Composite wear-resistant material

Abstract

The invention provides a composite wear-resistant material. The composite wear-resistant material comprises a supporting layer, a transition layer and a wear-resistant layer which are sequentially stacked, the supporting layer comprises thermoplastic polyetherimide, first reinforced fibers and inorganic filler, the heat deformation temperature of the supporting layer is T1 DEG C, and the compression strength at 150 DEG C is P1 MPa; the transition layer comprises thermoplastic polyimide, thermoplastic polyetherimide and second reinforced fibers, the thermal deformation temperature of the transition layer is T2 DEG C, and the compression strength at 150 DEG C is P2 MPa; the wear-resistant layer comprises thermoplastic polyimide, third reinforced fibers and a solid lubricant, the thermal deformation temperature of the wear-resistant layer is T3 DEG C, the compression strength at 150 DEG C is P3 MPa, the friction coefficient of the wear-resistant layer is 0.18-0.27, the absolute value of the difference between any two of T1, T2 and T3 is within 10, and the absolute value of the difference between any two of P1, P2 and P3 is within 5.

Description

Technical Field

[0001] The present application relates to the field of polymer materials, and in particular to a composite wear-resistant material. Background Art

[0002] Polymer composites are multiphase solid materials composed of polymer materials bonded with other substances of different composition, properties, and forms. In recent years, with the rapid development of the machinery industry, automobile industry and other fields, the demand for high-temperature resistant and wear-resistant polymer composite materials has increased. The most commonly used high-temperature resistant polymer materials are polyimide (PI), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), etc. Taking PI as an example, its glass transition temperature is usually above 250°C and its heat deformation temperature is 200°C. However, its high market price and high wear limit its application. It is necessary to develop high-temperature resistant and wear-resistant polymer composite materials with lower cost and better wear resistance to meet the application scenarios of high-frequency reciprocating friction wear and high-speed rotation wear in the machinery industry. Summary of the Invention

[0003] The present application provides a composite wear-resistant material, which achieves the purpose of high-temperature wear resistance based on the use of low-cost materials.

[0004] The present application provides a composite wear-resistant material, comprising a support layer, a transition layer and a wear-resistant layer stacked in sequence, the support layer comprising thermoplastic polyetherimide, a first reinforcing fiber and an inorganic filler, the heat deformation temperature of the support layer being T1°C and the compressive strength at 150°C being P1 MPa; the transition layer comprising thermoplastic polyimide, thermoplastic polyetherimide and a second reinforcing fiber, the heat deformation temperature of the transition layer being T2°C and the compressive strength at 150°C being P2 MPa; the wear-resistant layer comprising thermoplastic polyimide, a third reinforcing fiber and a solid lubricant, the heat deformation temperature of the wear-resistant layer being T3°C and the compressive strength at 150°C being P3 MPa, the friction coefficient of the wear-resistant layer being between 0.18 and 0.27, the absolute value of the difference between any two of T1, T2 and T3 being within 10, and the absolute value of the difference between any two of P1, P2 and P3 being within 6.

[0005] In any embodiment of the present application, the transition layer further comprises rare earth oxide particles and a dispersant;

[0006] Optionally, the rare earth oxide particles are selected from one or more of lanthanum oxide, yttrium oxide and cerium oxide, and / or the particle size of the rare earth oxide particles is between 800-5000 mesh;

[0007] Optionally, the dispersant includes one or more of white oil, liquid paraffin or polyethylene wax.

[0008] In any embodiment of the present application, the transition layer comprises, by weight, 35-45 parts of thermoplastic polyimide, 35-45 parts of thermoplastic polyetherimide, 10-20 parts of second reinforcing fibers, 5-15 parts of rare earth oxide particles, and 1-2 parts of a dispersant.

[0009] In any embodiment of the present application, the solid lubricant includes graphite and molybdenum disulfide;

[0010] Optionally, the particle size of the graphite is between 1000-5000 mesh;

[0011] Optionally, the particle size of molybdenum disulfide is between 1000-5000 mesh.

[0012] In any embodiment of the present application, the wear-resistant layer includes, by weight, 70-85 parts of thermoplastic polyimide, 10-15 parts of third reinforcing fibers, 1-10 parts of graphite, and 1-10 parts of molybdenum disulfide.

[0013] In any embodiment of the present application, the inorganic filler comprises calcium carbonate and aluminum oxide,

[0014] Optionally, the particle size of calcium carbonate is between 500-3000 mesh;

[0015] Optionally, the particle size of the aluminum oxide is between 500-3000 mesh.

