厚以使摩擦改性颗粒层具有包含摩擦改性材料的单独颗粒以及在这些单独颗粒之间的空隙或间隙的一种三维结构。在某些实施方案中,(摩擦改性颗粒的)顶层比(纤维基体材料的)下层孔隙度更小。
在该摩擦材料中不同类型的摩擦改性颗粒是有用的。在一个实施方案中,有用的摩擦改性颗粒包括硅石颗粒。其他实施方案可以有摩擦改性颗粒例如树脂粉末,像酚醛树脂、有机硅树脂、环氧树脂以及它们的混合物。另外的其他实施方案可以包括部分和/或完全碳化的碳粉末和/或颗粒以及它们的混合物;以及此类摩擦改性颗粒的多种混合物。在某些实施方案中,硅石颗粒,例如硅藻土、Celite,Celatom、和/或二氧化硅尤其有用。硅石颗粒是与基体材料键合的价廉的无机材料。硅石颗粒为摩擦材料提供了高的摩擦系数。硅石颗粒还为基体材料提供一个光滑的摩擦表面并且提供一个良好的“换档触感“以及为摩擦材料提供了摩擦特性质使任何“抖动”最小化。
在某些实施方案中,在本发明的摩擦中包括摩擦材料顶层的这些摩擦改性材料可以具有一种不规则的形状。该不规则形状的摩擦改性颗粒的作用是在该纤维基体材料的表面保持一个所希望量的润滑剂,这是由于该不规则形状的摩擦改性颗粒的表面上很多内陷的毛细作用。在某些实施方案中,硅石颗粒例如c盐作为一种摩擦改性材料是有用的,因为c盐具有一种不规则或粗糙的表面。
在某些实施方案中,该摩擦材料包括其中具有多个孔隙或间隙的一种纤维基体材料。在纤维基体材料中这些孔隙的大小可以是在从大约0.5μ到大约20μm的范围。
在某些实施方案中,该摩擦基体材料优选具有大约50%到60%的孔隙体积,这样与一种“多孔的”的纺织材料相比该摩擦基体材料被认为是“致密的”。在某些实施方案中,树脂材料至少部分地填充到纤维基体材料的孔隙中。该树脂材料实质上是均匀地分散在基体材料的整个厚度上。
实例
以下实例进一步提供证明,证明本发明的摩擦材料提供了一种超过常规摩擦材料的改进。
具有一种开放的三维结构并且其中具空隙的烧结的多孔碳是按以下方式生产。制造烧结的碳摩擦材料的方法包括以下步骤,在烧结前使用一种树脂浸渍纤维材料;烧结树脂浸渍的纤维材料;并且生产一种烧结的碳摩擦材料。该浸渍是用一种酚醛树脂来进行,并且该烧结是在一个600℃的温度下进行。纤维材料是非纺织的芳族聚酰胺纤维。
然后将烧结的多孔碳与一种基体材料一同使用。基体材料典型地包含按重量计大约5%到75%的一种芳族聚酰胺纤维,按重量计大约5%到大约75%的棉纤维,按重量计大约5%到大约75%的碳纤维,以及按重量计大约5%到大约75%的一种填充剂材料。
烧结方法包括的步骤有压紧原料纸片以便形成一种强度更好的密集的纸片,为了更好的强度在固化过程之中或之后压紧纸片并且为了更好的强度而使用高树脂汲取率(60%-150%)。该树脂包括酚醛的、改性酚醛的、环氧的、其他类型的有机树脂、陶瓷树脂等等。优选地,我们在氮气、氩气、水蒸汽、氨、胺等等中在从400到800℃的温度下烧结该材料。
本发明的碳摩擦材料的应用包括高压力(高达20MPa)以及高能量的***。其他应用包含低以及有限油流动或干燥条件的***。
表I示出用于碳化样品的材料处理。
表I
中间实验ID | A | B |
厚度(实际) | 0.031” | 0.031” |
方法一 | 大小到0.025” | 大小到0.025” |
方法二 | 60%PU | 60%PU |
烧结后的厚度 | 0.0245” | 0.0285” |
烧结后重量损失(%) | 12% | 9% |
实验的片厚度(测量值) | 0.023” | 0.023” |
实验的片密度(g/cm3) | 0.73 | 0.77 |
表II示出了烧结材料在油湿润、半干燥的耐用性实验中的结果。
表II
样品 | 对照(C) | 烧结后的C |
衬片厚度变化和衬片条件 | 0.001mm(0.2%)OK | 0.000mm(0.7%增加)OK |
分离片条件 | 黑色染色 | 热染色 |
摩擦水平变化 | 0.143-0.106-->26% | 0.121-0.139-->+13% |
总周期 | 1377 | 2226 |
结果显示
1.烧结的C比非烧结的具有更好的下行曲线。
2.烧结的C的mu水平随着实验周期而增加。
