CN112552641A - 一种适用于时速417km/h动车组的闸片 - Google Patents
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Abstract
本发明公开了一种适用于时速417km/h动车组的闸片,其摩擦体包括丁腈橡胶8‑10%、橡胶促进剂0.5‑1%、硫磺0.5‑1%、硬脂酸0.3‑0.5%、耐高温硼改性树脂8‑10%、丁腈胶粉3‑5%、硫酸钡6‑8%、二硫化钼3‑5%、焦炭粉2‑3%、碳化硅2‑3%、还原铁粉4‑6%、铬矿粉3‑5%、硫化锑2‑3%、云母粉3‑5%、氧化铁黑1‑2%、硅酸铝3‑5%、玄武岩纤维8‑10%、胶原纤维8‑10%、芳纶纤维4‑6%、钢纤维3‑5%、碳纤维3‑5%。其制备方法包括开炼,密炼,压制,热处理等步骤。本方案比重轻,物理性能好,对车轮无热伤害;从节能环保方面有了重大提高;还具有优良的耐温性、抗热衰退性、良好的热恢复性和优良的摩擦性能。
Description
技术领域
本发明属于高速铁路制动装置技术领域,具体涉及一种适用于时速417km/h动车组
的合成闸片。
背景技术
2008年,我国第一条高速铁路开通运营;2015年底,我国高铁运营里程居世界第一
位。高速铁路改变了我国的运输格局,给人们的生活带来了更多的便捷与惊喜。目前我国高
铁运行速度已经达到300-350km/h甚至更高,但作为准高速列车时速417km/h的铁路运行网
络已经形成,我国高速铁路采用的制动闸片基本使用的是金属烧结高速闸片,金属闸片有如
下的缺点,比重大,物理性能差,对车轮热伤害严重;耐高温性能差,易变形,制动噪音
大,摩擦层的分解残物性能不稳定;此外,还存在抗热衰退性不好的问题等。随着中国经济的发展,特别是时速417km/h动车组列车的铁路运行网已经形成,开
发一种适用于时速417km/h动车组的闸片是非常必要的。
发明内容
本发明的目的是提供一种适用于时速417km/h动车组的闸片,具有比重轻、硬度低、对车轮
无热伤害的优点。
本发明采用的技术方案是:
一种适用于时速417km/h动车组的闸片,包括摩擦体和
燕尾板,其特征在于:所述摩擦体由以下质量百分比的各组分制备而成:丁腈橡胶8-10%、
橡胶促进剂0.5-1%、硫磺0.5-1%、硬脂酸0.3-0.5%、耐高温硼改性树脂8-10%、丁腈胶粉
3-5%、硫酸钡6-8%、二硫化钼3-5%、焦炭粉2-3%、碳化硅2-3%、还原铁粉4-6%、铬矿
粉3-5%、硫化锑锦2-3%、云母粉3-5%、氧化铁黑1-2%、硅酸铝3-5%、玄武岩纤维8-10%、
胶原纤维8-10%、芳纶纤维4-6%、钢纤维3-5%、碳纤维3-5%。
本发明公开了一种适用于时速417km/h动车组的闸片的制备方法,其特征在于:首
先按重量百分比称取相应重量的各组分,其制备过程包括如下步骤:
1)将丁腈橡胶分两段开炼,第一段辊温40C-45C,辊距2mm-3mm,先加丁腈橡胶,再加
入硫化促进剂,8-10分钟炼至成片后出片停放;第二段辊温35C-40C,辊距3mm-4mm,先
加一段胶,割刀混均,加硫磺、硬脂酸,辊练约8-10分钟待全部混入后割刀薄通后,出片
停放待下序使用;
2)将1)得到的胶和摩擦体其余组分都加入密炼机加压混合,温度控制在<90C,强力混合,停放降温至室温,得到混合料;
3)将2)制得的混合料用模具压制在钢背上,压机压力为18-20MPa,冷压,不加温,得到
成型半成品;
4)将3)制得的压制成型半成品装入夹具夹紧,施加10KN/m2的压力;
5)将4)中处理后的闸片在烘箱中采用热风循环电加热的方式热处理40H,温度按10-20C
/H的速率升温至350C,剩余时间恒温;恒温后取出,即热处理完成。
6)将热处理完成的产品除去夹具,进行磨削打标包装。
与现有技术相比,本发明具有如下优点:
1、本方案比重轻,物理性能好,对车轮无热伤害;从节能环保方面有了重大提高;
2、本发明摩擦体主要由高分子材料构成,在满足制动要求的基础上,减轻了机车车辆重
量,符合“轻量化”的设计要求;
3、
本发明摩擦体材料组成中采用耐高温硼改性酚醛树脂,硼改性酚醛树脂具有更好的耐高温性能,避免了传统工艺中以纯酚醛树脂为基体的摩擦材料所引起的模量过高、强度过低、噪音大、热分解温度低、摩擦层的分解残物性能不稳定的问题,因此硼改性树脂是适用该合成闸片的工艺要求的最优选择。
4、本发明摩擦体材料组成中采用丁腈橡胶,顺丁橡胶与天然橡胶和丁苯橡胶相比
具有弹性高、耐磨性好、耐寒性好、生热低、耐曲挠性和动态性能好等特点,硫化后其耐寒
性、耐磨性和弹性特别优异,动负荷下发热少,耐老化性尚好,易与天然橡胶、氯丁橡胶或
丁腈橡胶并用。且顺丁橡胶良好耐候性,耐寒性可以很好地适应中国的铁路的实际情况。
5、本发明摩擦体材料组成中采用耐热增摩填料、纤维、橡胶配合使用,使产品具有
优良的耐温性、抗热衰退性、良好的热恢复性和优良的摩擦性能。
具体实施方式
实施例