[0016] In any embodiment of the present application, the support layer includes 70-80 parts of thermoplastic polyetherimide, 10-15 parts of first reinforcing fibers, 5-10 parts of calcium carbonate particles, and 5-10 parts of aluminum oxide.

[0017] In any embodiment of the present application, the first reinforcing fiber, the second reinforcing fiber and the third reinforcing fiber are each independently selected from glass fiber and / or carbon fiber;

[0018] Optionally, the first reinforcing fiber and the second reinforcing fiber are each independently chopped glass fibers, and further optionally glass fibers having a length of 0.1-5 mm;

[0019] Optionally, the third reinforcing fiber is selected from chopped carbon fibers, and further selected from carbon fibers with a length of 0.1-10 mm.

[0020] In any embodiment of the present application, the transition layer and the support layer further include a coupling agent, and the coupling agent is optionally selected from silane coupling agents.

[0021] In any embodiment of the present application, the ratio of the thickness of the support layer to the thickness of the intermediate layer is 80-90:5-10, and the ratio of the thickness of the support layer to the thickness of the wear-resistant layer is 80-90:5-10.

[0022] In any embodiment of the present application, the support layer, the intermediate layer and the wear-resistant layer are formed by a co-injection molding process.

[0023] The present application designs the composite wear-resistant material into a three-layer composite structure of a support layer, a transition layer and a wear-resistant layer, wherein the support layer is mainly composed of thermoplastic polyetherimide, and a first reinforcing fiber and an inorganic filler are used to reduce cost and increase strength; the wear-resistant layer uses thermoplastic polyimide to provide higher thermal stability, thereby better resisting thermal deformation caused by friction heat generated when the wear-resistant layer is used as a working contact surface, and at the same time, the third reinforcing fiber is used to further enhance the high temperature resistance of the wear-resistant layer, and solid lubricants are used to reduce the friction coefficient and enhance its wear resistance; the transition layer uses a mixture of thermoplastic polyimide and thermoplastic polyetherimide resins to adjust its thermal deformation temperature, and at the same time, the second reinforcing fiber is used to adjust its high temperature resistance and compression strength, playing a good transition role between the support layer and the wear-resistant layer, effectively reducing the risk of delamination and peeling of the support layer and the wear-resistant layer in application scenarios of high-frequency reciprocating friction wear and high-speed rotation wear in the mechanical industry. In summary, this application utilizes a support layer, a transition layer and a wear-resistant layer with the above-mentioned composition, and adjusts their respective thermal deformation temperatures and compression strengths to meet the above-mentioned conditions, thereby providing the composite material with good high temperature resistance and wear resistance, and making the three-layer structure firmly combined to meet the needs of application scenarios such as high-frequency reciprocating wear and high-speed rotation wear. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0025] Figure 1 A schematic structural diagram of a composite wear-resistant material provided in one embodiment of the present application is shown.

[0026] Reference numerals:

[0027] 10. Support layer; 20. Transition layer; 30. Wear-resistant layer. DETAILED DESCRIPTION

[0028] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and in no way constitutes any limitation on the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0029] Unless otherwise defined, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art. The terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" as used herein includes any and all combinations of one or more of the relevant listed items.

[0030] Unless otherwise specified, the mesh sizes described in this application correspond to the mesh sizes of the Taylor standard sieve, i.e., the aperture size of a 200-mesh sieve is 0.074 mm.

[0031] In order to develop a high-temperature resistant polymer composite material with lower cost and better wear resistance, the inventors of this application have tried to add reinforcing fibers, wear-resistant agents, etc. to the resin. However, the composite material is still mainly composed of resin components, so it is difficult to achieve the effect of cost reduction. In order to further reduce the problem of increased costs caused by the resin component as the main component, the inventors of this application have tried to use a multi-layer composite structure to prepare the composite material, that is, to separate the wear-resistant layer from the support layer mainly composed of resin. However, after the two are separated, stratification is likely to occur during use, resulting in the composite material failing to achieve the expected wear-resistant service life. In order to further solve this problem, the present application provides a composite wear-resistant material, such as Figure 1 As shown, it includes a support layer 10, a transition layer 20 and a wear-resistant layer 30 stacked in sequence, wherein the support layer 10 includes thermoplastic polyetherimide, a first reinforcing fiber and an inorganic filler, the heat deformation temperature of the support layer 10 is T1°C, and the compressive strength at 150°C is P1 MPa; the transition layer 20 includes thermoplastic polyimide, thermoplastic polyetherimide and a second reinforcing fiber, the heat deformation temperature of the transition layer 20 is T2°C, and the compressive strength at 150°C is P2 MPa; the wear-resistant layer 30 includes thermoplastic polyimide, a third reinforcing fiber and a solid lubricant, the heat deformation temperature of the wear-resistant layer 30 is T3°C, and the compressive strength at 150°C is P3 MPa, the friction coefficient of the wear-resistant layer 30 is between 0.18 and 0.27, the absolute value of the difference between any two of T1, T2 and T3 is within 10 (preferably within 8, more preferably within 5), and the absolute value of the difference between any two of P1, P2 and P3 is within 6 (preferably within 5, more preferably within 3).

