Composition for worm wheel having excellent durability with wear resistance and worm wheel prepared using the same

Abstract

The present disclosure relates to a composition for a worm wheel having excellent durability and wear resistance and a worm wheel manufactured using the same. In one embodiment, the composition for a worm wheel includes a polyamide resin, wherein the polyamide resin includes a polyamide 66 resin having a relative viscosity (RV) of about 2.5 or higher and a polyamide 12 resin having a relative viscosity (RV) of about 1.0 or higher.

Claims

1. A composition for a worm wheel comprising a polyamide resin, wherein the polyamide resin comprises a polyamide 66 resin having a relative viscosity (RV) set at higher than 4.0 and lower than or equal to 5.5 and a polyamide 12 resin having a relative viscosity (RV) set at about 1.0 or higher.

2. The composition of claim 1, wherein the composition further comprises a modified nano-clay.

3. The composition of claim 2, wherein the composition comprises about 90 wt % to about 99.9 wt % of the polyamide resin and about 0.1 wt % to about 10 wt % of the modified nano-clay.

4. The composition of claim 3, wherein the polyamide resin further comprises a polyamide 6 resin having a relative viscosity of (RV) set at about 2.5 or higher.

5. The composition of claim 4, wherein the polyamide resin comprises, based on the total weight of the composition, about 50 wt % to about 85 wt % of the polyamide 66 resin, about 5 wt % to about 20 wt % of the polyamide 6 resin, and about 5 wt % to about 40 wt % of the polyamide 12 resin.

6. The composition of claim 5, wherein the polyamide 66 resin has a relative viscosity (RV) set at higher than 4.0 and lower than or equal to 5.5, the polyamide 6 resin has a relative viscosity (RV) set at about 2.5 to about 3.5, and the polyamide 12 resin has a relative viscosity (RV) set at about 1.4 to about 2.8.

7. The composition of claim 2, wherein the modified nano-clay is a nano-clay treated with a modifier comprising one or more of a trialkyl ammonium salt and an alkyl quaternary ammonium salt, wherein the nano-clay comprises one or more of bentonite, hectorite, fluorohectorite, montmorillonite, saponite, beidellite, vermiculite and magadiite.

8. The composition of claim 7, wherein the modified nano-clay has a bulk density of about 0.11 g/cm.sup.3 to about 0.25 g/cm.sup.3 and a d-spacing of about 10 Å to about 35 Å.

9. The composition of claim 7, wherein the modifier is comprised at a concentration of about 85 meq/(100 g nano-clay) to about 125 meq/(100 g nano-clay).

10. The composition of claim 7, wherein the modifier comprises a bis(hydrogenated tallow alkyl) dimethyl salt.

11. The composition of claim 3, wherein the composition has a structure in which the modified nano-clay is attached at the hydrogen bonding position of the polyamide resin.

12. The composition of claim 1, wherein the composition has a weight difference of about 200 mg or less between before and after a Taber abrasion test (abrasive wheels: H-10; load applied to one wheel: 1 kg; 70 rpm; and 3,000 cycles) conducted in accordance with ISO 9352.

13. A worm wheel manufactured using the composition for a worm wheel according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 illustrates a worm wheel according to one embodiment of the present disclosure.

(2) FIG. 2 is a perspective view of the worm wheel according to one embodiment of the present disclosure.

(3) FIG. 3 shows (a) the hydrogen bonding structure of a polyamide resin, and (b) a structure in which a modified nano-clay is attached at the hydrogen bonding position of a polyamide resin according to the present disclosure.

(4) FIG. 4 is a photograph of a worm wheel manufactured using a composition for a worm wheel according to an Example of the present disclosure.

(5) FIG. 5 is a graph showing the results of evaluating the durability of the worm wheel of Example 7 according to the present disclosure and the worm wheel of Comparative Example 3 for the present disclosure.

(6) FIG. 6 shows (a) a photograph showing a lubricant after testing the durability of the worm wheel of Example 7 according to the present disclosure, and (b) a photograph showing a lubricant after testing the durability of the worm wheel of Comparative Example 3 for the present disclosure.

