SLIDING MEMBER

Abstract

The present invention provides a sliding member which enables further reduction of friction and improvement of seizure resistance without deteriorating wear resistance of a sliding surface. The sliding member includes a porous metal base material, and a resin material with which the porous metal base material is impregnated. The sliding member includes an exposed sliding surface. The sliding surface includes a top surface made of the resin material, and a bottom surface made of the porous metal base material. A height from the bottom surface to the top surface is 10 to 30 μm, and the resin material includes fluorine resin.

Claims

1. A sliding member comprising a porous metal base material, and a resin material with which the porous metal base material is impregnated, wherein the sliding member comprises an exposed sliding surface, the sliding surface comprises a top surface made of the resin material, and a bottom surface made of the porous metal base material, a height from the bottom surface to the top surface is 10 to 30 μm, and the resin material includes fluorine resin.

2. The sliding member according to claim 1, wherein the ratio of the total area of the bottom surface to the sliding surface is 5 to 60%.

3. The sliding member according to claim 1, further comprising a back metal, wherein the porous metal base material and the resin material are arranged on one surface of the back metal.

4. The sliding member according to claim 2, further comprising a back metal, wherein the porous metal base material and the resin material are arranged on one surface of the back metal.

5. The sliding member according to claim 1, wherein the porous metal base material is formed of a spherical or irregular-shaped metal or alloy.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0019] FIG. 1 is a schematic sectional view, perpendicular to a sliding surface, of a sliding member according to the present invention;

[0020] FIG. 2 is a schematic sectional view of the sliding member in FIG. 1 before the sliding surface is subjected to cutting; and

[0021] FIG. 3 is a schematic sectional view, perpendicular to a sliding surface, of another sliding member according to the present invention.

DESCRIPTION OF THE EMBODIMENTS

[0022] Regarding a sliding member 1 according to one embodiment of the present invention, its structure and manufacturing method will be described below in detail.

Structure of Sliding Member

[0023] FIG. 1 is a schematic sectional view of the sliding member 1. The sliding member 1 includes a back metal 40, a porous metal base material 20 formed on one surface 41 of the back metal 40, and a resin material 30 impregnated into a void of the porous metal base material 20, and is formed in a plate shape.

[0024] The sliding member 1 also includes a sliding surface 10 formed on a side opposite to another surface (i.e. a back surface) 42 of the back metal 40, and the porous metal base material 20 and the resin material 30 are exposed in a mixed state on the sliding surface 10. Specifically, the sliding surface 10 includes a flat top surface 31 made of the resin material 30, and a flat bottom surface 21 made of the porous metal base material 20. The bottom surface 21 has a distance i.e. a height Hp perpendicularly measured from the one surface 41 of the back metal 40, and the top surface 31 is formed so as to be higher than this height Hp. Note that, as illustrated in FIG. 3, the top surface 31 may not be limited to a flat shape.

[0025] In the present embodiment, the height Hp of the porous metal base material 20 may be 0.3 mm, for example. Further, according to the present invention, a distance or a height h measured perpendicularly to the sliding surface 10 (or to the one surface 41 of the back metal 40) from the bottom surface 21 to the top surface 31 is 10 to 30 μm. Note that when the top surface 31 is not flat as illustrated in FIG. 3, the height h is defined as a distance measured perpendicularly to the sliding surface 10 (or to the one surface 41 of the back metal 40) from the bottom surface 21 to the highest point of the top surface 31.

[0026] As illustrated in FIG. 1, the sliding surface 10 includes a recess 11 formed due to a step between the top surface 31 and the bottom surface 21, and it will be appreciated that the depth of this recess is 10 to 30 μm.

[0027] Note that according to the present invention, the ratio of the total area of the bottom surface 21 to the sliding surface 10 (i.e. the exposure rate of the porous metal base material 20) is preferably 5 to 60%, in consideration of the lower limit value relating to wear resistance and the upper limit value relating to seizure resistance.

Material of Sliding Member

[0028] Copper, a copper alloy, a bronze-based alloy, aluminum, an aluminum alloy, iron, steel, or the like can be used for the porous metal base material 20. Further, spherical powder or irregular-shaped powder can be used for the porous metal base material 20, while it is preferable to use the irregular-shaped powder in particular.

[0029] The resin material with which the porous metal base material is impregnated includes PTFE as fluorine resin, molten fluorine resin as another resin, and graphite or molybdenum disulfide as a solid lubricant. In addition, the resin material may include an inorganic material such as barium sulfate, or hard particles such as alumina.

Manufacturing Method of Sliding Member

[0030] The sliding surface 10 is manufactured by the following steps.

