Resin Sliding Layer with Semi-Graphite Fibers for Uniform Wear
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Solution Overview
Problem
Conventional sliding members with carbon fiber-reinforced synthetic resin layers suffer from excessive wear resistance leading to carbon fibers protruding and damaging counter shafts, causing abrasive wear due to the fibers not being worn uniformly with the resin matrix.
Innovation Solution
A sliding member with a back-metal layer and a sliding layer composed of synthetic resin and fibrous particles, where the fibrous particles are semi-graphite with a nano indenter hardness of 1000 to 5000 MPa, an average aspect ratio of not less than 5, and an average grain size of 5 to 50 µm, dispersed in the resin at a volume ratio of 1 to 15%, preventing excessive wear and damage to the counter shaft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon fiber particles are dispersed in synthetic resin to improve wear resistance and strength, then the sliding layer achieves high hardness and improved wear resistance, but the excessively high hardness damages the counter shaft and the carbon fibers protrude and fall off causing abrasive wear
Solution Approach 1:
The patent changes the particle characteristics parameters: uses semi-graphite particles with hardness of 1000 to 5000 MPa (lower than conventional carbon fibers), aspect ratio of 1.05 to 5 (controlled shape), and grain size of 5 to 50 μm (optimized dimensions). These parameter adjustments ensure the particles provide sufficient wear resistance while being soft enough to prevent counter shaft damage and wear uniformly with the resin matrix.
Solution Approach 2:
The patent creates a composite material system consisting of semi-graphite particles dispersed in a synthetic resin matrix. This composite structure combines the wear resistance benefits of semi-graphite particles with the toughness and bonding capabilities of the resin matrix, achieving balanced performance where neither component excessively wears or damages the counter shaft.
2Strength
If carbon fiber particles are used to improve strength of the sliding layer, then the fibrous shape improves strength, but the particles are not worn uniformly with the resin matrix leading to protrusion and fall-off
Solution Approach 1:
The patent optimizes the aspect ratio parameter to 1.05 to 5 (avoiding excessively high aspect ratios) and controls grain size within 5 to 50 μm. These parameter adjustments ensure that the semi-graphite particles maintain sufficient strength reinforcement while wearing at a rate compatible with the resin matrix, preventing protrusion and maintaining compositional stability.
Data Source
Figure 1~2
Figure 3
AI summary
A sliding member (1) includes a back-metal layer (2) and a sliding layer (3) on the back-metal layer (2), and the sliding layer (3) has a sliding surface (7). The sliding layer (3) includes a synthetic resin (4) and fibrous particles (5) dispersed in the synthetic resin (4). A volume ratio of the fibrous particles (5) in the sliding layer (3) is 1 to 15%, and the fibrous particles (5) are made of semi-graphite having a nano indenter hardness of 1000 to 5000 MPa. An average aspect ratio of the fibrous particles (5) is not less than 5, where an aspect ratio is defined as a ratio of a major axis to a minor axis of the fibrous particle (5) viewed from the sliding surface (7). An average grain size of the fibrous particles (5) in cross-sectional view perpendicular to the sliding surface (7) is 5 to 50 µm.