DETAILED DESCRIPTION

(7) In the following description, the detailed description of related publicly-known technology or configuration will be omitted when it may unnecessarily obscure the subject matter of the present disclosure.

(8) In addition, the terms used in the following description are terms defined taking into consideration the functions obtained in accordance with embodiments of the present disclosure, and may be changed in accordance with the option of a user or operator or a usual practice. Accordingly, the definition of the terms should be made based on the contents throughout the present specification.

(9) Composition for Worm Wheel

(10) One aspect of the present disclosure is directed to a composition for a worm wheel. In one embodiment, the composition for a worm wheel includes a polyamide resin, wherein the polyamide resin includes a polyamide 66 resin having a relative viscosity (RV) of about 2.5 or higher and a polyamide 12 resin having a relative viscosity (RV) of about 1.0 or higher.

(11) Polyamide Resin

(12) The polyamide resin may include an aliphatic polyamide resin. For example, the polyamide resin includes a polyamide 66 resin and a polyamide 12 resin. When the composition includes the polyamide resin satisfying this condition, the miscibility, wear resistance and elongation of the composition may be excellent.

(13) In one embodiment, the relative viscosity (RV) of the polyamide 66 resin is about 2.5 or higher. Under this relative viscosity condition, the wear resistance properties of the composition may be improved while the fluidity and miscibility of the composition are excellent. If the relative viscosity of the polyamide resin is lower than about 2.5, the fluidity and miscibility of the composition may be lowered or the wear resistance properties of the composition may deteriorate. For example, the relative viscosity of the polyamide 66 resin may be about 2.5 to about 5.5. For another example, the relative viscosity of the polyamide 66 resin may be about 2.6 to about 2.9. For example, it may be about 2.6, 2.7, 2.8 or 2.9.

(14) In one embodiment, the relative viscosity (RV) of the polyamide 12 resin is about 1.0 or higher. Under this relative viscosity condition, the fluidity and miscibility of the composition may be excellent. If the relative viscosity of the polyamide 12 resin is lower than about 1.0, the fluidity and miscibility of the composition may be lowered or the wear resistance properties of the composition may deteriorate. For example, the relative viscosity of the polyamide 12 resin may be about 1.4 to about 3.3. For another example, the relative viscosity of the polyamide 12 resin may be about 1.4 to about 2.8. For example, it may be about 1.4 to about 2.5. For example, it may be about 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2 or 3.3.

(15) In one embodiment, the relative viscosity is a value measured at 25° C. after adding 1 wt % of the polyamide resin to 96% sulfuric acid.

(16) In one embodiment, the polyamide resin may include, based on the total weight of the composition for a worm wheel, about 50 wt % to about 85 wt % of the polyamide 66 resin and about 15 wt % to about 50 wt % of the polyamide 12 resin. When the polyamide 66 resin and the polyamide 12 resin are included in amounts within the above ranges, the composition may have excellent miscibility, dimensional stability, durability and wear resistance.

(17) In one embodiment, the polyamide resin may further include a polyamide 6 resin. When the polyamide 6 resin is included, the wear resistance and elongation of the composition may be excellent.

(18) In one embodiment, the relative viscosity (RV) of the polyamide 6 resin may be about 2.5 or higher. Under this relative viscosity condition, the wear resistance properties of the composition may be improved while the fluidity and miscibility of the composition are excellent. For example, the relative viscosity of the polyamide 6 resin may be about 2.6 to about 3.5. For another example, it may be about 2.9 to about 3.3. For still another example, it may be about 3.0 to about 3.3.

(19) In other embodiments, the polyamide resin may include, based on the total weight of the composition for a worm wheel, about 50 wt % to about 85 wt % of the polyamide 66 resin, about 5 wt % to about 20 wt % of the polyamide 6 resin, and about 5 wt % to about 40 wt % of the polyamide 12 resin. Under these content conditions, an unpredictable synergistic effect between the constituent components of the polyamide resin may be created, and thus the miscibility and fluidity of the composition may be excellent, and the effect of improving the wear resistance and elongation of the composition may be excellent. For example, the polyamide resin may include, based on the total weight of the composition for a worm wheel, about 50 wt % to about 60 wt % of the polyamide 66 resin, about 10 wt % to about 20 wt % of the polyamide 6 resin, and about 25 wt % to about 35 wt % of the polyamide 12 resin.