3.未处理的C比其他材料具有更大的摩擦消退。
可见,本发明的烧结的碳摩擦材料比对比材料始终表现更好。因此,本发明的纤维基体材料在更高的速度下比对比材料表现要好得多。
4.烧结C比对照C样品具有更好的耐用性。
工业实用性
本发明作为一种高能量摩擦材料与离合器片、传输带、制动蹄、同步器环、摩擦盘或***板一同使用是有用的。本发明优选的以及可替代的实施方案的以上说明是为了说明的目的而并非为了限制以下权利要求的范围和内容。
本发明的以上详细说明是为了解释性目的而给出。显然对于本领域的技术人员来说无需脱离本发明的范围即可以进行多种的修改和变换。因此,以上全部说明应以一种说明性而非限制性的意义来进行解释,本发明的范围仅由所附的权利要求来定义。
Claims (32)
1.由在烧结前使用树脂浸渍的纤维材料制成的烧结的碳摩擦材料,其中该烧结的材料比原物具有一个更开放的孔隙度。
2.根据权利要求1的烧结的碳摩擦材料,其中该材料是一种烧结的多孔碳体,它具有按体积计至少百分之50的孔隙度。
3.根据权利要求2的烧结的碳摩擦材料,其中该烧结的多孔体具有一个相当大的比表面积。
4.根据权利要求2的烧结的碳摩擦材料,其中该烧结的多孔体是由芳族聚酰胺制成。
5.根据权利要求2的烧结的碳摩擦材料,其中该烧结的多孔体具有孔隙并且具有一个相当大的孔隙体积。
6.根据权利要求2的烧结的碳摩擦材料,其中该烧结的多孔体具有一种开放的孔结构。
7.根据权利要求1的烧结的碳摩擦材料,其中这些纤维材料是芳族聚酰胺纤维、纤维素纤维、有机纤维、玻璃纤维、碳纤维、或丙烯酸纤维或其他的合成纤维。
8.根据权利要求1的烧结的碳摩擦材料,具有一种高于百分之40的增加的树脂汲取。
9.根据权利要求1的烧结的碳摩擦材料,具有一种高于百分之60的增加的树脂汲取。
10.根据权利要求7的烧结的碳摩擦材料,包括至少一种填充剂,选自硅石、硅藻土、石墨、铝、腰果树灰、摩擦颗粒、碳颗粒、腈、腰果油颗粒、固体润滑剂,特氟龙以及二硫化钼组成的组。
11.根据权利要求1的烧结的碳摩擦材料,其中该烧结纤维材料是芳族聚酰胺纤维、丙烯酸纤维或它们的一个组合。
12.根据权利要求1的烧结的碳摩擦材料,其中该纤维材料是纺织、纸或非纺织型的纤维材料。
13.根据权利要求1的烧结的碳摩擦材料,其中该纤维材料是非纺织的纤维材料。
14.根据权利要求1的烧结的碳摩擦材料,其中该树脂是一种酚醛树脂。
15.根据权利要求2的烧结的碳摩擦材料,其中该烧结的多孔碳体是一种开放的三维结构,其中具有空隙。
16.由在烧结前使用树脂浸渍的纤维材料制成的烧结的碳摩擦材料,其中该烧结的材料是一种烧结的多孔的碳体,它具有一种大孔隙度。
17.根据权利要求16的烧结的碳摩擦材料,其中该烧结的多孔的体具有按体积计从高于50%到85%范围的一个平均空隙体积,并且其中该烧结的多孔体具有直径在平均大小从大约5到大约100微米范围的孔。
18.根据权利要求16的烧结的碳摩擦材料,其中该烧结的多孔体具有按体积计从高于60%到85%范围的一个平均空隙体积,并且其中该烧结的多孔体具有直径在平均大小从大约5到大约50微米范围的孔。
19.根据权利要求16的烧结的碳摩擦材料,其中该烧结的多孔的体具有按体积计从65%到85%范围的一个平均空隙体积,并且其中该烧结的多孔体具有直径在平均大小从大约5到大约25微米范围的孔。
20.与一种基体材料一同使用的根据权利要求1的摩擦材料,其中该基体材料包含按重量计大约5%到75%的一种芳族聚酰胺纤维,按重量计大约5%到大约75%的纤维素纤维,按重量计大约5%到大约75%的碳纤维,以及按重量计大约5%到大约75%的一种填充剂材料。
21.传送带形式的根据权利要求20的摩擦材料。
22.一种离合器面层形式的根据权利要求20的摩擦材料。
23.一种制动蹄形式的根据权利要求20的摩擦材料。
24.一种同步器形式的根据权利要求20的摩擦材料。
25.一种制造烧结的碳摩擦材料的方法,包括以下步骤:
在烧结前使用一种树脂浸渍纤维材料;
在从400到800℃范围的一个温度下烧结该树脂浸渍的纤维材料;并且
生产一种烧结的碳摩擦材料,其中该烧结的材料具有一个按体积计高于百分之50的孔隙度。
