CN109608710B - Manufacturing method of friction lining and brake pad - Google Patents
Manufacturing method of friction lining and brake pad Download PDFInfo
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- CN109608710B CN109608710B CN201811616994.4A CN201811616994A CN109608710B CN 109608710 B CN109608710 B CN 109608710B CN 201811616994 A CN201811616994 A CN 201811616994A CN 109608710 B CN109608710 B CN 109608710B
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- parts
- friction lining
- rubber
- graphite
- minutes
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 27
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 82
- 239000010439 graphite Substances 0.000 claims abstract description 65
- 229910002804 graphite Inorganic materials 0.000 claims abstract description 65
- 238000002156 mixing Methods 0.000 claims abstract description 54
- 238000000034 method Methods 0.000 claims abstract description 42
- 238000004898 kneading Methods 0.000 claims abstract description 40
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims abstract description 34
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims abstract description 34
- 239000000843 powder Substances 0.000 claims abstract description 33
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 28
- 230000003712 anti-aging effect Effects 0.000 claims abstract description 27
- 239000000835 fiber Substances 0.000 claims abstract description 22
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 19
- 239000007822 coupling agent Substances 0.000 claims abstract description 19
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims abstract description 19
- 229910010271 silicon carbide Inorganic materials 0.000 claims abstract description 19
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 18
- 229910001570 bauxite Inorganic materials 0.000 claims abstract description 18
- 239000010959 steel Substances 0.000 claims abstract description 18
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims abstract description 17
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 17
- 235000021355 Stearic acid Nutrition 0.000 claims abstract description 17
- 239000006230 acetylene black Substances 0.000 claims abstract description 17
- 239000004917 carbon fiber Substances 0.000 claims abstract description 17
- 239000010433 feldspar Substances 0.000 claims abstract description 17
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 claims abstract description 17
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 claims abstract description 17
- 229920001568 phenolic resin Polymers 0.000 claims abstract description 17
- 239000005011 phenolic resin Substances 0.000 claims abstract description 17
- 239000002994 raw material Substances 0.000 claims abstract description 17
- 239000008117 stearic acid Substances 0.000 claims abstract description 17
- 239000011787 zinc oxide Substances 0.000 claims abstract description 17
- 229920003048 styrene butadiene rubber Polymers 0.000 claims abstract description 14
- 239000005062 Polybutadiene Substances 0.000 claims abstract description 13
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229920002857 polybutadiene Polymers 0.000 claims abstract description 13
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims abstract description 11
- 239000000463 material Substances 0.000 claims description 72
- 229920001971 elastomer Polymers 0.000 claims description 63
- 239000005060 rubber Substances 0.000 claims description 63
- 239000000853 adhesive Substances 0.000 claims description 33
- IANQTJSKSUMEQM-UHFFFAOYSA-N 1-benzofuran Chemical compound C1=CC=C2OC=CC2=C1 IANQTJSKSUMEQM-UHFFFAOYSA-N 0.000 claims description 30
- 238000005096 rolling process Methods 0.000 claims description 30
- WPYMKLBDIGXBTP-UHFFFAOYSA-N benzoic acid Chemical compound OC(=O)C1=CC=CC=C1 WPYMKLBDIGXBTP-UHFFFAOYSA-N 0.000 claims description 20
- 239000010410 layer Substances 0.000 claims description 19
- 238000010074 rubber mixing Methods 0.000 claims description 19
- 230000001070 adhesive effect Effects 0.000 claims description 17
- 239000004568 cement Substances 0.000 claims description 17
- 229920000715 Mucilage Polymers 0.000 claims description 16
- 239000002245 particle Substances 0.000 claims description 16
- 239000000203 mixture Substances 0.000 claims description 14
- 239000002356 single layer Substances 0.000 claims description 14
- 238000005303 weighing Methods 0.000 claims description 14
- 238000005520 cutting process Methods 0.000 claims description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 12
- 239000012286 potassium permanganate Substances 0.000 claims description 11
- 238000003825 pressing Methods 0.000 claims description 11
- 238000007670 refining Methods 0.000 claims description 11
- 239000005711 Benzoic acid Substances 0.000 claims description 10
- 235000010233 benzoic acid Nutrition 0.000 claims description 10
- 238000004073 vulcanization Methods 0.000 claims description 10
- 238000010438 heat treatment Methods 0.000 claims description 8
- 238000003723 Smelting Methods 0.000 claims description 6
- 239000011230 binding agent Substances 0.000 claims description 5
- 238000001035 drying Methods 0.000 claims description 5
- 238000003756 stirring Methods 0.000 claims description 5
- 238000005238 degreasing Methods 0.000 claims description 4
- 238000013461 design Methods 0.000 claims description 4
- 238000007654 immersion Methods 0.000 claims description 4
- 238000010030 laminating Methods 0.000 claims description 4
- 238000007493 shaping process Methods 0.000 claims description 4
- 238000005406 washing Methods 0.000 claims description 4
- 239000000428 dust Substances 0.000 claims description 3
- 230000008569 process Effects 0.000 abstract description 22
- 230000017525 heat dissipation Effects 0.000 abstract description 15
- VKYKSIONXSXAKP-UHFFFAOYSA-N hexamethylenetetramine Chemical compound C1N(C2)CN3CN1CN2C3 VKYKSIONXSXAKP-UHFFFAOYSA-N 0.000 abstract description 14
- 235000010299 hexamethylene tetramine Nutrition 0.000 abstract description 7
- 239000004312 hexamethylene tetramine Substances 0.000 abstract description 7
- XAEFZNCEHLXOMS-UHFFFAOYSA-M potassium benzoate Chemical compound [K+].[O-]C(=O)C1=CC=CC=C1 XAEFZNCEHLXOMS-UHFFFAOYSA-M 0.000 abstract description 7
- 235000010235 potassium benzoate Nutrition 0.000 abstract description 3
- 239000004300 potassium benzoate Substances 0.000 abstract description 3
- 229940103091 potassium benzoate Drugs 0.000 abstract description 3
- 239000000126 substance Substances 0.000 description 22
- 230000009286 beneficial effect Effects 0.000 description 9
- 230000000694 effects Effects 0.000 description 9
- 230000001976 improved effect Effects 0.000 description 9
- 230000006870 function Effects 0.000 description 7
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- 238000012360 testing method Methods 0.000 description 7
- 238000005336 cracking Methods 0.000 description 6
- 238000005299 abrasion Methods 0.000 description 5
- 239000002253 acid Substances 0.000 description 5
- 230000002829 reductive effect Effects 0.000 description 5
- 230000003014 reinforcing effect Effects 0.000 description 5
- 239000010425 asbestos Substances 0.000 description 4
- 239000012752 auxiliary agent Substances 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 238000006555 catalytic reaction Methods 0.000 description 4
- 230000008859 change Effects 0.000 description 4
- 230000006835 compression Effects 0.000 description 4
- 238000007906 compression Methods 0.000 description 4
- 230000007547 defect Effects 0.000 description 4
- 239000003365 glass fiber Substances 0.000 description 4
- 230000020169 heat generation Effects 0.000 description 4
- 230000003647 oxidation Effects 0.000 description 4
- 238000007254 oxidation reaction Methods 0.000 description 4
- 230000009467 reduction Effects 0.000 description 4
- 229910052895 riebeckite Inorganic materials 0.000 description 4
- 238000005452 bending Methods 0.000 description 3
- 239000012876 carrier material Substances 0.000 description 3
- 230000002708 enhancing effect Effects 0.000 description 3
- 238000002474 experimental method Methods 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 230000006798 recombination Effects 0.000 description 3
- 238000005215 recombination Methods 0.000 description 3
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 230000003213 activating effect Effects 0.000 description 2
- 230000032683 aging Effects 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 230000000295 complement effect Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 239000002783 friction material Substances 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 238000013040 rubber vulcanization Methods 0.000 description 2