[0032] The present application designs the composite wear-resistant material into a three-layer composite structure of a support layer, a transition layer and a wear-resistant layer, wherein the support layer is mainly composed of thermoplastic polyetherimide, and a first reinforcing fiber and an inorganic filler are used to reduce cost and increase strength; the wear-resistant layer uses thermoplastic polyimide to provide higher thermal stability, thereby better resisting thermal deformation caused by friction heat generated when the wear-resistant layer is used as a working contact surface, and at the same time, the third reinforcing fiber is used to further enhance the high temperature resistance of the wear-resistant layer, and solid lubricants are used to reduce the friction coefficient and enhance its wear resistance; the transition layer uses a mixture of thermoplastic polyimide and thermoplastic polyetherimide resins to adjust its thermal deformation temperature, and at the same time, the second reinforcing fiber is used to adjust its high temperature resistance and compression strength, playing a good transition role between the support layer and the wear-resistant layer, effectively reducing the risk of delamination and peeling of the support layer and the wear-resistant layer in application scenarios of high-frequency reciprocating friction wear and high-speed rotation wear in the mechanical industry. In summary, this application utilizes a support layer, a transition layer and a wear-resistant layer with the above-mentioned composition, and adjusts their respective thermal deformation temperatures and compression strengths to meet the above-mentioned conditions, thereby providing the composite material with good high temperature resistance and wear resistance, and making the three-layer structure firmly combined to meet the needs of application scenarios such as high-frequency reciprocating wear and high-speed rotation wear.

[0033] In some embodiments, the transition layer further comprises rare earth oxide particles and a dispersant. Introducing the rare earth oxide into the thermoplastic polyimide and thermoplastic polyetherimide improves the bonding between the transition layer and the wear-resistant layer. The addition of the dispersant controls the agglomeration of the rare earth oxide particles in the resin, improving the dispersion of the rare earth oxide in the resin and thereby further enhancing the effectiveness of the rare earth oxide particles.

[0034] In some embodiments, the rare earth oxide particles are selected from one or more of lanthanum oxide, yttrium oxide, and cerium oxide.

[0035] In order to further reduce the agglomeration of the rare earth oxide particles and improve their dispersibility in the resin, in some embodiments, the particle size of the rare earth oxide particles is between 800-5000 mesh.

[0036] In some embodiments, in order to reduce the cost of the dispersant and avoid the influence of the dispersant on the cohesion of the resin, the dispersant preferably includes one or more of white oil, liquid paraffin or polyethylene wax.

[0037] In some embodiments, the transition layer includes 35-45 parts (optionally 35, 40, or 45 parts) of thermoplastic polyimide, 35-45 parts (optionally 35, 40, or 45 parts) of thermoplastic polyetherimide, 10-20 parts (optionally 10, 13, 14, 15, or 20 parts) of a second reinforcing fiber, 5-15 parts of rare earth oxide particles (optionally 5, 8, 9, or 15 parts), and 1-2 parts of a dispersant, with the total amount of the above components in the transition layer optionally being 100 parts. This is advantageous in controlling the heat deformation temperature of the transition layer to between 215-235°C (preferably between 220-230°C) and the compressive strength at 150°C to between 65-80 MPa (preferably between 67-76 MPa), thereby ensuring that the transition layer has relatively high high-temperature resistance and provides greater mechanical support for the wear-resistant layer.

[0038] The solid lubricant used in this application can be selected from conventional lubricants used in wear-resistant structures. In some embodiments, the solid lubricant includes graphite and molybdenum disulfide. Graphite has excellent self-lubricity and good thermal conductivity, effectively reducing the coefficient of friction and its fluctuation during friction. Molybdenum disulfide forms a protective film on the surface of the friction pair, significantly reducing wear and enhancing the stability of the wear-resistant layer during friction.

[0039] In order to improve the dispersion uniformity of graphite and / or molybdenum disulfide in the resin, optionally, the particle size of graphite is between 1000-5000 mesh; optionally, the particle size of molybdenum disulfide is between 1000-5000 mesh.