(20) If only the polyamide 66 resin is applied in the present disclosure, the seasonal dimensional changes of the composition may be significant due to its high moisture absorption rate, and hence the wear resistance properties of the composition may deteriorate due to shrinkage and expansion. On the other contrary, when the polyamide 66, polyamide 6 and polyamide 12 resins are applied together in the present disclosure, the composition may have low moisture absorption rate, low shrinkage rate, and high dimensional stability, and the seasonal dimensional changes thereof may be insignificant, so that the wear resistance of the composition may be prevented from deteriorating.

(21) In addition, it is possible to prevent the wear resistance of the composition from deteriorating due to, for example, surface crazing which is caused by a chemical reaction resulting from the application of a lubricant (such as grease) to the surface of the worm wheel of the present disclosure and by heat resulting from repeated friction between parts.

(22) The polyamide 12 resin has high chemical resistance to a lubricant such as grease. Thus, when the polyamide 12 resin is included in the composition of the present disclosure, it may have an excellent effect of preventing crazing and dry sliding from being caused by a lubricant (grease) applied to the surface of the worm wheel of the present disclosure.

(23) In addition, when the polyamide resin of the present disclosure is applied, the ductility thereof may be excellent, and thus deformation may occur within a range that does not break the worm wheel, even under a condition in which an excessive load is applied. Thus, the polyamide resin may have an excellent effect of preventing cracking of the worm wheel from being caused by fatigue wear.

(24) Although the polyamide 12 resin has a high molecular weight, it has high excellent injection moldability due to its low melting point and high fluidity, and also shows excellent dimensional stability due to its low moisture absorption properties. Due to these effects, the polyamide 12 resin may have an excellent effect of suppressing fatigue wear by minimizing internal stress.

(25) In addition, the polyamide 6 resin has a high shear strength than the polyamide 12 resin, has a better fluidity due to a lower melting point than the polyamide 66 resin, and may maximize the synergistic effect between the polyamide 12 resin and the polyamide 66 resin by imparting the intermediate properties therebetween.

(26) In one embodiment, the polyamide resin may be included in an amount of about 90 wt % to about 99.9 wt % based on the total weight of the composition. When the polyamide resin is included in an amount within the above range, the durability, wear resistance and impact resistance of the composition may be excellent. For example, the polyamide resin may be included in an amount of about 95 wt % to about 99.5 wt %. For another example, it may be included in an amount of about 97 wt % to about 99.4 wt %. For example, it may be included in an amount of about 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8 or 99.9 wt %.

(27) Modified Nano-Clay

(28) The modified nano-clay is a material obtained by treating nano-clay with a modifier. When the composition includes the modified nano-clay, it may have excellent chemical resistance and wear resistance properties. The nano-clay has a structure in which lamellar crystalline layers, each having a width and length of about 1 nm to about 100 nm and a thickness of about 0.1 nm to about 3 nm, are stacked.

(29) In one embodiment, the nano-clay may include one or more of bentonite, hectorite, fluorohectorite, montmorillonite, saponite, beidellite, vermiculite and magadiite.

(30) In one embodiment, the modified nano-clay may have a bulk density of about 0.11 g/cm.sup.3 to about 0.25 g/cm.sup.3 and a d-spacing of about 10 Å to about 35 Å. Under these conditions, the wear resistance of the composition may be excellent. For example, the modified nano-clay may have a bulk density of about 7 lb/ft.sup.3 to about 14 lb/ft.sup.3 and a d-spacing of about 15 Å to about 25 Å. For another example, the modified nano-clay may have a bulk density of about 7 lb/ft.sup.3 to about 14 lb/ft.sup.3.