- 238000010008 shearing Methods 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- KGRVJHAUYBGFFP-UHFFFAOYSA-N 2,2'-Methylenebis(4-methyl-6-tert-butylphenol) Chemical group CC(C)(C)C1=CC(C)=CC(CC=2C(=C(C=C(C)C=2)C(C)(C)C)O)=C1O KGRVJHAUYBGFFP-UHFFFAOYSA-N 0.000 description 1
- 239000004606 Fillers/Extenders Substances 0.000 description 1
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 1
- 239000004902 Softening Agent Substances 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 230000005587 bubbling Effects 0.000 description 1
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical compound C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 230000000711 cancerogenic effect Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 231100000315 carcinogenic Toxicity 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 229910052681 coesite Inorganic materials 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000010410 dusting Methods 0.000 description 1
- 238000004945 emulsification Methods 0.000 description 1
- 230000001804 emulsifying effect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 238000003286 fusion draw glass process Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- -1 hexa-potassium-ethylene tetramine Chemical compound 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
- 230000002452 interceptive effect Effects 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- 238000005461 lubrication Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000013081 microcrystal Substances 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 238000006748 scratching Methods 0.000 description 1
- 230000002393 scratching effect Effects 0.000 description 1
- 238000004904 shortening Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- KHDSWONFYIAAPE-UHFFFAOYSA-N silicon sulfide Chemical compound S=[Si]=S KHDSWONFYIAAPE-UHFFFAOYSA-N 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 229910052682 stishovite Inorganic materials 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
- 229920003051 synthetic elastomer Polymers 0.000 description 1
- 239000005061 synthetic rubber Substances 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 230000001988 toxicity Effects 0.000 description 1
- 231100000419 toxicity Toxicity 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 229910052905 tridymite Inorganic materials 0.000 description 1
- 239000012936 vulcanization activator Substances 0.000 description 1
- 239000004636 vulcanized rubber Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L9/00—Compositions of homopolymers or copolymers of conjugated diene hydrocarbons
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L61/00—Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
- C08L61/04—Condensation polymers of aldehydes or ketones with phenols only
- C08L61/06—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L9/00—Compositions of homopolymers or copolymers of conjugated diene hydrocarbons
- C08L9/06—Copolymers with styrene
-
- 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
- F16D69/023—Composite materials containing carbon and carbon fibres or fibres made of carbonizable material
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend
-
- 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
- F16D2200/0034—Materials; Production methods therefor non-metallic
- F16D2200/0052—Carbon
-
- 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
- F16D2200/0082—Production methods therefor
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Health & Medical Sciences (AREA)
- General Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Manufacture Of Macromolecular Shaped Articles (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Braking Arrangements (AREA)
Abstract
The invention relates to a manufacturing method of a friction lining and a brake pad, which is characterized in that butadiene rubber, styrene-butadiene rubber, graphite, reduced iron powder, sulfur powder, barium sulfate, zinc oxide, phenolic resin, feldspar powder, silicon carbide, acetylene black, bauxite, steel fiber, carbon fiber, an anti-aging agent, a coupling agent, an accelerator, hexamethylenetetramine, potassium benzoate, stearic acid and other raw materials are reasonably selected and mixed, and the friction lining is prepared by adopting the processes of plastication, mixing, kneading and remixing, and then is pressed, refitted and vulcanized into the brake pad, so that the brake pad has stable friction coefficient, strong wear resistance and heat dissipation capacity and low cost.
Description
Technical Field
The invention belongs to the field of brake materials, relates to a friction lining and a method for preparing a brake pad by using the friction lining, and particularly relates to a method for preparing the friction lining by adopting plastication, mixing and kneading processes and a method for preparing the brake pad by using the friction lining.
Background
The friction material is widely applied to braking of ships, armored vehicles and the like of trains and automobiles (large-load transportation automobiles and cars). Most of the existing friction materials are prepared by plasticating rubber and plastic respectively, then mixing the rubber and the plastic together, then crushing the mixed materials, adding iron powder, an accelerator, an anti-aging agent, crushed asbestos and glass fiber, uniformly mixing the materials to prepare sheets or particles, putting the sheets or particles into a mould for pressing, vulcanizing and curing the sheets or the particles to obtain finished products, and the main problems exist: (1) the materials are added with carcinogenic asbestos and glass fiber, and the brake pad can generate dust by friction in the working process, release harmful substances to pollute the environment and harm health. (2) The proper working temperature of the brake pad is 100-350 ℃, but the friction performance requirement under high heat during vehicle braking is difficult to meet due to poor heat resistance, unstable high-temperature friction coefficient and poor impact resistance, and the friction coefficient of many inferior brake pads is rapidly reduced when the temperature reaches 250 ℃, so that brake failure is caused. (3) Rubber and plastic are respectively plasticated, then the mixture is further mixed, the mixed mixture is crushed, and then the iron powder, the accelerator, the anti-aging agent, the crushed asbestos and the glass fiber are added and mixed, so that the molecular activation level is low during preparation, the bonding force of a molecular chain is not strong, and the product is easy to crack, bubble, rugged, warped, twisted, crack and break. (4) The friction coefficient is too high or too low, the braking is insensitive when the friction coefficient is too low, and the tire locking phenomenon when the friction coefficient is too high, so that the tail flicking and the slipping of the vehicle are caused, and the driving safety is seriously threatened. In addition, a high coefficient of friction can cause vehicle shudder, noise, and wear during braking. (5) The hardness is unreasonable to control, either the wear resistance is poor or the surface hardness is too high, so that the actual contact area of the brake pad and the brake disc is small, and the problems of wheel scratch, heat crack, hot spot, metal inlay, high noise and the like are easily caused. (6) The pressing and vulcanizing processes are combined, the vulcanization needs high temperature for 1-1.5 hours, the pressing needs high-pressure equipment, one mold can only produce one brake pad at a time, the process has high equipment requirement, low production efficiency and high cost, and defective products cannot be screened and repaired after the pressing, so that the process is wasted and the rejection rate is high. (7) Although pressing and vulcanizing procedures are separated in some enterprises, the products are easy to crack and deform in the vulcanizing process due to unreasonable earlier procedures, an anti-cracking and anti-deformation mold needs to be additionally arranged and then the products are vulcanized in a vulcanizing box to form finished products, and the procedures are complicated and high in cost.
Disclosure of Invention
The invention aims to provide a novel friction lining and brake pad forming process, which prepares the friction lining by reasonably selecting and matching raw materials and adopting the working procedures of plastication, mixing, kneading and remixing, and then presses, refits and vulcanizes the friction lining into the brake pad, and the brake pad has stable friction coefficient, strong wear resistance and heat dissipation capacity and low cost.