[0040] In some embodiments, the wear-resistant layer includes 70-85 parts (optionally 70, 75, 80, or 85 parts) of thermoplastic polyimide, 10-15 parts of a third reinforcing fiber, 1-10 parts (optionally 1, 4, 8, or 10 parts) of graphite, and 1-10 parts (optionally 1, 4, 8, or 10 parts) of molybdenum disulfide, with the total of these components in the wear-resistant layer optionally being 100 parts. This facilitates controlling the heat deformation temperature of the wear-resistant layer to between 210 and 230° C. (preferably between 215 and 225° C.), and the compressive strength at 150° C. to between 64 and 80 MPa (preferably between 65 and 75 MPa), while also more stably controlling the friction coefficient of the wear-resistant layer.

[0041] In order to maintain the high heat resistance of the support layer at the lowest possible cost, in some embodiments, the inorganic filler includes calcium carbonate and aluminum oxide.

[0042] In some embodiments, in order to improve the dispersion uniformity of calcium carbonate and aluminum oxide in the resin, optionally, the particle size of calcium carbonate is between 500-3000 mesh; optionally, the particle size of aluminum oxide is between 500-3000 mesh.

[0043] In some embodiments, the support layer includes 70-80 parts (optionally 70, 75, or 80 parts) of thermoplastic polyetherimide, 10-15 parts (optionally 10, 12, or 15 parts) of first reinforcing fiber, 5-10 parts (optionally 5, 8, or 10 parts) of calcium carbonate particles, and 5-10 parts (optionally 5, 8, or 10 parts) of aluminum oxide, with the total of these components in the support layer optionally being 100 parts. This is advantageous in controlling the heat deformation temperature of the support layer to between 220-235°C (preferably between 220-230°C) and the compressive strength at 150°C to between 65-80 MPa (preferably between 67-76 MPa).

[0044] The first reinforcing fiber, the second reinforcing fiber, and the third reinforcing fiber used in the present application are each independently selected from conventional reinforcing fibers. In some embodiments, in order to control costs, the above-mentioned reinforcing fibers are each independently selected from glass fibers and / or carbon fibers.

[0045] In order to utilize limited reinforcing fibers to improve the high temperature resistance of the support layer and the transition layer, optionally, the first reinforcing fiber and the second reinforcing fiber are each independently chopped glass fibers, further optionally glass fibers with a length of 0.1-5 mm, and more optionally glass fibers with a length of 1-5 mm.

[0046] In order to control the influence of the third reinforcing fiber on the wear resistance of the wear-resistant layer on the basis of improving the high temperature resistance of the wear-resistant layer, optionally, the third reinforcing fiber is selected from short-cut carbon fiber, further selected as carbon fiber with a length of 0.1-10 mm, and more selected as carbon fiber with a length of 1-10 mm.

[0047] In some embodiments, in order to improve the uniformity of dispersion of the inorganic particles in the resin, the transition layer and the support layer further include a coupling agent, optionally selected from silane coupling agents, such as KH550 or KH560.

[0048] In some embodiments, the ratio of the thickness of the support layer to the thickness of the intermediate layer is 80-90:5-10, and the ratio of the thickness of the support layer to the thickness of the wear-resistant layer is 80-90:5-10. With these thickness adjustments, the support layer provides more adequate mechanical support and a high-temperature resistance foundation for the composite material, while the transition layer provides more adequate mechanical transition conditions and bonding conditions between the support layer and the wear-resistant layer, thereby providing the composite material with more adequate wear resistance.

[0049] The preparation of the support layer, intermediate layer and wear-resistant layer in the composite material can refer to the conventional preparation method of the composite material, for example, they can be extruded separately and then pressed together, or a co-extrusion process can be used. In some embodiments, the support layer, intermediate layer and wear-resistant layer are formed by a co-injection molding process. The materials of the three-layer structure have similar thermal deformation temperature and compression strength, which is conducive to the implementation of the co-injection molding process, and the co-injection molding process can further enhance the bonding strength between the layers.

[0050] The beneficial effects of the present application will be further illustrated below with reference to examples and comparative examples.

[0051] Example 1

[0052] Preparation of granules for wear-resistant layer injection molding:

[0053] The raw materials are 80 parts of thermoplastic polyimide (M200 produced by Changchun Gaoqi), 8 parts of 2500-5000 mesh graphite, 10 parts of 1±0.2mm short-cut carbon fiber and 2 parts of 2500-5000 mesh molybdenum disulfide. The above raw materials are put into a high-speed mixer and mixed evenly, and then extruded and granulated through a twin-screw extruder to obtain granules for wear-resistant layer injection molding.