本发明公开了一种适用于时速417km/h动车组的闸片,其组成包括摩擦体和燕尾板,所述摩
擦体材料组成包括如下质量百分比的各组分:丁腈橡胶9%、橡胶促进剂0.5%、硫磺
0.75%、硬脂酸0.5%、FB88#耐高温硼改性树脂10%、丁腈胶粉5%、硫酸钡8%、二硫化钼
3%、焦炭粉3%、碳化硅3%、还原铁粉5%、铬矿粉5%、硫化锑3%、云母粉3%、氧化铁
黑1%、硅酸铝5%、玄武岩纤维10%、胶原纤维10%、芳纶纤维5%、钢纤维5%、碳纤维
5%;
上述闸片的制备方法包括如下步骤:1)将丁腈橡胶分两段开炼,第一段辊温40C-45C,辊距2mm-3mm,先加丁腈橡胶,再加
入硫化促进剂,8-10分钟炼至成片后出片停放;第二段辊温35C-40C,辊距3mm-4mm,先
加一段胶,割刀混均,加硫磺、硬脂酸,辊练约8-10分钟待全部混入后割刀薄通后,出片
停放待下序使用;
2)将1)得到的胶和摩擦体其余组分都加入密炼机加压混合,温度控制在<90C,强力混
合,停放降温至室温,得到混合料;
3)将2)制得的混合料用模具压制在特定钢背上,压机压力为18~18.5MPa,冷压,不加
温,得到成型半成品;
4)将3)制得的压制成型半成品放到自制的专用夹具夹紧,施加大约10KN/m2的压力。
5)处理后的闸片在烘箱中采用热风循环电加热热处理48H,前20H温度逐渐升高
直至最高热处理温度达到350C,后28H保持热处理温度350C,让所有原材料充分反应,保
证彻底熟透,制得合成闸瓦。热处理采用分段热处理的方式,温度逐渐升高,保证闸片表面
与其内部温度一致,力保合成材料熟成度一致,采用热风循环电加热既能保证热处理的有效
进行。
经实验检测和对比,本方案与现有技术相比具有如下优点:
1、本方案比重轻,物理性能好,对车轮无热伤害;从节能环保方面有了重大提高;
2、本发明摩擦体主要由高分子材料构成,在满足制动要求的基础上,减轻了机车车辆重
量,符合“轻量化”的设计要求;
3、
本发明摩擦体材料组成中采用耐高温硼改性酚醛树脂,硼改性酚醛树脂具有更好的耐高
温性能,避免了传统工艺中以纯酚醛树脂为基体的摩擦材料所引起的模量过高、强度过低、
噪音大、热分解温度低、摩擦层的分解残物性能不稳定的问题,因此硼改性树脂是适用该合
成闸片的工艺要求的最优选择。
4、本发明摩擦体材料组成中采用丁腈橡胶,丁腈橡胶与天然橡胶和丁苯橡胶相比,
具有弹性高、耐磨性好、耐寒性好、生热低、耐曲挠性和动态性能好等特点,硫化后其耐寒
性、耐磨性和弹性特别优异,动负荷下发热少,耐老化性尚好,易与天然橡胶、氯丁橡胶并
用。且丁腈橡胶良好耐候性,耐寒性可以很好地适应中国的铁路的实际情况。
5、本发明摩擦体材料组成中采用耐热耐热增摩填料、纤维、橡胶配合使用,使产品
具有优良的耐温性、抗热衰退性、良好的热恢复性和优良的摩擦性能。
Claims (2)
1.一种适用于时速417km/h动车组的闸片,包括摩擦体和燕尾板,其特征在于:所述摩擦
体由以下质量百分比的各组分制备而成:丁腈橡胶8-10%、橡胶促进剂0.5-1%、硫磺0.5-
1%、硬脂酸0.3-0.5%、耐高温硼改性树脂8-10%、丁腈胶粉3-5%、硫酸钡6-8%、二硫化钼
3-5%、焦炭粉2-3%、碳化硅2-3%、还原铁粉4-6%、铬矿粉3-5%、硫化锑2-3%、云母粉
3-5%、氧化铁黑1-2%、硅酸铝3-5%、玄武岩纤维8-10%、胶原纤维8-10%、芳纶纤维4-
6%、钢纤维3-5%、碳纤维3-5%。
2.一种适用于时速417km/h动车组的闸片的制备方法,其特征在于:首先按重量百分比称
取相应重量的各组分,其制备过程包括如下步骤:
1)将丁腈橡胶分两段开炼,第一段辊温40C-45C,辊距2mm-3mm,先加丁腈橡胶,再加
入硫化促进剂,8-10分钟炼至成片后出片停放;第二段辊温35C-40C,辊距3mm-4mm,先
加一段胶,割刀混均,加硫磺、硬脂酸,辊练约8-10分钟待全部混入后割刀薄通后,出片
停放待下序使用;
2)将1)得到的胶和摩擦体其余组分都加入密炼机加压混合,温度控制在<90C,强力混
合,停放降温至室温,得到混合料;
3)将2)制得的混合料用模具压制在钢背上,压机压力为18-20MPa,冷压,不加温,得到
成型半成品;
4)将3)制得的压制成型半成品装入夹具夹紧,施加10KN/m2的压力;
5)将4)中处理后的闸片在烘箱中采用热风循环电加热的方式热处理40H,温度按10-20C/H的速率升温至350C,剩余时间恒温;恒温后取出,即热处理完成;
将热处理完成的产品除去夹具,进行磨削打标包装。
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CN106366366A (zh) * | 2016-08-31 | 2017-02-01 | 沈阳远程摩擦密封材料有限公司 | 时速300km/h高速铁路制动用合成闸片 |
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