CN111527319A - 具有孔的湿式摩擦材料 - Google Patents

具有孔的湿式摩擦材料 Download PDF

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CN111527319A
CN111527319A CN201980007060.7A CN201980007060A CN111527319A CN 111527319 A CN111527319 A CN 111527319A CN 201980007060 A CN201980007060 A CN 201980007060A CN 111527319 A CN111527319 A CN 111527319A
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proportion
outer layer
base layer
wet friction
thickness
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拉希德·法拉哈尼
奥卢桑米·阿德里安
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Schaeffler Technologies AG and Co KG
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Abstract

一种制造湿式摩擦材料的方法，其包括在基层上设置外层来形成湿式摩擦材料。基层包括一定比例的第一纤维材料和一定比例的第一填充材料，并且外层包括一定比例的第二纤维材料和一定比例的第二填充材料。第二纤维材料的比例小于第一纤维材料的比例，并且第二填充材料的比例大于第一填充材料的比例。该方法还包括形成穿过外层的多个孔。

Description

具有孔的湿式摩擦材料
技术领域
本公开总地涉及转矩变换器中使用的摩擦离合器和板以及机动车辆变速器，并且更具体地涉及湿式摩擦材料。
背景技术
湿式摩擦离合器中的摩擦材料一般在浸油环境中运行，并且常常是用来形成摩擦材料环的纸基材料。已知的是，在造纸工艺期间，当纸基材料沿着传送机移动时，在长网造纸机中在机器的湿端直接将以商品名CELITE出售的硅藻土喷射或喷洒到基材的顶部。对于非常大量的纸，这种工艺是良好的，但是在初始设定期间存在大量浪费，因此对于较少量的生产是不实际的。
美国专利6,013,696公开了使用激光器在固化的树脂浸渍的摩擦材料中形成孔隙。
美国专利6,318,534公开了具有形成在表面上的微穴的摩擦材料。
美国公布2017/0089415公开了包括形成纸复合物的底层和顶层的摩擦材料，其中通过激光器在顶表面中产生孔隙。
美国公布2017/0261057、美国公布2006/0008635、美国公布2017/0335913和美国专利9,499,759公开了包括两层或更多层的摩擦材料。
发明内容
提供了一种制造湿式摩擦材料的方法。该方法包括在基层上设置外层来形成湿式摩擦材料。基层包括一定比例的第一纤维材料和一定比例的第一填充材料，并且外层包括一定比例的第二纤维材料和一定比例的第二填充材料。第二纤维材料的比例小于第一纤维材料的比例，并且第二填充材料的比例大于第一填充材料的比例。该方法还包括形成穿过外层的多个孔。
根据方法的实施例，基层具有第一厚度，外层具有第二厚度，湿式摩擦材料可以具有等于第一厚度加上第二厚度的总厚度，并且第二厚度可以为总厚度的10％至30％。孔可以具有50μm至200μm的最大直径。孔可以占据外层的外表面的总表面积的10％至30％。第一填充材料和第二填充材料可以各自由一种或多种填料形成，该一种或多种填料来自由硅藻土和/或黏土构成的组。第一纤维材料和第二纤维材料可以各自由一种或多种纤维形成，该一种或多种纤维来自由芳族聚酰胺纤维、有机纤维和/或碳纤维构成的组。第一纤维材料的比例可以在基层的35％至60％之间，并且第二纤维材料的比例可以在外层的5％至25％之间。第一填充材料的比例按照重量百分比计可以在基层的15％至50％之间，并且第二填充材料的比例按照重量百分比计可以在外层的45％至75％之间。在基层上设置外层来形成湿式摩擦材料可以包括将外层层压在基层上。基层和外层中的至少一者可以包括粘合剂。将外层层压在基层上可以包括对外层施加热量和压力来经由粘合剂将外层和基层固定在一起。