The invention relates to a preparation method of a friction lining, which comprises the following steps:
A. plasticating: weighing 6-8 parts by weight of butadiene rubber and styrene butadiene rubber, mixing the butadiene rubber and the styrene butadiene rubber in a ratio of 1:1, conveying the mixture to a rubber refining machine, adjusting the roller spacing of the rubber refining machine to repeatedly plasticate the mixture until the rubber sheet is flat, bright, smooth and crack-free, and flatly placing the rubber sheet in a shade place for naturally airing for 3-5 days;
B. infiltrating graphite: weighing 30-40 parts by weight of graphite, immersing the graphite in 0.002-0.01mol/L potassium permanganate solution, preferably without dust, wherein the weight of potassium permanganate solution is 1.5-2.5 times that of the graphite according to the humidity of the graphite, and drying in a constant temperature box after uniform immersion;
C. primary mixing: the circulating water temperature of the roller of the rubber mixing machine is 15-20 ℃,
c1, rewetting: the rubber sheets dried in the step A are sent to a rubber mixing mill to be repeatedly refined for 2 to 3 times,
c2, primary mixing: b, adding the graphite in the step B while adjusting the roller spacing, smelting until the graphite completely enters the film, adding 0-2 parts by weight of plasticizing softener according to the graphite entering condition,
c3, remixing: repeatedly mixing the primarily mixed films for 3-5 times to prepare prefabricated films;
D. kneading: weighing 4-8 parts of sulfur powder, 4-7 parts of acetylene black, 1-2 parts of coupling agent, 1-3 parts of bauxite, 2-4 parts of silicon carbide, 1-3 parts of zinc oxide, 3-4 parts of barium sulfate, 2-5 parts of feldspar powder, 6-10 parts of steel fiber, 6-8 parts of carbon fiber, 7-11 parts of reduced iron powder, 5-8 parts of phenolic resin, 0.5-1 part of anti-aging agent, 1.5-4 parts of promoter and 1-6 parts of plasticizing softener according to parts by weight, adding the raw materials into a kneader, kneading the raw materials at the temperature of 100-120 ℃ for 5-8 minutes to prepare a kneaded material;
E. and (3) secondary mixing: and C, conveying the prefabricated rubber sheet in the step C to a rubber mixing mill, wherein the circulating water temperature of a roller of the rubber mixing mill is 15-20 ℃, the temperature of a front roller is 8-10 ℃ lower than that of a rear roller, the roller spacing is adjusted, kneading materials are added while the roller spacing is refined, the mixture is mixed for 5-8 minutes, the roller spacing is adjusted to the designed thickness, and the mixture is mixed for 20-25 minutes to form the friction lining which is uniformly mixed, flat, bright, smooth and crack-free.
In the preparation process of the friction lining, plastication, primary mixing, kneading and secondary mixing processes are included. The plastication process is to plasticate the butadiene and the styrene butadiene rubber in a rubber mixing mill according to the weight ratio of 1: 1. The primary mixing is to mix the treated graphite with the plasticated rubber. The treatment method of the graphite comprises the following steps: soaking the graphite in 0.002-0.01mol/L potassium permanganate solution uniformly and then drying; according to the humidity of the graphite, the weight of the potassium permanganate solution is 1.5-2.5 times of that of the graphite, the potassium permanganate solution and the graphite are mixed to form flocculence, and the graphite is flake graphite with 100 meshes. The kneading is to knead the phenolic resin in the raw materials with acetylene black, coupling agent, hexa-potassium-methylene tetramine, bauxite, silicon carbide, zinc oxide, barium sulfate, feldspar powder, steel fiber, carbon fiber, reduced iron powder, phenolic resin, anti-aging agent, promoter and plasticizing softener in a kneader for 5-8 minutes at the temperature of 100 ℃ and 120 ℃. Wherein the steel fiber is produced by a fusion-drawing method. The secondary kneading is to knead the rubber pieces after the primary kneading and the kneaded material after the primary kneading. The auxiliary agent is selectively added in the primary mixing and secondary mixing processes according to the rubber condition during plastication, and if the rubber has better plasticizing property and softening degree and is easy to mix, the auxiliary agent can be completely added in the kneading step. On the contrary, a small amount of auxiliary agent is added in the primary mixing and the secondary mixing.
Further, the plasticating process in the step A is adjusting roll spacing for longitudinal and transverse sheet rolling, and comprises the following steps:
a1, plasticating for 3-5 minutes at a roller spacing of 1-3mm,
a2, plasticating for 3 to 4 minutes at a roller spacing of between 5 and 8mm,
a3, plasticating for 5-6 minutes at a roller spacing of 1-3mm,
a4, and plasticating for 3-5 times at a roll spacing of 0.5-1 mm.
The steps a1, a2, a3 and a4 comprise the step of laminating 2-3 layers of plastication on films, and the thickness of the laminated films is larger than 1mm of the pre-plastication roller distance.
During plastication, the water temperature of 15-20 ℃ is helpful for activating the flexibility of the rubber, the shearing effect of the step a1 is good, the heat generation is large, the viscosity of the rubber compound is reduced, the longitudinal stretching of the rubber is facilitated, and the combination of the two rubbers in the longitudinal direction and the extension in the transverse direction are enhanced. The step a2 requires 2-3 plastication of the film obtained in the step a1 by stacking, and can enhance flexibility and make mixing uniform. The step a3 can firstly extend the film of the step a2 in a single layer, and can enhance the bonding force and the flatness in thickness and avoid cracks. and a4, single-layer thin pass plastication or stacking plastication is carried out on the basis of the a3 step, so that the tensile force, the bonding force and the flatness of the film are further increased, and the film is more flexible, smooth and flat. Thus, the repeated plastication with different roller distances, different time and different directions can obtain better plasticity, flexibility and strength, the rubber molecular chains are recombined for many times, the graphite can be favorably eaten in the subsequent steps, the excessive plastication is avoided, the power consumption is increased, and the strength, the elasticity and the wear resistance of the rubber are reduced.
And step c1, the method comprises the step of laminating 2-3 layers of plasticated films, wherein the thickness of the laminated films is more than 1mm of the pre-plasticated roller spacing. In step c1, longitudinal and transverse rolling sheets are rewetted by changing the roller spacing between 2mm and 3 mm.
In step c2, changing the roll distance between 2mm and 4mm, and primarily mixing longitudinally and transversely in a single-layer rolling way; in the step c3, the longitudinal and transverse sheet rolling and remixing are carried out by changing the roller spacing between 2mm and 4mm, the step of plasticating by overlapping 2-3 layers of films is included, and the thickness of the overlapped films is more than 1mm of the roller spacing of the pre-refining.
And step E, changing the roll spacing between 3mm and 5mm, carrying out single-layer longitudinal rolling and transverse rolling, gradually feeding the kneaded material, adjusting the roll spacing to the designed thickness, and carrying out single-layer longitudinal rolling and transverse rolling or double-layer laminating rolling and sheet mixing for 20-25 minutes. In step E, 0 to 2 parts by weight of a plasticizing softener is added according to the feeding of the kneaded material. The plasticizing softener is a mixture of benzoic acid, stearic acid and coumarone, and the weight ratio of the benzoic acid to the stearic acid to the coumarone is 2:1
The stack plastication can be convenient for misce bene on the one hand, strengthens the calendering effect, and on the other hand need avoid the number of piles too much, cuts the transition and causes the swell, influences roughness and smooth degree.
In the preparation method, plastication can reduce the elasticity of rubber, improve the plasticity and activate the flexibility of the rubber, thereby providing a foundation for subsequent graphite feeding and mixing with kneading materials. In the kneading process, materials are subjected to strong kneading effects of continuous change and repeated shearing, tearing, stirring and friction, the materials are fully fused, the physical and chemical properties are changed, the molecules are recombined, the molecular chains are tightly combined, and the strength is increased. The kneading temperature is controlled to ensure the melting of each material, which is beneficial to mixing, and to avoid the reduction of physical and mechanical properties caused by the over-high temperature which is not beneficial to the crushing and dispersion of particles. The kneading time is controlled to ensure the dispersion degree of the materials, so that enough time is provided for matter recombination and molecular chain combination, such as chemical and physical catalysis of reduced iron powder on bauxite, zinc oxide, silicon carbide, barium sulfate and feldspar powder, crosslinking of phenolic resin and deoxidation of silicon sulfide, and reduction of physical and mechanical properties and reduction of production efficiency caused by overlong time are avoided. The kneading step facilitates the binding of new chemical substances, can achieve a high degree of plasticity in a short time, and contributes to the friction lining to achieve desired mechanical strength, wear resistance and heat resistance. The plasticizing softener, the accelerator and the anti-aging agent are beneficial to improving the kneading effect and shortening the kneading time. The roller temperature is controlled at 15-20 ℃, equipment cannot be damaged due to too low temperature, and the low-melting-point material can be prevented from being damaged due to too high temperature. The rubber sheet is axially and radially uniform by virtue of transverse and longitudinal alternate refining, and the successive generation structures of the rubber are vertically and horizontally complementary. In the secondary mixing process, the roller distance is adjusted to 3-5mm firstly, so that the film is thick and is convenient for adding the kneading materials, the temperature of the front roller is 8-10 ℃ lower than that of the rear roller, the phenomenon that the film tightly embraces the front roller, the film is separated from the roller to form a bag shape, the phenomenon that the film is adhered to the roller and wrapped is avoided, and the phenomenon that the film is not uniform in the axial direction and the radial direction is also avoided. Plasticizing and softening agents are added while refining, and the materials are mixed and milled alternately in the transverse direction and the longitudinal direction, so that the molecular structure chain of the materials can be changed and recombined, and the performance of new materials is more stable. And finally, refining for 20-25 minutes by using a roller with a designed thickness, so that the flexibility and the uniformity of the film are enhanced, and the glossiness is better.
