Composite Sliding Member with Segmented Fiber Layers for Adhesion
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Solution Overview
Problem
Conventional low-friction sliding members with fluororesin fibers suffer from inadequate adhesion to the substrate, leading to peeling issues and insufficient durability and abrasion resistance under strong forces, which complicates their integration and increases time, effort, and cost.
Innovation Solution
A composite sliding member is developed by integrating a multilayer woven fabric with a fluororesin fiber front surface layer and a heat-resistant fiber rear surface layer, where the heat-resistant fibers are strategically positioned to enhance adhesion with a thermoplastic resin substrate, optimizing the ratio of monofilaments in contact and not in contact with the resin for improved durability and slidability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a fluororesin fiber fabric is used on the surface of the sliding member to achieve low friction, then the friction property is improved, but the adhesion to the substrate deteriorates due to the non-sticky nature of fluorine fiber
Solution Approach 1:
The fabric is divided into two distinct layers: a fluororesin fiber layer on the front surface for low friction, and a thermoplastic resin fiber layer on the rear surface for adhesion. This segmentation allows each layer to perform its specific function optimally without compromising the other.
Solution Approach 2:
Different regions of the fabric have different material properties tailored to their specific functions. The front surface uses fluororesin fibers for low friction, while the rear surface uses thermoplastic resin fibers for adhesion. This local differentiation resolves the contradiction between low friction and adhesion.
2Strength
If engagement holes are formed in the fluorine fiber woven fabric to improve adhesion, then the adhesion is improved, but the structural integrity and durability deteriorate under strong sliding forces
Solution Approach 1:
The engagement holes are extracted from the fluororesin fiber layer and relocated to the thermoplastic resin fiber layer. This allows the fluororesin layer to maintain its structural integrity for durability while the thermoplastic layer provides the necessary adhesion through engagement holes.
Solution Approach 2:
The thermoplastic resin fiber layer acts as an intermediary between the fluororesin fiber layer and the substrate. It provides both adhesion to the substrate and structural support to the fluororesin layer, resolving the contradiction between adhesion and durability.
3Strength
If thermally fusible fibers are incorporated in the fabric surface to improve adhesion to vibration-isolating rubber, then the adhesion is improved, but the low friction property deteriorates
Solution Approach 1:
The fabric is segmented into two functional layers: the fluororesin fiber layer for low friction and the thermoplastic resin fiber layer for adhesion. This segmentation allows each layer to be optimized for its specific function without compromising the other.
Solution Approach 2:
Different regions of the fabric have different material properties tailored to their specific functions. The front surface uses fluororesin fibers for low friction, while the rear surface uses thermoplastic resin fibers for adhesion. This local differentiation resolves the contradiction between low friction and adhesion.
4Strength
If the same thermoplastic resin is used for both the fiber fabric and the molding material to achieve firm adhesion through thermal fusion, then the adhesion is improved, but the low friction property is lost
Solution Approach 1:
The fabric is constructed as a composite material combining two different fiber types: fluororesin fibers for low friction and thermoplastic resin fibers for adhesion. This composite structure allows the material to simultaneously achieve both low friction and firm adhesion properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a low-friction, heat-resistant composite sliding member with enhanced adhesion, durability, and abrasion resistance, suitable for applications in OA equipment, where it maintains performance under pressure and heat, with improved peel strength and reduced wear.
Implementation Method 1
the substrate material is injected to the rear surface of the surface layer to form the substrate while the front surface layer is softened by heating to realize the integration by thermal fusion
Implementation Method 2
sliding members having a substrate with a surface layer having a fluororesin laminated or coated thereon
Data Source
AI summary
A composite sliding member includes a combination of a fiber woven fabric and a resin member, wherein the fiber woven fabric is a multilayer woven fabric having a front surface layer serving as a sliding surface and a rear surface layer adhered to the resin member, the front surface layer mainly including a fluororesin fiber and the rear surface layer mainly including a heat resistant fiber; wherein when a cross section of the composite sliding member crossing the fiber woven fabric, the resin member, and their composite interface is observed, one heat resistant fiber A of such heat resistant fiber at a position adjacent to the resin member with no intervening other fiber in the cross section is observed, and a ratio of a number of monofilaments in the heat resistant fiber A not in close contact with the resin constituting the resin member or adjacent monofilaments in relation to a number of all monofilaments constituting the heat resistant fiber A is R1, and R1 is 0 to 70%.