还提供了一种离合器组件，其包括金属部件和固定在金属部件上的湿式摩擦材料。
还提供了一种湿式摩擦材料。该湿式摩擦材料包括基层和基层上的外层。基层包括一定比例的第一纤维材料和一定比例的第一填充材料，并且外层包括一定比例的第二纤维材料和一定比例的第二填充材料。第二纤维材料的比例小于第一纤维材料的比例，并且第二填充材料的比例大于第一填充材料的比例。外层包括穿过外层的多个孔。
根据湿式摩擦材料的实施例，基层具有第一厚度，外层具有第二厚度，湿式摩擦材料可以具有等于第一厚度加上第二厚度的总厚度，并且第二厚度可以为总厚度的10％至30％。孔可以具有50μm至200μm的最大直径。孔可以占据外层的外表面的总表面积的10％至30％。第一填充材料和第二填充材料可以各自由一种或多种填料形成，该一种或多种填料来自由硅藻土和/或黏土构成的组。第一纤维材料和第二纤维材料可以各自由一种或多种纤维形成，该一种或多纤维来自由芳族聚酰胺纤维、有机纤维和/或碳纤维构成的组。第一纤维材料的比例可以在基层的50％至80％之间，并且第二纤维材料的比例可以在外层的5％至30％之间。第一填充材料的比例按照重量百分比计可以在基层的15％至50％之间，并且第二填充材料的比例按照重量百分比计可以在外层的45％至75％之间。
附图说明
以下参照附图来描述本公开，其中：
图1示出根据本公开的一个实施例的用于形成湿式摩擦材料的基层和外层；
图2示出层压到基层的外层；
图3示出外层中形成孔的激光器；
图4示出固定到金属部件的、在外层中具有孔的湿式摩擦材料；
图5示出包括外层中具有孔的湿式摩擦材料的转矩变换器的锁止离合器组件；和
图6示出摩擦材料的外表面的示例性实施例的俯视平面图。
具体实施方式
本公开提供了能够在高滑速下提供足够的摩擦力同时仍然维持孔隙度的湿式摩擦材料的实施例。向顶表面添加摩擦改性剂层改善了摩擦性能，但堵塞了下部的湿式摩擦材料的孔隙。本公开在摩擦改性剂层中设置小孔来提高孔隙度和高滑速下的性能。
图1至图4示意性地示出了根据本公开的实施例的形成湿式摩擦材料的方法和离合器组件。湿式摩擦材料基层10与外层12分离地或者作为单件来加工。图1示出了作为分离件的基层10和外层12。
基层10是由纤维、填充材料和粘合剂形成的湿式摩擦材料。纤维可以是芳族聚酰胺纤维、有机纤维、碳纤维和/或玻璃纤维。有机纤维包括纤维素纤维或棉纤维。填料可以是硅藻土和/或黏土。粘合剂可以是酚醛树脂、乳胶或硅烷。可选地，基层10中也可以包括比如石墨的摩擦改性剂。
外层12包括纤维、填充材料和粘合剂。纤维可以是芳族聚酰胺纤维、有机纤维、碳纤维和/或玻璃纤维。有机纤维包括纤维素纤维或棉纤维。填料可以是硅藻土和/或黏土。粘合剂可以是酚醛树脂、乳胶或硅烷。可选地，外层12中也可以包括比如石墨的摩擦改性剂。外层12的成分包括相较于基层更高比率的填充材料和更低比率的纤维，使得外层12相较于基层10孔更少并且更稠密，具有比基层10更高的摩擦系数和比基层10更高的耐磨性。层10和12的纤维具有45至55微米的平均直径和1至2毫米的平均长度。
在一个优选的实施例中，基层10包括按照重量百分比计的35％至60％的纤维、15％至40％的填充材料和20％至30％的粘合剂。在另一个优选的实施例中，基层10包括按照重量百分比计的35％至55％的纤维、15％至40％的填充材料和20％至30％的粘合剂。更具体地，在一个优选的实施例中，基层10包括按照重量百分比计的30％至55％的芳族聚酰胺和有机纤维和5％至10％的碳纤维、15％至40％的填充材料以及20％至30％的粘合剂。在另一个优选的实施例中，基层10包括按照重量百分比计的40％至60％的芳族聚酰胺和有机纤维以及5％至10％的碳纤维、15％至40％的填充材料以及20％至30％的粘合剂。