In the raw materials of the invention, asbestos and glass fiber are abandoned, rubber is taken as a carrier material, materials of graphite, silicon carbide, acetylene black, steel fiber and carbon fiber which are used for determining the friction coefficient are reasonably combined, and the strength of the friction lining is adjusted by sulfur powder, barium sulfate, zinc oxide, feldspar powder, silicon carbide and bauxite; the heat dissipation performance of the friction lining is adjusted through graphite, acetylene black and carbon fiber; the softening performance of the friction lining is controlled by the anti-aging agent, the auxiliary agent and the coupling agent, so that the friction lining which is environment-friendly, stable in friction coefficient, strong in wear resistance and heat dissipation capacity and low in cost is obtained.
The rubber is used as a carrier material, has high elasticity, good wear resistance and low heat generation, is easy to mix, can be fused with other materials, and enhances the binding force among the materials. The butadiene rubber and the styrene butadiene rubber are two kinds of synthetic rubber in the rubber boundary, and have regular structure and better physical structural performance than other rubbers. The butadiene rubber can form a net structure through longitudinal and transverse plastication and mixing, and is easy to synthesize and use with the styrene butadiene rubber. The styrene butadiene rubber has good comprehensive performance. After the two are combined and vulcanized, the rubber has the advantages of cold resistance, heat resistance, wear resistance, good elasticity, less heat generation under dynamic load, aging resistance, strong plasticity, easy mixing and cost reduction.
The graphite is a main material for controlling the friction coefficient of the brake pad, the lubricating property is good, the larger the scale of the graphite is, the smaller the friction coefficient is, the lower the friction coefficient is caused by the overhigh content of the graphite, and the higher the friction coefficient is caused by the overlow content of the graphite, and the friction coefficient can be kept between 0.3 and 0.5 by adopting 30 to 40 parts of 100-mesh scale graphite. Meanwhile, the good heat conductivity of the graphite can increase the heat dissipation performance of the friction lining; the characteristics of small thermal expansion coefficient, good thermal shock resistance and strength enhanced along with the rise of temperature are beneficial to maintaining the form of the friction lining, and high strength is achieved, so that high-temperature deformation, cracking, bubbling, unevenness, warping and distortion are avoided; good chemical stability contributes to the improvement of the anti-corrosion properties of the friction lining; the characteristics of good toughness and strong plasticity are beneficial to mixing with other raw materials, and the binding force is strong.
The graphite is modified after being soaked and oxidized by potassium permanganate, so that the graphite has stronger electric conductivity, heat conductivity, high temperature resistance, lubrication, thermal shock resistance, plasticity and chemical stability. And the treated graphite is easier to be added and uniformly dispersed in the rubber sheet during mixing, and is further stably combined with the rubber.
The silicon carbide has the advantages of stable chemical property, high heat conductivity coefficient, small thermal expansion coefficient and good wear resistance, is favorable for forming the characteristics of wear resistance, erosion resistance, good heat dissipation and difficult deformation and crack resistance of the friction lining, and coordinates with steel fibers and carbon fibers to enhance the wear resistance, heat dissipation and strength of the friction lining.
The acetylene black and the rubber are mixed to form a reinforcing structure, so that the modulus and the wear resistance of vulcanized rubber can be improved, hysteresis heat generation is reduced, the heat dissipation and the antistatic property of a friction lining can be improved, and the acetylene black and the rubber are used as a graphite extender to enhance the heat conductivity of the friction lining and the rubber.
The steel fiber and the carbon fiber play a reinforcing role, the fibers cannot be agglomerated and are uniformly distributed in the kneading and mixing processes, and the steel fiber produced by the melting and pumping method has the advantages of rough surface, irregular shapes at two ends and irregular cross section, is easy to bond with other materials, enhances the mechanical bonding force, and improves the poking resistance, toughness, hardness and abrasion resistance. Thereby improving the compression strength, the tensile strength, the bending resistance, the impact strength and the toughness of the friction lining; the carbon fiber is formed by piling up organic fibers such as crystalline flake graphite microcrystals along the axial direction of the fiber, has light weight, soft outer part and rigid inner part, good wear resistance and heat conductivity, can stabilize the friction coefficient, and improves the strength and the deformation resistance of the friction lining. The two fibers are used together, so that the bonding force between the materials is improved, the friction lining is not easy to deform, the compressive strength, the tensile strength, the impact strength, the toughness, the impact toughness and the bending strength are stronger, and the low abrasion loss, the stable friction coefficient, the stable material quality, no crack and no crazing of the materials are ensured.
The sulfur powder is a vulcanizing agent of rubber, can prevent rubber from cracking, and enables the rubber to be hard and the friction lining to be more wear-resistant. The barium sulfate can improve the chemical stability and the density of the friction lining, so that the friction coefficient is stable, the abrasion is small, the service life is prolonged, and a stable friction boundary layer can be formed at high temperature to prevent the friction boundary layer from being occluded with a hub and scratching the hub. The zinc oxide is a catalyst and is used for reinforcing and activating the rubber, so that the rubber has good corrosion resistance, tear resistance and elasticity. The feldspar powder comprises SiO2、Al2O3、K2O、Na2O, CaO, etc., can enhance the wear resistance of the material. The bauxite is wear-resistant, the refractoriness of the bauxite is as high as 1780 ℃, the heat resistance and the wear resistance of the friction lining can be enhanced, and the friction coefficient is kept stable. The silicon carbide, barium sulfate, bauxite and zinc oxide are all dissolved in water, are easily dissolved in acid and alkali and can be used as a catalyst. The combination of silicon carbide, barium sulfate, bauxite, zinc oxide and feldspar powder can make the friction lining have stable performance, good heat conductivity, high wear resistance and small thermal expansion coefficient. An accelerator,The anti-aging agent and the coupling agent have softening functions, and the three are used together to give full play to respective functions and have synergistic effect with other materials, so that the interface bonding force and the mechanical strength of the rubber and other materials are improved. The accelerator has the main functions of reinforcing and promoting the adhesion of rubber, steel fibers and carbon fibers, and the anti-aging agent has the main functions of inhibiting oxidation, so that the friction lining is kept heat-resistant and flex-aging-resistant for ever, and is prevented from cracking and ripping. The coupling agent has the main functions of enhancing the bonding force of the material interface, enhancing the overall mechanical strength of the friction lining, overcoming the dispersibility of other additives, enhancing the overall material strength and improving the wear resistance. The common iron powder only enhances the hardness, and the reduced iron powder is adopted in the invention, so that the high-temperature resistance and oxidation resistance of the brake pad can be improved, the density and heat dissipation performance of the friction block are enhanced, the braking noise and the jitter are reduced, and the reduced iron powder is also used for catalysis. Bauxite, zinc oxide, silicon carbide, barium sulfate and feldspar powder in the kneading material have no chemical reaction at low temperature, and new chemical change and physical change are generated by means of the catalysis of reduced iron powder in the high-temperature kneading process.
