Sea-Island Solid Lubricant for Copper Alloy Sliding Members
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Solution Overview
Problem
Existing solid lubricants for copper alloy sliding members, such as those containing melamine-isocyanuric acid adducts or polyethylene resin with melamine cyanurate, lack malleability and effective film-forming ability, leading to poor friction coefficients and abrasion resistance, especially under high loads and micro swinging movements.
Innovation Solution
A solid lubricant with a sea-island structure comprising a hydrocarbon-based wax and polyethylene resin sea phase, and a dispersion phase containing low-molecular-weight tetrafluoroethylene resin, higher fatty acid salt, phosphate of basic nitrogen-containing compounds, and zinc stannate, with high-molecular-weight tetrafluoroethylene resin fibers, enhancing malleability and film formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If graphite-based solid lubricants are used, then the lubricant maintains lubricating performance in a wide temperature range, but the film-forming ability is insufficient and film lifetime is inadequate against repeated friction
Solution Approach 1:
The patent uses a composite solid lubricant consisting of tetrafluoroethylene resin as the base material, lead particles dispersed throughout, polyolefin resin as binder, and wax components. This composite structure combines the temperature stability of tetrafluoroethylene resin with the film-forming ability of lead and polyolefin, resolving the contradiction between temperature range performance and film lifetime.
2Duration of action of stationary object
If solid lubricants containing lead are used, then film-forming ability and film lifetime are superior, but environmental burden increases
Solution Approach 1:
The patent modifies the chemical composition parameters by replacing lead with alternative materials such as copper particles or other metal powders, while adjusting the ratios of tetrafluoroethylene resin, polyolefin resin, and wax to maintain the desired film-forming ability and film lifetime without the environmental burden of lead.
3Object-affected harmful factors
If solid lubricants without lead are used, then environmental burden is reduced, but malleability and film-forming ability become insufficient
Solution Approach 1:
The patent creates a composite structure where tetrafluoroethylene resin provides the base matrix, copper particles or other metal powders replace lead for malleability and film formation, polyolefin resin acts as binder to hold the structure, and wax components enhance the lubricating properties. This composite approach achieves environmental friendliness while maintaining necessary malleability and film-forming ability.
4Ease of manufacture
If existing solid lubricant compositions are used, then manufacturing is simplified, but sliding properties such as friction coefficient and abrasion resistance are insufficient under high load
Solution Approach 1:
The patent optimizes the compositional parameters by controlling the particle size distribution of lead or copper particles, adjusting the molecular weight and content of polyolefin resin, and fine-tuning the wax content and type. These parameter changes enhance sliding properties under high load while maintaining ease of manufacture through conventional mixing and molding processes.
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 solid lubricant achieves superior malleability, low friction coefficients, and improved abrasion resistance, enabling effective sliding via lubrication film even for micro swinging movements, while maintaining strength and moldability.
Implementation Method 1
solid lubricant, which is used for embedding in a sliding surface of a sliding member substrate
Implementation Method 2
graphite shows high resistance in the load direction and shows low resistance in the sliding direction due to its layered structure
Implementation Method 3
gives a sliding effect by forming as solid lubricant film on the sliding surface
Data Source
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AI summary
Provided are: a solid lubricant having a low friction coefficient and excellent abrasion resistance; and a sliding member having this solid lubricant embedded therein. The solid lubricant (4) has a sea-island structure, comprising: a sea phase as a continuous phase, containing a hydrocarbon-based wax and a polyethylene resin; and an island phase as a dispersion phase, containing a low-molecular weight tetrafluoroethylene resin, a higher fatty acid salt, a phosphate of basic nitrogen-containing compound, and zinc stannate. A high-molecular weight tetrafluoroethylene resin is contained in this continuous-phase sea phase in a fibrous and mesh state. The hydrocarbon-based wax content is 30-60 vol%, the polyethylene resin content is 3-10 vol%, the low-molecular weight tetrafluoroethylene resin content is 10-30% vol%, the higher fatty acid salt content is 20-40% vol%, the basic nitrogen-containing compound phosphate content is 0.5-5 vol%, the zinc stannate content is 0.5-5 vol%, and the high-molecular weight tetrafluoroethylene resin content is 1-10 vol%.