[0054] Preparation of transition layer injection molding pellets:

[0055] The raw materials are 40 parts of thermoplastic polyimide (M200 produced by Changchun Gaoqi), 40 parts of thermoplastic polyetherimide (PEI 1000 of SABIC), 15 parts of 1.5±0.2 mm short-cut glass fiber treated with 1% coupling agent KH550, 5 parts of 3000-5000 mesh lanthanum oxide powder treated with 1.5% coupling agent KH550, and 1 part of white oil. The above raw materials are put into a high-speed mixer and mixed evenly, and then extruded and granulated by a twin-screw extruder to obtain transition layer injection molding pellets.

[0056] Preparation of support layer injection molding granules:

[0057] The raw materials are 75 parts of thermoplastic polyetherimide (SABIC's PEI 1000), 12 parts of 2±0.2 mm short-cut glass fibers treated with 1% coupling agent KH550, 8 parts of 2500-3000 mesh calcium carbonate, and 5 parts of 2500-3000 mesh aluminum oxide. The above raw materials are put into a high-speed mixer and mixed evenly, and then extruded and granulated through a twin-screw extruder to produce support layer injection molding pellets.

[0058] The above three kinds of pellets were placed in an oven at 150°C and dried for 4 hours, and then added to a three-barrel injection molding machine for injection molding. The total thickness was designed to be 10 mm through the mold cavity size, the wear-resistant layer thickness was 20% of the total thickness, the transition layer thickness was 20% of the total thickness, and the support layer thickness was 60% of the total thickness. During the injection molding process, the mold temperature was continuously maintained at 230±2°C to obtain the wear-resistant composite material of Example 1.

[0059] In addition, the wear-resistant layer injection molding pellets, transition layer injection molding pellets and support layer injection molding pellets in Example 1 were dried in a 150°C oven for 4 hours and then separately injection molded. During the injection molding process, the mold temperature was continuously maintained at 230±2°C to obtain separate wear-resistant layers, transition layers and support layers.

[0060] Refer to GB / T1634.2 to test the heat deformation temperature of the raw material thermoplastic polyimide, each wear-resistant layer, transition layer, support layer and wear-resistant composite material.

[0061] Refer to GB / T3960 to test the friction coefficient and wear amount of the raw material thermoplastic polyimide and the wear-resistant layer.

[0062] Refer to GB / T 1041 to test the compressive strength of each layer at 150°C.

[0063] GB / T 41501 was used to test the interlaminar shear strength.

[0064] The test results are recorded in Table 1.

[0065] Table 1

[0066] The data in Table 1 shows that the heat deformation temperatures of the wear-resistant layer, transition layer, and support layer are all higher than those of thermoplastic polyimide, and the difference between the three heat deformation temperatures is within 5, resulting in a higher heat deformation temperature for the resulting wear-resistant composite material. Furthermore, the compressive strengths of the wear-resistant layer, transition layer, and support layer are relatively uniform, resulting in similar deformation properties and high structural stability during use. A comparison of the friction coefficient and wear volume of the wear-resistant layer and thermoplastic polyimide also shows that the wear resistance of the wear-resistant layer is significantly improved compared to that of thermoplastic polyimide.

[0067] Example 2

[0068] Preparation of granules for wear-resistant layer injection molding:

[0069] The raw materials are 70 parts of thermoplastic polyimide (M200 produced by Changchun Gaoqi), 10 parts of 2500-5000 mesh graphite, 15 parts of 1±0.2mm short-cut carbon fiber and 5 parts of 2500-5000 mesh molybdenum disulfide. The above raw materials are put into a high-speed mixer and mixed evenly, and then extruded and granulated through a twin-screw extruder to obtain pellets for wear-resistant layer injection molding.

[0070] Preparation of transition layer injection molding pellets:

[0071] The raw materials are 35 parts of thermoplastic polyimide (M200 produced by Changchun Gaoqi), 45 parts of thermoplastic polyetherimide (PEI 1000 of SABIC), 14 parts of 1.5±0.2mm short-cut glass fiber treated with 1% coupling agent KH550, 5 parts of 3000-5000 mesh lanthanum oxide powder treated with 1.5% coupling agent KH550, and 1 part of white oil. The above raw materials are put into a high-speed mixer and mixed evenly, and then extruded and granulated by a twin-screw extruder to obtain transition layer injection molding pellets.

[0072] Preparation of support layer injection molding pellets: same as Example 1.

[0073] The wear-resistant composite material, the separate wear-resistant layer and the transition layer of Example 2 were obtained in the manner of Example 1.

[0074] The test was performed using the method of Example 1, and the test results are recorded in Table 2.