The plasticizing softener is a mixture of benzoic acid, stearic acid and coumarone, and the weight ratio of the benzoic acid to the stearic acid to the coumarone is 2:1: 1. Accelerators include hexamethylenetetramine and thiuram-type vulcanization accelerators. The anti-aging agent is phenol anti-aging agent. The potassium benzoate is cold-resistant plasticizer, stabilizer, surfactant and rubber vulcanization accelerator, and has emulsifying effect. Stearic acid is a vulcanization activator, having plasticizing and softening effects. The emulsification of the potassium benzoate is combined, so that the plasticization and softening effects of the stearic acid are better, the film can be softened during mixing, and the graphite and the kneaded material can be easily eaten. As a plasticizing softener, coumarone has good adhesiveness, is beneficial to dispersing acetylene black, improves the processing performance, and has the functions of reinforcing, tackifying and softening rubber. The hexa-potassium-ethylene tetramine is mainly used as an accelerator for rubber vulcanization, has the functions of catalysis, foaming and assimilation, can promote the combination of rubber and other materials, accelerates the vulcanization process and improves the vulcanization effect. The anti-aging agent is used for preventing rubber from aging.
Phenolic resin is used as a binder and is compatible with various materials. The phenolic resin is resistant to high temperature, can maintain the structural integrity and dimensional stability even at very high temperature, is beneficial to maintaining the form of the friction lining and obtaining stable friction coefficient, and can enhance the mechanical strength and heat resistance of the lining after being crosslinked. The phenolic resin, acetylene black, a coupling agent, hexamethylenetetramine, bauxite, silicon carbide, zinc oxide, barium sulfate, feldspar powder, steel fiber, carbon fiber, reduced iron powder, the phenolic resin and an anti-aging agent are kneaded in a kneader according to the proportion at the temperature of 100 ℃ and 120 ℃ for 5-8 minutes, the molecular structure of the phenolic resin can be changed, and the toxicity can be eliminated.
In the invention, the carrier material is used as a leading material and is fused with other materials; the friction coefficient materials are reasonably proportioned to ensure that the friction coefficient is appropriate and stable; the heat dissipation material is reasonably proportioned to realize rapid heat dissipation, avoid bonding and peeling caused by high temperature, protect the product quality, enable the whole material to meet the requirements of technology and mechanical strength, and ensure low abrasion loss; the softening material is beneficial to fully combining various materials with different strengths, specific gravities, oxidation properties and softening temperatures. The materials are interactive and mutually promoted, the proportion of each component is obtained through a large number of experiments and analyses, and if the proportion of the strength and heat dissipation materials is insufficient, the strength is low, the heat dissipation performance is poor, the friction coefficient is influenced, and the friction coefficient is unstable; if the material is not softened enough, the mixing and kneading effects are not good, the recombination strength of the molecular chains of the material is not enough, and the friction coefficient and the abrasion loss are also influenced. In conclusion, the materials are supported and promoted mutually, and cooperate to ensure that the friction coefficient of the friction lining is appropriate and stable, and the friction lining is wear-resistant, good in heat dissipation performance, environment-friendly, excellent in quality and low in price.
A method for manufacturing a brake pad using the friction lining, comprising the steps of:
A. manufacturing a tile back: manufacturing a tile back according to the design requirement of a brake pad;
B. cutting: cutting the friction lining into pieces according to the size and the shape of the tile back for standby;
C. preparing a binder: b, crushing the leftover materials in the cutting process in the step B into particles, weighing the particles according to the proportion, weighing gasoline, immersing the particles into the gasoline for 20-26 hours, and uniformly stirring to prepare dilute mucilage with the concentration of 10-20 percent, thick mucilage with the concentration of 20-30 percent and mucilage for repairing with the concentration of 45-55 percent;
D. bonding a friction lining:
degreasing, derusting and washing the tile back in the step A, heating the tile back in a constant temperature box at the temperature of 100 ℃ and 120 ℃ for 1 to 3 minutes, taking out the tile back,
heating the friction lining cut in the step B in a constant temperature box at the temperature of 80-100 ℃ for 2-4 minutes, taking out the friction lining,
c, bonding 2-4 layers of friction linings together by using the thin mucilage and the thick mucilage in the step C,
c, integrally bonding 2-4 layers of friction linings in the tile back by using the thin adhesive cement and the thick adhesive cement in the step C;
E. pressing: e, placing the friction lining and the tile back which are bonded into a whole in the step E into a die cavity of a press machine, preheating the die cavity to 100-120 ℃, keeping the pressure of a male die for 3-5 minutes at the pressure of not less than 500KN, and taking out the formed brake pad;
F. and (3) dressing: c, shaping and repairing the brake pad by using the repairing adhesive cement in the step C;
G. and (3) vulcanization: putting the brake pad into a constant temperature box, and keeping the box temperature at 140 ℃ and 160 ℃ for 45-55 minutes;
H. and (6) inspecting and warehousing.
In the preparation process of the brake pad, the leftover materials are utilized to prepare the adhesive cement which is used for bonding each layer of friction lining, bonding the friction lining in the tile back and repairing the friction lining, the leftover materials are effectively utilized, the material waste is avoided, the friction lining and the tile back can be integrally combined, and the brake pad is not easy to fall off. The mould pressing and the vulcanizing working procedure are separated, so that the mould pressing working procedure can be quickly carried out, the efficiency is improved, the equipment can be fully utilized, and the pressed friction lining can be repaired. Through the high-temperature kneading step, all materials are recombined to generate a new material, the molecular chains are tightly combined, the materials cannot deform or crack after being pressed, the materials can be directly vulcanized at high temperature, an anti-deformation mold is not needed, the cost is saved, and the process steps are simplified.
The invention has the beneficial effects that: 1. through a large number of experiments, the invention reasonably combines the raw materials, and the raw materials have complementary mechanisms and strong mutual promotion. The feldspar powder, the silicon carbide, the acetylene black and the steel fiber are added, so that the friction lining has proper friction coefficient, hardness and strength, and better wear resistance and heat dissipation performance are kept. By accurately controlling the content of the graphite and utilizing potassium permanganate to perform infiltration treatment on the graphite, the graphite can be conveniently eaten into the rubber film and combined with rubber, and further the friction coefficient meets the technical requirements of the brake pad. The high temperature resistance and oxidation resistance of the friction lining are improved through the catalytic kneading process of the reduced iron powder. The performance of the friction lining is improved by the plasticizing softener, the coupling agent and the accelerant, and simultaneously, the melting and mixing of the raw materials are promoted, and the plastication, kneading and mixing effects are improved. The Hardness (HRC) of the friction lining is kept between 60 and 70, the impact strength is kept between 6.5 KJ/square meter, the compression strength is kept between 50MPa, the bending strength is kept between 12.5MPa, the porosity is 9.3, the density is kept between 2.16 g/cm for cultivating trees, the friction coefficient is small in high and low temperature change, the stability is kept between 0.3 and 0.42, the national standard regulation is met, and the wear rate is lower than 0.2. The friction lining and the brake pad prepared from the friction lining have the advantages of compact structure, proper hardness, strength, porosity, friction characteristic and compression characteristic, no noise, no deformation, no cracking, no need of mold vulcanization, high production efficiency, cheap common chemical materials as raw materials and low cost. 2. The steps of each process are closely connected, and parameters of roll spacing, temperature, time and pressure are reasonably determined through a large amount of experiments so as to ensure that each material is uniformly mixed and fully acted; and the kneading step further promotes material fusion and molecular recombination, so that molecular chains are tightly bonded, the friction lining and the brake pad prepared by the friction lining are compact in structure, proper in hardness, strength, porosity, friction characteristic and compression characteristic, free of noise, deformation and cracking, free of mold vulcanization, high in production efficiency and low in cost.
Detailed Description
Example one, a method for preparing a friction lining, comprising the following raw materials in parts by weight:
6 parts of butadiene rubber and 6 parts of styrene-butadiene rubber
Graphite 30 parts and reduced iron powder 8 parts
6 parts of sulfur powder and 3 parts of barium sulfate
Zinc oxide 1 part and phenolic resin 6 parts
Feldspar powder 3 parts and silicon carbide 2 parts
Acetylene black 6 parts of accelerator 0.5 part
Anti-aging agent 0.5 parts of bauxite 1 part
2 parts of benzoic acid potassium acid and 1 part of stearic acid
1 part of coumarone and 1 part of hexamethylenetetramine
Coupling agent 1 part steel fiber 9 parts
6 parts of carbon fiber
The benzoic acid, the stearic acid and the coumarone are uniformly mixed to prepare the plasticizing softener.