26.根据权利要求25的一种方法,其中所生产的烧结的碳摩擦材料是一种烧结的多孔碳体。
27.根据权利要求25的一种方法,其中该浸渍是用一种酚醛树脂来进行。
28.根据权利要求25的一种方法,其中该烧结是在从400℃到600℃范围的一个温度下进行。
29.根据权利要求25的一种方法,其中这些纤维材料是非纺织、纺织或纸纤维材料。
30.根据权利要求25的一种方法,其中该烧结的多孔碳体是一种开放的三维结构,其中具有空隙。
31.根据权利要求25的一种方法,其中该烧结的多孔碳体是一种自身支持骨架。
32.根据权利要求25的一种方法,其中该烧结是在从400℃到550℃范围的一种温度下进行的。
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JP (1) | JP5043024B2 (zh) |
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- 2006-10-31 KR KR1020087012560A patent/KR20080064890A/ko not_active Application Discontinuation
- 2006-10-31 WO PCT/US2006/042342 patent/WO2007055951A1/en active Application Filing
- 2006-10-31 EP EP06827098.2A patent/EP1943300B1/en not_active Expired - Fee Related
- 2006-10-31 JP JP2008538950A patent/JP5043024B2/ja not_active Expired - Fee Related
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2013
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Cited By (4)
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CN106460981A (zh) * | 2014-05-21 | 2017-02-22 | 舍弗勒技术股份两合公司 | 用于制造湿式摩擦衬片的方法和湿式摩擦衬片 |
CN107922666A (zh) * | 2015-08-24 | 2018-04-17 | 摩根先进材料与技术公司 | 包括石墨粒子的物品的制备 |
CN107922666B (zh) * | 2015-08-24 | 2020-07-17 | 摩根先进材料与技术公司 | 包括石墨粒子的物品的制备 |
CN107477116A (zh) * | 2017-09-29 | 2017-12-15 | 北京天宜上佳新材料股份有限公司 | 一种具有多孔结构的降噪摩擦体和降噪摩擦块及制备方法 |
Also Published As
Publication number | Publication date |
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EP1943300A1 (en) | 2008-07-16 |
WO2007055951A1 (en) | 2007-05-18 |
JP2009514767A (ja) | 2009-04-09 |
US20130288552A1 (en) | 2013-10-31 |
EP1943300B1 (en) | 2016-07-06 |
US20100304631A1 (en) | 2010-12-02 |
JP5043024B2 (ja) | 2012-10-10 |
EP1943300A4 (en) | 2010-04-28 |
US8394452B2 (en) | 2013-03-12 |
KR20080064890A (ko) | 2008-07-09 |
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