(31) In one embodiment, the modifier may be included at a concentration of about 85 meq/(100 g nano-clay) to about 125 meq/(100 g nano-clay). Under this condition, the wear resistance of the composition may be excellent. For example, the modifier may be included at a concentration of about 90 meq/(100 g nanoclay) to about 100 meq/(100 g nanoclay).

(32) In one embodiment, the modifier may include one or more of a trialkyl ammonium salt and an alkyl quaternary ammonium salt.

(33) In one embodiment, the alkyl quaternary ammonium salt may include one or more of dimethyl benzyl hydrogenated tallow quaternary ammonium, dimethyl hydrogenated tallow quaternary ammonium, methyl tallow bis-2-hydroxyethyl quaternary ammonium, dimethyl hydrogenated tallow 2-ethylhexyl quaternary ammonium and bis(hydrogenated tallow alkyl)dimethyl salts.

(34) In one embodiment, the alkyl quaternary ammonium salt may include a bis(hydrogenated tallow alkyl)dimethyl salt including a structure of the following Formula 1:

(35) ##STR00001##

(36) wherein T is a tallow including 65 wt % or less of C.sub.18, 30 wt % or less of C.sub.16 and 5 wt % or less of C.sub.14.

(37) FIG. 3(a) shows the hydrogen bonding structure of the polyamide resin, and FIG. 3(b) shows a structure in which the modified nano-clay is attached at the hydrogen bonding position of the polyamide resin according to the present disclosure.

(38) Referring to FIG. 3, the composition for a worm wheel according to the present disclosure may have a structure in which the modified nano-clay is attached at the hydrogen bonding position of the polyamide resin. The attached modified nano-clay may suppress polymer chain decomposition caused by penetration of the lubricant, thereby blocking the discoloration mechanism of the product and suppressing adhesive wear and corrosive debris from being caused by the decomposed lubricant component. In addition, the modified nano-clay, intercalated and exfoliated in the polyamide resin of the present disclosure, may reduce the scratch depth, exhibit an excellent effect of suppressing wear and dry sliding by increasing hardness, and improve the wear resistance of the composition.

(39) In one embodiment, the modified nano-clay may be included in an amount of about 0.1 wt % to about 10 wt % based on the total weight of the composition. When the modified nano-clay is included in an amount within the above range, it may have an excellent effect of improving wear resistance, and the elongation, durability and impact resistance of the composition may be excellent. For example, the modified nano-clay may be included in an amount of about 0.5 wt % to about 5 wt %. For another example, it may be included in an amount of about 0.6 wt % to about 3 wt %. For example, it may be included in an amount of about 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 wt %.

(40) In one embodiment, the composition for a worm wheel may be finally prepared by extruding a mixture including the polyamide 66 resin, the polyamide 6 resin, the polyamide 12 resin and the modified nano-clay through an extruder. For example, the composition for a worm wheel may be prepared by introducing a mixture including the polyamide resin and the modified nano-clay into a twin-screw extruder, and melt-kneading and extruding the mixture. In one embodiment, the extrusion may be performed at an extrusion temperature of about 200° C. to about 280° C. and a screw rotation speed of about 100 rpm to about 350 rpm. Under these conditions, the composition for a worm wheel may be easily prepared.

(41) In one embodiment, the composition for a worm wheel may have a weight difference of about 200 mg or less between before and after a Taber Abrasion Test (abrasive wheels: H-10; load applied to one wheel: 1 kg; 70 rpm; and 3,000 cycles) conducted in accordance with ISO 9352. For example, the weight difference may be 120 mg or less. For another example, the weight difference may be about 60 mg or less.

(42) In other embodiments, the composition for a worm wheel may have a weight difference of about 150 mg or less between before and after a Taber Abrasion Test (abrasive wheels: H-18; load applied to one wheel: 1 kg; 70 rpm; and 3,000 cycles) conducted in accordance with ISO 9352. For example, the weight difference may be about 100 mg or less. For another example, the weight difference may be about 50 mg or less.