[0075] Table 2

[0076] Example 3

[0077] Preparation of granules for wear-resistant layer injection molding:

[0078] The raw materials are 80 parts of thermoplastic polyimide (M200 produced by Changchun Gaoqi), 8 parts of 2500-5000 mesh graphite, 10 parts of 10±0.2mm short-cut carbon fiber and 2 parts of 2500-5000 mesh molybdenum disulfide. The above raw materials are put into a high-speed mixer and mixed evenly, and then extruded and granulated through a twin-screw extruder to obtain pellets for wear-resistant layer injection molding.

[0079] Preparation of transition layer injection molding pellets:

[0080] The raw materials are 35 parts of thermoplastic polyimide (M200 produced by Changchun Gaoqi), 35 parts of thermoplastic polyetherimide (PEI 1000 of SABIC), 20 parts of 3±0.2 mm short-cut glass fiber treated with 1% coupling agent KH550, 9 parts of 3000-5000 mesh lanthanum oxide powder treated with 1.5% coupling agent KH550, and 1 part of white oil. The above raw materials are put into a high-speed mixer and mixed evenly, and then extruded and granulated by a twin-screw extruder to obtain transition layer injection molding pellets.

[0081] Preparation of support layer injection molding pellets: same as Example 2.

[0082] The wear-resistant composite material, the separate wear-resistant layer and the transition layer of Example 3 were obtained in the manner of Example 1.

[0083] The method of Example 1 was used for testing, and the test results are recorded in Table 3.

[0084] Table 3

[0085] Example 4

[0086] Preparation of granules for wear-resistant layer injection molding:

[0087] The raw materials are 85 parts of thermoplastic polyimide (M200 produced by Changchun Gaoqi), 4 parts of 2500-5000 mesh graphite, 10 parts of 1±0.2mm short-cut carbon fiber and 1 part of 2500-5000 mesh molybdenum disulfide. The above raw materials are put into a high-speed mixer and mixed evenly, and then extruded and granulated through a twin-screw extruder to obtain granules for wear-resistant layer injection molding.

[0088] Preparation of transition layer injection molding pellets:

[0089] The raw materials are 45 parts of thermoplastic polyimide (M200 produced by Changchun Gaoqi), 35 parts of thermoplastic polyetherimide (PEI 1000 of SABIC), 10 parts of 4±0.2mm short-cut glass fibers treated with 1% coupling agent KH550, 8 parts of 3000-5000 mesh lanthanum oxide powder treated with 1.5% coupling agent KH550, and 2 parts of white oil. The above raw materials are put into a high-speed mixer and mixed evenly, and then extruded and granulated by a twin-screw extruder to obtain transition layer injection molding pellets.

[0090] Preparation of support layer injection molding granules:

[0091] The raw materials are 80 parts of thermoplastic polyetherimide (SABIC's PEI 1000), 10 parts of 2±0.2 mm short-cut glass fibers treated with 1% coupling agent KH550, 5 parts of 2500-3000 mesh calcium carbonate, and 5 parts of 2500-3000 mesh aluminum oxide. The above raw materials are put into a high-speed mixer and mixed evenly, and then extruded and granulated through a twin-screw extruder to produce support layer injection molding pellets.

[0092] The wear-resistant composite material, the separate wear-resistant layer and the transition layer of Example 4 were obtained in the manner of Example 1.

[0093] The method of Example 1 was used to perform the test, and the test results are recorded in Table 4.

[0094] Table 4

[0095] Example 5

[0096] Preparation of pellets for wear-resistant layer injection molding: same as in Example 1.

[0097] Preparation of transition layer injection molding pellets:

[0098] The raw materials are 45 parts of thermoplastic polyimide (M200 produced by Changchun Gaoqi), 45 parts of thermoplastic polyetherimide (PEI 1000 of SABIC) and 10 parts of 1.5±0.2mm short-cut glass fiber treated with 1% coupling agent KH550. The above raw materials are put into a high-speed mixer and mixed evenly, and then extruded and granulated by a twin-screw extruder to obtain transition layer injection molding pellets.

[0099] Preparation of support layer injection molding pellets: same as Example 1.

[0100] The wear-resistant composite material and the separate transition layer of Example 5 were obtained in the manner of Example 1.

[0101] The test was performed using the method of Example 1, and the test results are recorded in Table 5.

[0102] Table 5

[0103] In Example 5, rare earth lanthanum oxide and white oil are not added to the transition layer, resulting in reduced bonding energy between the transition layer and the wear-resistant layer, and the shear strength is not as good as that of Examples 1 to 4.

[0104] Comparative Example 1

[0105] Preparation of pellets for wear-resistant layer injection molding: same as in Example 1.

[0106] Preparation of support layer injection molding pellets: same as Example 1.

[0107] No transition layer is set.