在一个优选的实施例中，外层12包括按照重量百分比计的5％至25％的纤维、45％至75％的填充材料和20％至30％的粘合剂。
图2示出了经由层压接合在一起的两个分离的层10、12。层压包括通过热板14将外层12按压在基层10上以使层10、12中的至少一者中的粘合剂硬化，从而将外层12和基层10固定在一起。将粘合剂设置到由层10、12的纤维和填充材料形成的基质的孔隙中。当外层12的下表面12b安置在支撑表面上时，将热板14压靠在外层12的外表面12a上的力导致粘合剂积聚在外层12的内表面12b和基层10的外表面10a的交界面处，同时粘合剂通过热板14的热量的固化在基层10与外层12之间产生永久连接。在一个优选的实施例中，板14的与外层的外表面12a接触的表面14a处的热量为375至425华氏度。
图3示出了通过针对图2所述的基层10和外层12的接合而形成的湿式摩擦材料16。湿式摩擦材料16形成为使得外层12在外表面12a与内表面12b之间具有厚度T1，基层14在外表面10a与下表面10b之间具有厚度T2，并且湿式摩擦材料16在外表面10a与下表面10b之间具有总厚度T3。在一个优选的实施例中，外层12的厚度T2等于总厚度T3的10％至30％，因此基层10的厚度T1为总厚度T3的70％至90％。
在形成湿式摩擦材料16之后，通过激光器20在外层12中形成多个孔18。孔18从外表面12a延伸到内表面12b，使得孔18通过外层12延伸到所覆盖的基层10的多孔基质。因此，孔18允许外层12的外表面12a处的流体进入基层10的多孔基质。激光器20以受控的方式在外层12的表面12a上移动，并且重复地跳动以形成孔18。在一个优选的实施例中，孔18在外层12中形成，孔18各自具有50μm至200μm的最大直径，并且占据外层的外表面12a的总表面积的10％至30％。最大直径定义为从外表面12a所测量的孔的两个边缘点之间的最大距离。总表面积是指添加孔18之前的外表面12a的表面积，即添加孔18之后的外表面12a的表面积加上通过形成孔18而去除的表面积。
图4示出了粘合到金属部件22的湿式摩擦材料16。具体地，将粘着剂施加到基层10的下表面10b或金属部件22的表面22a，并且将湿式摩擦材料16以表面12a和孔18背向金属部件22的方式粘合到金属部件22。
图5示出了粘合到金属部件的两侧的湿式摩擦材料16，金属部件是转矩变换器34的锁止离合器组件32的离合器板30的形式。锁止离合器组件32的活塞36迫使离合器板30抵靠转矩变换器34的前盖38的内侧表面38a。活塞36接触后件湿式摩擦材料16的设置有孔18(图4)的表面12a，以迫使前件湿式摩擦材料16上的设置有孔18的表面12a抵靠前盖38的内侧表面38a。通过活塞36迫使离合器板30抵靠前盖38锁定了锁止离合器组件32，使得转矩变换器34中的到达变速器输入轴的转矩路径绕过转矩变换器34的叶轮40和涡轮42，并且反而从前盖38流到离合器板30并且通过阻尼器组件44流到变速器输入轴，该变速器输入轴连接到转矩变换器34的输出毂46。
图6示出了外表面12a的示例性实施例的俯视平面图。外表面12a包括彼此间隔开的多个孔18。孔18各自为椭圆形，并且在外表面12a处具有最大直径D1和最小直径D2。
在前面的说明书中，已经参考特定的示例性实施例及其示例描述了本公开。然而，显而易见的是，可以在不脱离所附权利要求书中所阐述的本公开的更广泛的精神和范围的情况下对其进行各种修改和改变。因此，说明书和附图应当被认为是说明性的而非限制性的。
附图标记表
10 基层
10a 外表面
10b 下表面
12 外层
12a 外表面
12b 内表面
14 热板
14a 板表面
16 湿式摩擦材料
18 孔
20 激光器
22 金属部件
22a 表面
30 离合器板
32 锁止离合器组件
34 转矩变换器
36 活塞
38 前盖
38a 内侧表面
40 叶轮
42 涡轮
44 阻尼器组件
46 输出毂