[0031] (1) After fluorine resin and various fillers are mixed together, a molding aid is added to an obtained mixture, and the molding aid and the mixture are stirred and mixed together to obtain a resin raw material.

[0032] (2) The resin raw material obtained in the above step (1) is scattered and supplied onto a porous metal base material provided on a back metal made of a steel plate. The resin raw material is rolled by a roller, and impregnated into a void of the porous metal base material provided by sintering while a coating layer made of the resin raw material is uniformly formed on a surface of the porous metal base material.

[0033] (3) The member obtained in the above step (2) is held in a drying furnace heated to 100 to 200° C. to remove the molding aid.

[0034] (4) The member from which the molding aid has been removed is introduced into a heating furnace, sintered by being heated within a temperature range of 380 to 420° C., then cooled, and rolled into a predetermined dimension by a roller to form a member 1′ having a predetermined thickness (FIG. 2).

[0035] (5) A coating layer 32 side of the member 1′ obtained through the above steps (1) to (4) is cut so that the resin material and the porous metal base material have a desired height (thickness) Hp (see the broken line in FIG. 2), and a sliding member having a desired thickness is formed. Note that this cutting step may be carried out for a flat plate of the member 1′ cut into a predetermined dimension, or carried out after the member 1′ is formed into a cylindrical rolled bushing. In the case of providing a cylindrical sliding member, the cutting step is preferably carried out after the member 1′ is formed into a rolled bushing because dimensional accuracy is improved.

[0036] Although the sliding surface is once formed uniformly (i.e. flat) by the above step (5), the top surface 31 made of the resin material 30 becomes higher than the bottom surface 21 made of the porous metal base material 20 (i.e. the distance measured perpendicularly from the back metal becomes large) after the elapse of a certain time. The principle thereof is that the resin impregnated and pressed into the void of the porous metal base material in the above step (4) is at least partly unbound (relaxation of internal pressure) from the porous metal base material due to the cutting in the above step (5), and expands.

[0037] The present inventors found that the above internal pressure was determined depending on the balance of the amount of a molding aid to be mixed in a resin material, the porosity of a porous metal, the height Hp of the porous metal, and the rolling amount in the above step (4). In one embodiment of the present invention, the internal pressure of the resin material within the void of the porous metal base material was increased by setting the rolling amount in the above step (4) within a specific range, and the internal pressure was relaxed by the cutting in the above step (5), whereby a predetermined amount of a height difference was formed between the bottom surface made of the porous metal base material and the top surface made of the resin material.

[0038] Specifically, a reference rolling amount L.sub.R (mm) can be obtained by the following equation:

L.sub.R=X/100×Hp×V/100

where

[0039] L.sub.R: Reference rolling amount (mm)

[0040] X: Parts by weight (%) of a molding aid to a resin material in which fluorine resin and a filler are mixed together

[0041] V: Porosity (%) of a porous metal base material

[0042] Hp: Height (mm) of the porous metal base material.

[0043] In order to obtain the present embodiment, a rolling amount L (mm) needs to be within a range of 100 to 200% with respect to the reference rolling amount L.sub.R (mm), i.e. needs to satisfy the equation:

100≤L/L.sub.R×100 ≤200.

[0044] When L/L.sub.R×100 is less than 100%, the internal pressure of the resin material is insufficient, so that the height from the bottom surface made of the porous metal base material to the top surface made of the resin material became less than 10 μm, whereas when L/L.sub.R×100 is more than 200%, the internal pressure of the resin material became excessively high, so that the height from the bottom surface to the top surface is more than 30 μm. In addition, if a rolling amount is excessively large, there is the problem that the porous metal base material is crushed, and the ratio (exposure rate) of the area of the bottom surface (i.e. the porous metal base material) to the sliding surface after cutting varies.

[0045] In order to form a height difference between the bottom surface 21 and the top surface 31, the resin material preferably includes 65% or more of fluorine resin. This is because when the content is less than 65%, it becomes difficult for the resin material to expand by the relaxation of internal pressure. Moreover, the resin material more preferably includes PTFE and a solid lubricant. This is because a simple composition is more suited to utilize the expansibility of the resin material, whereas the solid lubricant is suited to the reduction of friction. Further, the porous metal base material is preferably irregular-shaped powder. This is because the irregular-shaped powder makes it difficult for the resin material expanded by the relaxation of internal pressure to return to an original position.

EXAMPLES

Performance Evaluation Test

[0046] In order to evaluate the wear amount, frictional coefficient, and seizure time of the sliding member according to the present invention, performance evaluation tests were conducted for Examples 1 to 7 and Comparative Examples 1 and 2.