(43) Worm Wheel Manufactured Using Composition for Worm Wheel

(44) Another aspect of the present disclosure is directed to a worm wheel manufactured using the composition for a worm wheel. FIG. 1 illustrates a worm wheel according to one embodiment of the present disclosure, and FIG. 2 is a perspective view of the worm wheel according to one embodiment of the present disclosure.

(45) Referring to FIGS. 1 and 2, a worm wheel 1000 according to the present disclosure may include: a cylindrical boss portion 300 having a cavity formed in the center thereof; a gear portion 100 having a plurality of gear teeth 110 formed along the outer circumference thereof; and a hub portion 200 formed between the outer circumference of the boss portion 300 and the inner circumference of the gear portion 100, wherein one or more of the boss portion 300, the gear portion 100 and the hub portion 200 may be manufactured using the composition for a worm wheel.

(46) The composition for a worm wheel according to the present disclosure and a worm wheel manufactured using the same may have excellent durability, wear resistance, dimensional stability, chemical resistance and moisture absorption resistance. In particular, the composition for a worm wheel and the worm wheel may exhibit excellent wear resistance properties even under a condition in which a load is applied repeatedly to the product surface for a long period of time. In addition, the composition for a worm wheel and the worm wheel may have excellent fluidity, injection moldability, productivity and economic efficiency.

(47) Hereinafter, the configuration and effects of the present disclosure will be described in more detail with reference to preferred examples. However, these examples are presented as preferred examples of the present disclosure and may not be construed as limiting the scope of the present disclosure in any way. The contents that are not described herein can be sufficiently and technically envisioned by those skilled in the art, and thus the description thereof will be omitted herein.

Examples and Comparative Examples

(48) The components used in the Examples of the present disclosure and Comparative Examples are as follows.

(49) (A) Polyamide 66 resin: (A1) a polyamide 66 resin having a relative viscosity of at least 2.2 and lower than 2.5 was used. (A2) a polyamide 66 resin having a relative viscosity of 2.5 to 2.9 was used. (A3) a polyamide 66 resin having a relative viscosity of 4.8 to 5.3 was used.

(50) (B) Polyamide 12 resin: (B1) a polyamide 12 resin having a relative viscosity of 1.4 to 3.3 was used. (B2) a polyamide 12 resin having a relative viscosity lower than 1.0 was used.

(51) (C) Polyamide 6 resin: (C1) a polyamide 6 resin having a relative viscosity of 2.4 to 2.7 was used. (C2) a polyamide 6 resin having a relative viscosity of 2.9 to 3.3 was used.

(52) (D) Modified nano-clay: (D1) a modified nano-clay obtained by treating bentonite with bis(hydrogenated tallow alkyl)dimethyl salt was used. (D2) a modified nan-clay obtained by treating bentonite with an alkyl quaternary ammonium salt was used. (D3) a modified nano-clay obtained by treating bentonite with a trialkyl ammonium salt was used.

Examples 1 to 10 and Comparative Examples 1 to 6

(53) Using the components and contents shown in Tables 1 and 2 below, the components were fed into a twin-screw extruder (screw rotation speed: 250 rpm; 40Φ; feed rate: 50 kg/h), melt-kneaded, and extruded at an extrusion temperature of 260° C. to 280° C., thereby preparing a pellet-shaped worm wheel composition (worm wheel gear teeth). Then, the worm wheel composition was fed into a 220-ton injection molding machine, and injection-molded under the following conditions, thereby manufacturing a worm wheel shown in FIG. 4. The conditions are as follows: the temperature around the cylinder gate: 280° C. to 290° C.; the cylinder middle temperature: 270° C. to 280° C.; the cylinder inlet temperature: 260° C. to 270° C.; the cycle time: 190 seconds; and the cooling time: 130 seconds.