[0108] The above two kinds of pellets were placed in an oven at 150 ° C and dried for 4 hours, and added to a two-barrel injection molding machine for injection molding. The total thickness of the mold cavity size was designed to be 10 mm, the thickness of the wear-resistant layer was 40% of the total thickness, and the thickness of the support layer was 60% of the total thickness. During the injection molding process, the mold temperature was continuously maintained at 230 ± 2 ° C to obtain the wear-resistant composite material of Comparative Example 1.

[0109] After testing, the wear-resistant composite material has a thermal deformation temperature of 220.6°C and a compressive strength of 67.7 MPa, but its shear strength is only 54.3 MPa.

[0110] The performance of the supporting layer, transition layer and wear-resistant layer are examined below.

[0111] To prepare the support layer injection molding pellets, the chopped glass fibers in Example 1 were replaced with 1±0.2 mm long chopped glass fibers, the calcium carbonate with 500-2000 mesh size calcium carbonate, and the aluminum oxide with 5 parts 500-2000 mesh size aluminum oxide. The support layer injection molding pellets were dried in a 150°C oven for 4 hours and then individually injection molded. The mold temperature was maintained at 230±2°C during the injection molding process to produce the support layer. The support layer had a heat deformation temperature of 228°C and a compressive strength of 72.5 MPa.

[0112] To prepare the support layer injection molding pellets, chopped glass fibers with a length of 5±0.2 mm were used in place of the chopped glass fibers in Example 1. The support layer injection molding pellets were dried in a 150°C oven for 4 hours and then individually injection molded. The mold temperature was maintained at 230±2°C during the injection molding process to produce the support layer. The support layer had a heat deformation temperature of 232°C and a compressive strength of 75.6 MPa.

[0113] The transition layer injection molding compound was prepared from 35 parts thermoplastic polyimide (M200, manufactured by Changchun Gaoqi), 35 parts thermoplastic polyetherimide (PEI 1000, manufactured by SABIC), 13 parts 1.5±0.2 mm chopped glass fiber treated with 1% coupling agent KH550, 15 parts 3000-5000 mesh lanthanum oxide powder treated with 1.5% coupling agent KH550, and 2 parts white oil. These ingredients were mixed thoroughly in a high-speed mixer and then extruded and pelletized using a twin-screw extruder to produce transition layer injection molding pellets. The transition layer pellets were dried in a 150°C oven for 4 hours before being individually injection molded. The mold temperature was maintained at 230±2°C during the molding process to produce the transition layer. The resulting transition layer had a heat deformation temperature of 225°C and a compressive strength of 72 MPa.

[0114] To prepare the transition layer injection molding compound, the lanthanum oxide powder in Example 1 was replaced with 800-2500 mesh lanthanum oxide powder treated with 1.5% coupling agent KH550. The transition layer injection molding pellets were dried in a 150°C oven for 4 hours and then individually injection molded. The mold temperature was maintained at 230±2°C during the molding process to produce the transition layer. The transition layer had a heat deformation temperature of 222°C and a compressive strength of 68 MPa.

[0115] The wear-resistant layer injection molding compound was prepared from 85 parts thermoplastic polyimide (M200, manufactured by Changchun Gaoqi), 1 part 2500-5000 mesh graphite, 10 parts 1±0.2 mm chopped carbon fiber, and 4 parts 2500-5000 mesh molybdenum disulfide. These ingredients were mixed thoroughly in a high-speed mixer and then extruded and granulated using a twin-screw extruder to produce wear-resistant layer injection molding pellets. The wear-resistant layer injection molding pellets were dried in a 150°C oven for 4 hours before being individually injection molded. The mold temperature was maintained at 230±2°C during the molding process to produce the transition layer. This transition layer exhibited a heat deformation temperature of 214°C, a compressive strength of 65 MPa, and a coefficient of friction of 0.27.

[0116] Preparation of wear-resistant layer injection molding pellets: 3±0.2 mm chopped carbon fibers were substituted for the chopped carbon fibers in Example 1 to produce wear-resistant layer injection molding pellets. Each wear-resistant layer injection molding pellet was dried in a 150°C oven for 4 hours and then individually injection molded. The mold temperature was maintained at 230±2°C during the molding process to produce a transition layer. This transition layer exhibited a heat deformation temperature of 226°C, a compressive strength of 75 MPa, and a coefficient of friction of 0.21.