Wherein the accelerator TT produced by Puyang Weilin chemical industry Co., Ltd is selected as the accelerator, the anti-aging agent D produced by Puyang Weilin chemical industry Co., Ltd is selected as the anti-aging agent, and the coupling agent is purchased from Chongqing Jiashitai chemical industry Co., Ltd.
The specific preparation method of the friction lining comprises the following steps:
A. plasticating: mixing butadiene rubber and styrene butadiene rubber, feeding the mixture into a rubber mixing mill, circulating water temperature of a roller of the rubber mixing mill to 16 ℃,
1, adjusting the roller spacing between 1mm and 3mm, stacking, rolling longitudinally and transversely, plastifying for 4 minutes,
2, adjusting the roller spacing between 5mm and 8mm, stacking, rolling longitudinally and transversely, plastifying for 4 minutes,
3, adjusting the roller spacing between 1mm and 3mm, stacking, rolling longitudinally and transversely, plastifying for 5 minutes,
4, adjusting the roller spacing between 0.5 mm and 1mm, single-layer, overlapping, longitudinal and transverse sheet rolling and plasticating for 4 times,
in the plasticating process, the thickness of the rubber sheet before the pre-plastication is kept to be larger than 1mm of the pre-plastication roller distance, the rubber sheet is plasticated until the rubber sheet is flat, smooth and crack-free, and the rubber sheet is flatly placed in a shade place and naturally aired for 4 days.
B. Infiltrating graphite: immersing graphite in 0.002mol/L potassium permanganate solution, and drying in a constant temperature oven after uniform immersion.
C. Primary mixing:
c1, rewetting: c, circulating water by a roller at the temperature of 16 ℃, and re-moistening the film dried in the step A for 3 times by changing the roller distance between a rubber mixing mill and a longitudinal roller and a transverse roller for 2-3 mm;
c2, primary mixing: changing roller distance between 2mm and 4mm, rolling longitudinally and transversely, adding the graphite in the step B while rolling, refining until the graphite completely enters the film, and if the graphite difficultly enters the film, adding a proper amount of plasticizing softener, wherein the addition amount of the plasticizing softener is not more than one half of the total amount;
c3, remixing: and changing the roller spacing between 2mm and 4mm, rolling the sheets longitudinally and transversely, mixing the sheets for 5 times to prepare a prefabricated film, and keeping the thickness of the film before pre-smelting to be larger than the roller spacing of pre-smelting by 1 mm.
D. Kneading: adding sulfur powder, acetylene black, a coupling agent, bauxite, silicon carbide, zinc oxide, barium sulfate, feldspar powder, steel fibers, carbon fibers, reduced iron powder, phenolic resin, an anti-aging agent, an accelerant and a plasticizing softener into a kneading machine, kneading for 6 minutes at the temperature of 120 ℃ to prepare a kneaded material; wherein the addition amount of the plasticizing softener is selected according to the graphite feeding condition, if the graphite feeding is easy, all or the rest of the plasticizing softener is added into the kneader, and if the graphite feeding is hard, no more than one fourth of the total amount of the plasticizing softener is reserved and added in the secondary mixing step.
E. And (3) secondary mixing: c, conveying the prefabricated rubber sheets in the step C to a rubber mixing mill, wherein the circulating water temperature of a roller of the rubber mixing mill is 20 ℃, the temperature of a front roller is 10 ℃ lower than that of a rear roller, the roller distance is changed between 3mm and 5mm, the longitudinal and transverse single-layer sheet rolling is carried out for 7 minutes, kneading materials are gradually fed, the roller distance is adjusted to 2mm, the longitudinal and transverse single-layer or double-layer laminated sheet rolling is carried out for mixing for 25 minutes, and the thickness of the rubber sheets before pre-mixing is kept to be 1mm larger than that of the pre-; during the process, the pre-reserved plasticizing softener is added according to the feeding condition of the kneaded material.
The method for manufacturing the brake pad by using the friction lining comprises the following steps:
A. manufacturing a tile back: manufacturing a tile back according to the design requirement of a brake pad;
B. cutting: cutting the friction lining into pieces according to the size and the shape of the tile back for standby;
C. preparing a binder: b, crushing the leftover materials in the cutting process in the step B into particles, weighing the particles according to the proportion, weighing gasoline, immersing the particles into the gasoline for 20 hours, and uniformly stirring to prepare dilute mucilage with the concentration of 15 percent, thick mucilage with the concentration of 25 percent and mucilage for repairing with the concentration of 50 percent;
D. bonding a friction lining:
degreasing, derusting and washing the tile back in the step A, heating the tile back in a constant temperature box at 110 ℃ for 3 minutes, taking out the tile back,
heating the friction lining cut in the step B in a constant temperature box at 100 ℃ for 3 minutes and taking out,
c, bonding the 3 layers of friction linings together by using the thin adhesive cement and the thick adhesive cement in the step C,
c, integrally bonding the friction lining in the tile back by using the thin adhesive cement and the thick adhesive cement in the step C;
E. pressing: e, placing the friction lining and the tile back which are bonded into a whole in the step E into a die cavity of a press machine, preheating the die cavity to 120 ℃, keeping the pressure of a male die for 4 minutes at the pressure of 500KN, and taking out the formed brake pad;
F. and (3) dressing: c, shaping and repairing the brake pad by using the repairing adhesive cement in the step C;
G. and (3) vulcanization: the brake pad is put into a thermostat and the thermostat is kept at 150 ℃ for 50 minutes.
The prepared brake pad has no defects of cracks, bubbles, edge defects, corner drop, warping, distortion and the like of the lining.
According to the testing method of the national standard GB5763-2008, the brake pad prepared in the first embodiment is tested on a constant speed friction machine, and the specific test results are shown in Table 1.
TABLE 1
In the second embodiment, the friction lining of the present embodiment is made from the following raw materials in parts by weight:
8 parts of butadiene rubber and 8 parts of styrene-butadiene rubber
40 parts of graphite and 11 parts of reduced iron powder
8 parts of sulfur powder and 4 parts of barium sulfate
2 parts of zinc oxide and 8 parts of phenolic resin
Feldspar powder 5 parts and silicon carbide 3 parts
Acetylene black 7 parts of accelerator 0.8 part
Antioxidant 1 part and bauxite 3 parts
3 parts of benzoic acid potassium acid 1.5 parts of stearic acid
1.5 parts of coumarone and 3 parts of hexamethylenetetramine
Coupling agent 1.5 parts and steel fiber 10 parts
And 7 parts of carbon fiber.
In this example, benzoic acid, stearic acid and coumarone were mixed uniformly to make a plasticizing softener. Wherein the accelerator TT produced by Puyang Weilin chemical industry Co., Ltd is selected as the accelerator, the anti-aging agent D produced by Puyang Weilin chemical industry Co., Ltd is selected as the anti-aging agent, and the coupling agent is purchased from Chongqing Jiashitai chemical industry Co., Ltd.
The specific preparation method of the friction lining comprises the following steps:
A. plasticating: mixing butadiene rubber and butadiene styrene rubber, feeding into a rubber mixing mill, circulating water temperature of a roller of the rubber mixing mill is 20 ℃,
1, adjusting the roller spacing between 1mm and 3mm, stacking, rolling longitudinally and transversely, plastifying for 3 minutes,
2, adjusting the roller spacing between 5mm and 8mm, stacking, rolling longitudinally and transversely, plastifying for 3 minutes,
3, adjusting the roller spacing between 1mm and 3mm, stacking, rolling longitudinally and transversely, plastifying for 6 minutes,
4, adjusting the roller spacing between 0.5 mm and 1mm, single-layer, overlapping, longitudinal and transverse sheet rolling and plastifying for 5 times,
in the plasticating process, the thickness of the rubber sheet before the pre-plastication is kept to be larger than 1mm of the pre-plastication roller distance, the rubber sheet is plasticated until the rubber sheet is flat, smooth and crack-free, and the rubber sheet is flatly placed in a shade place and naturally aired for 5 days.