Claims (10)

1.一种制造湿式摩擦材料的方法，包括：
在基层上设置外层来形成所述湿式摩擦材料，所述基层包括一定比例的第一纤维材料和一定比例的第一填充材料，所述外层包括一定比例的第二纤维材料和一定比例的第二填充材料，所述第二纤维材料的比例小于所述第一纤维材料的比例，所述第二填充材料的比例大于所述第一填充材料的比例；和
形成穿过所述外层的多个孔。
2.根据权利要求1所述的方法，其中，所述基层具有第一厚度，并且所述外层具有第二厚度，所述湿式摩擦材料具有等于所述第一厚度加上所述第二厚度的总厚度，所述第二厚度为所述总厚度的10％至30％。
3.根据权利要求1所述的方法，其中，所述孔各自具有50μm至200μm的最大直径，并且所述孔占据所述外层的外表面的总表面积的10％至30％。
4.根据权利要求1所述的方法，其中，所述第一填充材料和所述第二填充材料各自由一种或多种填料形成，所述一种或多种填料来自由硅藻土和/或黏土构成的组，其中，所述第一纤维材料和所述第二纤维材料各自由一种或多种纤维形成，所述一种或多种纤维来自由芳族聚酰胺纤维、有机纤维和/或碳纤维构成的组。
5.根据权利要求1所述的方法，其中，所述第一纤维材料的比例按照重量百分比计在所述基层的35％至60％之间，并且所述第二纤维材料的比例按照重量百分比计在所述外层的5％至25％之间，其中，所述第一填充材料的比例按照重量百分比计在所述基层的15％至50％之间，并且所述第二填充材料的比例按照重量百分比计在所述外层的45％至75％之间。
6.根据权利要求1所述的方法，其中，所述基层和所述外层中的至少一者包括粘合剂，并且在所述基层上设置所述外层来形成所述湿式摩擦材料包括通过对所述外层施加热量和压力来将所述外层层压在所述基层上，以经由所述粘合剂将所述外层和所述基层固定在一起。
7.一种湿式摩擦材料，包括：
基层；和
所述基层上的外层，所述基层包括一定比例的第一纤维材料和一定比例的第一填充材料，所述外层包括一定比例的第二纤维材料和一定比例的第二填充材料，所述第二纤维材料的比例小于所述第一纤维材料的比例，所述第二填充材料的比例大于所述第一填充材料的比例，所述外层包括穿过所述外层的多个孔。
8.根据权利要求7所述的湿式摩擦材料，其中，所述基层具有第一厚度，并且所述外层具有第二厚度，所述湿式摩擦材料具有等于所述第一厚度加上所述第二厚度的总厚度，所述第二厚度为所述总厚度的10％至30％。
9.根据权利要求7所述的湿式摩擦材料，其中，所述孔具有50μm至200μm的最大直径，并且所述孔占据所述外层的外表面的总表面积的10％至30％。
10.根据权利要求7所述的湿式摩擦材料，其中，所述第一填充材料和所述第二填充材料各自由一种或多种填料形成，所述一种或多种填料来自由硅藻土和/或黏土构成的组，其中，所述第一纤维材料和所述第二纤维材料各自由一种或多种纤维形成，所述一种或多种纤维来自由芳族聚酰胺纤维、有机纤维和/或碳纤维构成的组，所述第一纤维材料的比例按照重量百分比计在所述基层的35％至60％之间，并且所述第二纤维材料的比例按照重量百分比计在所述外层的5％至25％之间，所述第一填充材料的比例按照重量百分比计在所述基层的15％至50％之间，并且所述第二填充材料的比例按照重量百分比计在所述外层的45％至75％之间。
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Application publication date: 20200811