[0117] Preparation of wear-resistant layer injection molding pellets: 1000-2000 mesh graphite was used to replace the graphite in the wear-resistant layer injection molding pellets of Example 1, and 1000-2000 mesh molybdenum disulfide was used to replace the molybdenum disulfide in the wear-resistant layer injection molding pellets of Example 1. The remaining conditions were the same as in Example 1 to prepare the wear-resistant layer injection molding pellets. The wear-resistant layer injection molding pellets were dried in a 150°C oven for 4 hours and then individually injection molded. The mold temperature was maintained at 230±2°C during the injection molding process to produce a transition layer. The transition layer had a heat deformation temperature of 220°C, a compressive strength of 68 MPa, and a coefficient of friction of 0.23.

[0118] The above describes exemplary embodiments of the present invention. However, the scope of protection of the present invention is not limited to the above embodiments. Any modifications, equivalent substitutions, improvements, etc. made by those skilled in the art within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A composite wear-resistant material comprising a supporting layer, a transition layer and a wear-resistant layer stacked in sequence, wherein: The support layer comprises thermoplastic polyetherimide, a first reinforcing fiber and an inorganic filler, wherein the support layer has a thermal deformation temperature of T1°C and a compressive strength of P1 MPa at 150°C; The transition layer comprises thermoplastic polyimide, thermoplastic polyetherimide and a second reinforcing fiber, wherein the thermal deformation temperature of the transition layer is T2°C and the compressive strength at 150°C is P2 MPa; The wear-resistant layer comprises thermoplastic polyimide, a third reinforcing fiber and a solid lubricant. The wear-resistant layer has a thermal deformation temperature of T3°C, a compressive strength of P3 MPa at 150°C, and a friction coefficient of 0.18-0.

27. The absolute value of the difference between any two of T1, T2 and T3 is within 10, and the absolute value of the difference between any two of P1, P2 and P3 is within 6.

2. The composite wear-resistant material according to claim 1, wherein: The transition layer also includes rare earth oxide particles and a dispersant; Optionally, the rare earth oxide particles are selected from one or more of lanthanum oxide, yttrium oxide and cerium oxide, and / or the particle size of the rare earth oxide particles is between 800-5000 mesh; Optionally, the dispersant includes one or more of white oil, liquid paraffin or polyethylene wax.

3. The composite wear-resistant material according to claim 2, wherein: In parts by weight, the transition layer includes 35-45 parts of the thermoplastic polyimide, 35-45 parts of the thermoplastic polyetherimide, 10-20 parts of the second reinforcing fiber, 5-15 parts of the rare earth oxide particles and 1-2 parts of the dispersant.

4. The composite wear-resistant material according to any one of claims 1 to 3, wherein: The solid lubricant includes graphite and molybdenum disulfide; Optionally, the particle size of the graphite is between 1000-5000 mesh; Optionally, the particle size of the molybdenum disulfide is between 1000-5000 mesh.

5. The composite wear-resistant material according to claim 4, wherein: In parts by weight, the wear-resistant layer includes 70-85 parts of the thermoplastic polyimide, 10-15 parts of the third reinforcing fiber, 1-10 parts of the graphite and 1-10 parts of the molybdenum disulfide.

6. The composite wear-resistant material according to any one of claims 1 to 5, wherein: The inorganic filler includes calcium carbonate and aluminum oxide, Optionally, the particle size of the calcium carbonate is between 500-3000 mesh; Optionally, the particle size of the aluminum oxide is between 500-3000 mesh.

7. The composite wear-resistant material according to claim 6, wherein: In parts by weight, the support layer includes 70-80 parts of the thermoplastic polyetherimide, 10-15 parts of the first reinforcing fiber, 5-10 parts of the calcium carbonate particles and 5-10 parts of the aluminum oxide.

8. The composite wear-resistant material according to any one of claims 1 to 7, wherein: The first reinforcing fiber, the second reinforcing fiber and the third reinforcing fiber are each independently selected from glass fiber and / or carbon fiber; Optionally, the first reinforcing fiber and the second reinforcing fiber are each independently chopped glass fibers, and further optionally glass fibers having a length of 0.1-5 mm; Optionally, the third reinforcing fiber is selected from chopped carbon fibers, and further selected from carbon fibers with a length of 0.1-10 mm.

9. The composite wear-resistant material according to any one of claims 1 to 8, wherein: The transition layer and the support layer further comprise a coupling agent, and optionally the coupling agent is selected from a silane coupling agent.

10. The composite wear-resistant material according to any one of claims 1 to 9, wherein: The ratio of the thickness of the support layer to the thickness of the intermediate layer is 80-90:5-10, and the ratio of the thickness of the support layer to the thickness of the wear-resistant layer is 80-90:5-10.

11. The composite wear-resistant material according to any one of claims 1 to 10, wherein: The supporting layer, the middle layer and the wear-resistant layer are formed by a co-injection process.

Images