(54) TABLE-US-00001 TABLE 1 Compo- nents Examples (wt %) 1 2 3 4 5 6 7 8 9 10 (A1) — — — — — — — — — — (A2) 70 85 — 69 55 84 54 54 54 — (A3) — — 54 — — — — — — 70 (B1) 30 — 30 30 30 — 30 30 30 30 (C1) — — — — — — — — — — (C2) — 15 15 — 15 15 15 15 15 — (D1) — — — — — — — —  1 — (D2) — — — — — — —  1 — — (D3) — —  1  1 —  1  1 — — — Wear 140  198  190  101  75 174  58 60 58 231  resistance test 1 (mg) Wear 98 140  125  73 56 123  39 42 45 152  resistance test 2 (mg)

(55) TABLE-US-00002 TABLE 2 Compo- nents Comparative Examples (wt %) 1 2 3 4 5 6 (A1) 100 — — — — — (A2) — 100 — — — 50 (A3) — — 100 — — — (B1) — — — — 100 — (B2) — — — — — 50 (C1) — — — — — — (C2) — — — 100 — — (D1) — — — — — — (D2) — — — — — — (D3) — — — — — — Wear 384 278 202 221 252 240  resistance test 1 (mg) Wear 232 196 165 153 135 179  resistance test 2 (mg)

Evaluation of Physical Properties

(56) For Examples 1 to 10 and Comparative Examples 1 to 6 above, the physical properties were evaluated under the conditions described below, and the results of the evaluation are shown in Tables 1 and 2 above.

(57) (1) Wear resistance test 1 (mg): A wear resistance test was conducted in accordance with the standard ISO 9352. Specifically, the wear resistance test was conducted using a wear resistance tester (Toyoseiki rotary abrasion tester), and the worm wheel compositions of the Examples and the Comparative Examples were used to prepare their respective 3-mm disk-shaped specimens. Each of the specimens was placed between two abrasive wheels (H-10 products) and rotated for 3,000 cycles at 70 rpm while applying a load thereto using a 1 kg weight, and then the change in weight of each specimen between before and after the test was examined.

(58) (2) Wear resistance test 2 (mg): Evaluation was conducted in the same manner as the wear resistance test 1, except that two H-18 products were used as the abrasive wheels.

(59) (3) Evaluation of durability: For Example 7 and Comparative Example 3 representative of the Examples and the Comparative Examples, a durability test was conducted under the conditions shown in Table 3 below, and the results of the test are shown in Table 5.

(60) TABLE-US-00003 TABLE 3 1 cycle Rotation Torque angle Speed Durability evaluation Conditions 85 Nm ±450° 180°/sec Durability: evaluated up to 1,000,000 cycles; Backlash: measured every 100,000 cycles

(61) Referring to the results in FIG. 5, it could be seen that the worm wheel of Example 7 according to the present disclosure showed a smaller change in the backlash than the worm wheel of Comparative Example 3, suggesting that the worm wheel of Example 7 according to the present disclosure has better durability performance than the worm wheel of Comparative Example 3.

(62) (4) Evaluation of chemical resistance: Chemical resistance was evaluated by examining whether or not a lubricant applied to the worm wheel would be discolored. During the evaluation of durability of (3) above, a lubricant (grease) was applied to the worm wheels of Example 7 and Comparative Example 3, and the durability of the worm wheels was evaluated. Next, whether or not the lubricant applied to the worm wheels of Example 7 and Comparative Example 3 would be discolored was observed, and the results of the observation are shown in FIG. 6. FIG. 6(a) is a photograph showing the results of evaluating the chemical resistance of the worm wheel of Example 7, and FIG. 6(b) is a photograph showing the results of evaluating the chemical resistance of the worm wheel of Comparative Example 3. Referring to the results in FIG. 6, it can be seen that the lubricant in Example 7 according to the present disclosure was not discolored, but the lubricant in Comparative Example 3 which is out of the scope of the present disclosure was discolored black. This suggests that when the composition of the present disclosure is applied, it prevents polymer chain decomposition caused by lubricant penetration, and exhibits an excellent effect of suppressing adhesive wear of the worm wheel and corrosive debris from being generated by a finely decomposed lubricant component, thereby exhibiting an excellent effect of preventing discoloration (excellent chemical resistance).

(63) Simple modifications or variations of the present disclosure may be easily carried out by those skilled in the art, and all such modifications or variations can be considered included in the scope of the present disclosure.