Test Conditions

[0047] Test equipment: Thrust sliding test equipment

[0048] Load: (a: initial stage) 3 MPa.fwdarw.(b: later) 6 MPa

[0049] Speed: 1.5 m/s

[0050] Time: (a) 10 minutes .fwdarw.(b) up to seizure

[0051] Lubrication state: (a) oil bath.fwdarw.(b) oil removing

[0052] Mating shaft: S55C quenching

Test Piece

[0053] A sliding member obtained by the manufacturing method including the above steps (1) to (5) was cut to prepare a specimen having one side of 30 mm This specimen was further cut into a given thickness with a grinding wheel while using water-soluble cutting liquid to obtain a test piece.

Test Results

[0054] Test results of Examples 1 to 7 are shown in Table 1 below, and test results of Comparative Examples 1 and 2 are shown in Table 2 below. “PTFE” in the tables is CD097 manufactured by AGC, “other resins” are resins such as molten fluorine resin which are not PTFE, and “porous metal base material” is a bronze-based alloy (irregular shape) of Cu-10%Sn or a Cu-3%Sn-8%Bi alloy (spherical). Further, “amount X of molding aid” means the parts by weight (%) of a molding aid with respect to a resin material in which PTFE and a filler are mixed together, and “top surface height” means a height (μm) from the bottom surface to the top surface.

[0055] 15 to 30 parts by weight of the molding aid X are mixed to the resin material, a porous metal base material having a porosity ranging from 40% to 70% is used, a porous metal base material having a height of 0.2 to 0.4 mm is used, and a resin material in which the rolling amount L is adjusted to 0.02 to 0.08 mm is used.

[0056] Furthermore, each item in the tables was determined by the following method.

[0057] Top surface height: the test piece was observed with a laser microscope to measure a height difference

[0058] Exposure rate of porous alloy base material: the luminance of the porous metal was detected with an optical microscope, binarization was performed, and the ratio of the porous metal was determined as an exposure rate

[0059] Wear amount: a thickness difference of the test piece before and after the test was measured

[0060] Frictional coefficient: a frictional coefficient immediately after oil removing was measured

[0061] Seizure time: a time from the removal of oil to test stopping (stopped at 190° C.) was measured

[0062] As shown in Table 1, a top surface height of the present invention of 15 to 30 μm was able to be obtained by setting the ratio of the rolling amount to the reference rolling amount to 107 to 163%, and in each of these cases, the wear amount was 10 μm or less, the frictional coefficient was 0.04 or less, and the seizure time was 12 minutes or more. On the contrary, when the top surface height is 33 μm as shown in Comparative Example 1 of Table 2, the wear amount becomes an excessively large amount of 18 μm, and the frictional coefficient increases to 0.08. Further, when the top surface height is a small height of 7 μm as shown in Comparative Example 2, the wear amount is a small amount of 5 μm, but the frictional coefficient increases to 0.12, and the seizure time also worsens to 2 minutes.

[0063] While the embodiment and examples of the present invention have been described in detail with reference to the drawings and in relation to the performance evaluation tests, specific configurations are not limited thereto, and a modification which does not go so far as to depart from the spirit of the present invention set forth in claims falls within the present invention.

TABLE-US-00001 TABLE 1 Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Composition PTFE 92 78 85 65 92 85 78 of resin Other resins — 10 — 15 — — 10 material Solid Graphite 8 10 10 — — 15 10 (vol%) lubricant MoS.sub.2 — — 5 10 8 — — Inorganic material — — — 10 — — — Hard particles — 2 — — — — 2 Porous metal Kind Bronze- Bronze- Bronze- Bronze- Cu-Sn-Bi Bronze- Bronze- base material based based based based alloy based based alloy alloy alloy alloy alloy alloy L/L.sub.R × 100 (%) 129 107 119 112 163 119 107 Top surface height(μm) 28 23 20 15 30 20 18 Exposure rate of porous metal (%) 20 15 27 46 37 58 8 Wear amount(μm) 6 5 5 4 3 2 10 Frictional coefficient 0.01 0.03 0.01 0.02 0.02 0.04 0.01 Seizure time (minute) 45 30 40 12 45 16 72

TABLE-US-00002 TABLE 2 Comparative Comparative Example 1 Example 2 Composition of PTFE 92 65 resin material Other resins — 15 (vol %) Solid Graphite 8 — lubricant MoS.sub.2 — 10 Inorganic material — 10 Hard particles — — Porous metal Kind Bronze-based Bronze-based base material alloy alloy L/L.sub.R × 100 (%) 202 94 Top surface height (μm) 33 7 Exposure rate of porous metal 25 32 Wear amount (μm) 18 5 Frictional coefficient 0.08 0.12 Seizure time (minute) 10 2