B. Infiltrating graphite: immersing graphite in 0.008mol/L potassium permanganate solution preferably without dusting, and drying in a constant temperature oven after uniform immersion.
C. Primary mixing:
c1, rewetting: c, circulating water temperature of a roller is 18 ℃, and the film dried in the step A is sent to a rubber mixing mill to be re-moistened for 3 times by changing roller spacing in a longitudinal and transverse direction;
c2, primary mixing: changing roller distance between 2mm and 4mm, rolling longitudinally and transversely, adding the graphite in the step B while rolling, refining until the graphite completely enters the film, and if the graphite difficultly enters the film, adding a proper amount of plasticizing softener, wherein the addition amount of the plasticizing softener is not more than one half of the total amount;
c3, remixing: and changing the roller spacing between 2mm and 4mm, rolling the sheets longitudinally and transversely, mixing the sheets for 5 times to prepare a prefabricated film, and keeping the thickness of the film before pre-smelting to be larger than the roller spacing of pre-smelting by 1 mm.
D. Kneading: adding sulfur powder, acetylene black, a coupling agent, bauxite, silicon carbide, zinc oxide, barium sulfate, feldspar powder, steel fibers, carbon fibers, reduced iron powder, phenolic resin, an anti-aging agent, an accelerant and a plasticizing softener into a kneading machine, kneading for 8 minutes at the temperature of 110 ℃ to prepare a kneaded material; wherein the addition amount of the plasticizing softener is selected according to the graphite feeding condition, if the graphite feeding is easy, all or the rest of the plasticizing softener is added into the kneader, and if the graphite feeding is hard, no more than one fourth of the total amount of the plasticizing softener is reserved and added in the secondary mixing step.
E. And (3) secondary mixing: c, conveying the prefabricated rubber sheets in the step C to a rubber mixing mill, wherein the circulating water temperature of a roller of the rubber mixing mill is 18 ℃, the temperature of a front roller is 10 ℃ lower than that of a rear roller, the roller distance is changed between 3mm and 5mm, the longitudinal and transverse single-layer sheet rolling is carried out for 8 minutes, kneading materials are gradually fed, the roller distance is adjusted to 2mm, the longitudinal and transverse single-layer or double-layer laminated sheet rolling is carried out for mixing for 20 minutes, and the thickness of the rubber sheets before pre-mixing is kept to be 1mm larger than that of the pre-; during the process, the pre-reserved plasticizing softener is added according to the feeding condition of the kneaded material.
The method for manufacturing the brake pad by using the friction lining comprises the following steps:
A. manufacturing a tile back: manufacturing a tile back according to the design requirement of a brake pad;
B. cutting: cutting the friction lining into pieces according to the size and the shape of the tile back for standby;
C. preparing a binder: b, crushing the leftover materials in the cutting process in the step B into particles, weighing the particles according to the proportion, weighing gasoline, immersing the particles into the gasoline for 26 hours, and uniformly stirring to prepare dilute mucilage with the concentration of 15 percent, thick mucilage with the concentration of 25 percent and mucilage for repairing with the concentration of 50 percent;
D. bonding a friction lining:
degreasing, derusting and washing the tile back in the step A, heating the tile back in a constant temperature box at 110 ℃ for 3 minutes, taking out the tile back,
heating the friction lining cut in the step B in a constant temperature box at 100 ℃ for 3 minutes and taking out,
c, bonding the 3 layers of friction linings together by using the thin adhesive cement and the thick adhesive cement in the step C,
c, integrally bonding the friction lining in the tile back by using the thin adhesive cement and the thick adhesive cement in the step C;
E. pressing: e, placing the friction lining and the tile back which are bonded into a whole in the step E into a die cavity of a press machine, preheating the die cavity to 120 ℃, keeping the pressure of a male die for 4 minutes at the pressure of 500KN, and taking out the formed brake pad;
F. and (3) dressing: c, shaping and repairing the brake pad by using the repairing adhesive cement in the step C;
G. and (3) vulcanization: the brake pad is put into a thermostat and the thermostat is kept at 150 ℃ for 50 minutes.
The prepared brake pad has no defects of cracks, bubbles, edge defects, corner drop, warping, distortion and the like of the lining.
According to the testing method of the national standard GB5763-2008, the brake pad of the second embodiment is tested on a constant speed friction machine, and the specific test results are shown in Table 2.
TABLE 2
In the third embodiment, the friction lining of the present embodiment is made from the following raw materials in parts by weight:
butadiene rubber 7 parts and styrene-butadiene rubber 7 parts
Graphite 35 parts and reduced iron powder 10 parts
Sulfur powder 7 parts barium sulfate 3.5 parts
3 parts of zinc oxide and 7 parts of phenolic resin
Feldspar powder 4 parts and silicon carbide 2.5 parts
Acetylene black 5 parts of accelerator 0.9 part
Anti-aging agent 0.8 parts of bauxite 2.5 parts
1 part of benzoic acid potassium acid 0.5 part of stearic acid
0.5 part of coumarone and 2 parts of hexamethylenetetramine
Coupling agent 2 parts steel fiber 8 parts
7.5 parts of carbon fiber.
In this example, benzoic acid, stearic acid and coumarone were mixed uniformly to make a plasticizing softener. Wherein the accelerator TT produced by Puyang Weilin chemical industry Co., Ltd is selected as the accelerator, the anti-aging agent D produced by Puyang Weilin chemical industry Co., Ltd is selected as the anti-aging agent, and the coupling agent is purchased from Chongqing Jiashitai chemical industry Co., Ltd. The friction lining and the brake pad were prepared in the same manner as in example one. According to the test method of the national standard GB5763-2008, the brake pad of the third embodiment is tested on a constant speed friction machine, and the specific test result is shown in Table 3.
TABLE 3
Example four, the friction lining of this example was made from the following raw materials in parts by weight:
butadiene rubber 7.5 parts and styrene-butadiene rubber 7.5 parts
Graphite 33 parts and reduced iron powder 7 parts
6 parts of sulfur powder and 3.2 parts of barium sulfate
Zinc oxide 1.5 parts phenolic resin 5 parts
Feldspar powder 2 parts and silicon carbide 4 parts
Acetylene black 4 parts of accelerator 1 part
Anti-aging agent 0.7 parts of bauxite 1.5 parts
2.4 parts of benzoic acid potassium acid 1.2 parts of stearic acid
1.2 parts of coumarone and 2.5 parts of hexamethylenetetramine
Coupling agent 1.8 parts and steel fiber 6 parts
8 parts of carbon fiber.
In this example, benzoic acid, stearic acid and coumarone were mixed uniformly to make a plasticizing softener. Wherein the accelerator TT produced by Puyang Weilin chemical industry Co., Ltd is selected as the accelerator, the anti-aging agent D produced by Puyang Weilin chemical industry Co., Ltd is selected as the anti-aging agent, and the coupling agent is purchased from Chongqing Jiashitai chemical industry Co., Ltd. The friction lining and the brake pad were prepared in the same manner as in the examples. According to the testing method of the national standard GB5763-2008, the brake pad of the fourth embodiment is tested on a constant speed friction machine, and the specific test result is shown in Table 4.
TABLE 4
Claims (10)
1. A method of making a friction lining characterized by the steps of:
A. plasticating: weighing 6-8 parts by weight of butadiene rubber and styrene butadiene rubber, mixing the butadiene rubber and the styrene butadiene rubber in a ratio of 1:1, conveying the mixture to a rubber refining machine, adjusting the roller spacing of the rubber refining machine to repeatedly plasticate the mixture until the rubber sheet is flat, bright, smooth and crack-free, and flatly placing the rubber sheet in a shade place for naturally airing for 3-5 days;
B. infiltrating graphite: weighing 30-40 parts by weight of graphite, immersing the graphite in 0.002-0.01mol/L potassium permanganate solution, preferably without dust, wherein the weight of the potassium permanganate solution is 1.5-2.5 times that of the graphite according to the humidity of the graphite, and drying the graphite in a constant temperature box after uniform immersion;
C. primary mixing: the circulating water temperature of the roller of the rubber mixing machine is 15-20 ℃,
c1, rewetting: the rubber sheets dried in the step A are sent to a rubber mixing mill to be repeatedly refined for 2 to 3 times,
c2, primary mixing: b, adding the graphite in the step B while adjusting the roller spacing, smelting until the graphite completely enters the film, adding 0-2 parts by weight of plasticizing softener according to the graphite entering condition,
c3, remixing: repeatedly mixing the primarily mixed films for 3-5 times to prepare prefabricated films;
D. kneading: weighing 4-8 parts of sulfur powder, 4-7 parts of acetylene black, 1-2 parts of coupling agent, 1-3 parts of bauxite, 2-4 parts of silicon carbide, 1-3 parts of zinc oxide, 3-4 parts of barium sulfate, 2-5 parts of feldspar powder, 6-10 parts of steel fiber, 6-8 parts of carbon fiber, 7-11 parts of reduced iron powder, 5-8 parts of phenolic resin, 0.5-1 part of anti-aging agent, 1.5-4 parts of promoter and 1-6 parts of plasticizing softener according to parts by weight, adding the raw materials into a kneader, kneading the raw materials at the temperature of 100-120 ℃ for 5-8 minutes to prepare a kneaded material;
E. and (3) secondary mixing: and C, conveying the prefabricated rubber sheet in the step C to a rubber mixing mill, wherein the circulating water temperature of a roller of the rubber mixing mill is 15-20 ℃, the temperature of a front roller is 8-10 ℃ lower than that of a rear roller, the roller spacing is adjusted, kneading materials are added while the roller spacing is refined, the mixture is mixed for 5-8 minutes, the roller spacing is adjusted to the designed thickness, and the mixture is mixed for 20-25 minutes to form the friction lining which is uniformly mixed, flat, bright, smooth and crack-free.
2. The method for producing a friction lining according to claim 1, wherein the masticating in step a is a longitudinal and transverse rolling of a sheet with a controlled roll gap, comprising:
a1, plasticating for 3-5 minutes at a roller spacing of 1-3mm,
a2, plasticating for 3 to 4 minutes at a roller spacing of between 5 and 8mm,
a3, plasticating for 5-6 minutes at a roller spacing of 1-3mm,
a4, and plasticating for 3-5 times at a roll spacing of 0.5-1 mm.
3. The method for producing a friction lining according to claim 2, characterized in that: the steps a1, a2, a3 and a4 comprise the step of laminating 2-3 layers of plastication on films, and the thickness of the laminated films is larger than 1mm of the pre-plastication roller distance.
4. The method for producing a friction lining according to claim 3, characterized in that: and step c1, the method comprises the step of stacking 2-3 layers of plasticated films, wherein the thickness of the stacked films is larger than 1mm of the pre-plasticated roller spacing.
5. The method for producing a friction lining according to claim 4, characterized in that: in the step c1, the roll spacing is changed between 2mm and 3mm, and the longitudinal and transverse rolling sheets are rewetted.
6. The method for producing a friction lining according to claim 5, wherein in step c2, the roll pitch is changed between 2 and 4mm for the longitudinal and transverse single-layer sheet preliminary mixing; in the step c3, the longitudinal and transverse sheet rolling and remixing are carried out by changing the roller spacing between 2mm and 4mm, the step of plasticating by overlapping 2-3 layers of films is included, and the thickness of the overlapped films is more than 1mm of the roller spacing of the pre-refining.
7. The method of producing a friction lining according to claim 6, wherein in the step E, the roll gap is changed between 3 and 5mm and the longitudinal and transverse single-layer rolled sheets are gradually fed with the kneaded material, and the roll gap is adjusted to the designed thickness and the longitudinal and transverse single-layer or double-layer laminated rolled sheets are kneaded for 20 to 25 minutes.
8. The method for producing a friction lining according to claim 7, characterized in that: in the step E, 0 to 2 parts by weight of plasticizing softener is added according to the feeding condition of the kneaded material.
9. The method for producing a friction lining according to claim 8, characterized in that: the plasticizing softener is a mixture of benzoic acid, stearic acid and coumarone, and the weight ratio of the benzoic acid to the stearic acid to the coumarone is 2:1: 1.
10. A method of manufacturing a brake pad using the friction lining as claimed in claim 1, characterized by comprising the steps of:
A. manufacturing a tile back: manufacturing a tile back according to the design requirement of a brake pad;
B. cutting: cutting the friction lining into pieces according to the size and the shape of the tile back for standby;
C. preparing a binder: b, crushing the leftover materials in the cutting process in the step B into particles, weighing the particles according to the proportion, weighing gasoline, immersing the particles into the gasoline for 20-26 hours, and uniformly stirring to prepare dilute mucilage with the concentration of 10-20 percent, thick mucilage with the concentration of 20-30 percent and mucilage for repairing with the concentration of 45-55 percent;
D. bonding a friction lining:
degreasing, derusting and washing the tile back in the step A, heating the tile back in a constant temperature box at the temperature of 100 ℃ and 120 ℃ for 1 to 3 minutes, taking out the tile back,
heating the friction lining cut in the step B in a constant temperature box at the temperature of 80-100 ℃ for 2-4 minutes, taking out the friction lining,
c, bonding 2-4 layers of friction linings together by using the thin mucilage and the thick mucilage in the step C,
c, integrally bonding 2-4 layers of friction linings in the tile back by using the thin adhesive cement and the thick adhesive cement in the step C;
E. pressing: e, placing the friction lining and the tile back which are bonded into a whole in the step E into a die cavity of a press machine, preheating the die cavity to 100-120 ℃, keeping the pressure of a male die for 3-5 minutes at the pressure of not less than 500KN, and taking out the formed brake pad;
F. and (3) dressing: c, shaping and repairing the brake pad by using the repairing adhesive cement in the step C;
G. and (3) vulcanization: putting the brake pad into a constant temperature box, and keeping the box temperature at 140 ℃ and 160 ℃ for 45-55 minutes;
H. and (6) inspecting and warehousing.
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| CN1038190C (en) * | 1994-09-30 | 1998-04-29 | 吴学仁 | Processing method for non-pollution low-friction coefficient synthetic hem shoe and its products |
| CN1209381A (en) * | 1998-06-16 | 1999-03-03 | 谭美田 | Rubber multielement synthesized brake shoe and producing method therefor |
| CN101418090A (en) * | 2008-10-16 | 2009-04-29 | 吴有站 | Low temperature type high friction rubber and whisker composite brake shoe |
| CN104072832A (en) * | 2014-06-27 | 2014-10-01 | 青岛大学 | Oil-filled and graphene oxide emulsion-filled co-coagulated rubber and preparation method thereof |
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2018
- 2018-12-28 CN CN201811616994.4A patent/CN109608710B/en active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1038190C (en) * | 1994-09-30 | 1998-04-29 | 吴学仁 | Processing method for non-pollution low-friction coefficient synthetic hem shoe and its products |
| CN1209381A (en) * | 1998-06-16 | 1999-03-03 | 谭美田 | Rubber multielement synthesized brake shoe and producing method therefor |
| CN101418090A (en) * | 2008-10-16 | 2009-04-29 | 吴有站 | Low temperature type high friction rubber and whisker composite brake shoe |
| CN104072832A (en) * | 2014-06-27 | 2014-10-01 | 青岛大学 | Oil-filled and graphene oxide emulsion-filled co-coagulated rubber and preparation method thereof |
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