Lip seal for water pump

Abstract

Disclosed is a lip seal for water pump made of a rubber-like elastic material, fixed to a housing as a fixed side and in sliding contact with a shaft rotating relative to the housing; the lip seal having sliding surface with a surface roughness Ra (according to JIS B0601 corresponding to ISO 4287) of 1 to 30 m, being obtained by vulcanization-molding of a rubber composition comprising 100 parts by weight of the rubber-like elastic material, 1 to 150 parts by weight of a reinforcing filler, 5 to 90 parts by weight of a non-reinforcing filler having an average particle diameter of 1 m or more, 0.1 to 5 parts by weight of a coupling agent, 1 to 15 parts by weight of a co-crosslinking agent, and 0.5 to 10 parts by weight of an organic peroxide. The lip seal effects to prevent softening and volume swelling of the rubber-like elastic material and furthermore the generation of deposits in the rotating shaft, which are problematic for rotation torque and LLC resistance.

Claims

1. A lip seal for water pump made of a rubber-like elastic material, fixed to a housing as a fixed side and in sliding contact with a shaft rotating relative to the housing; the lip seal having sliding surface with a surface roughness Ra (according to JIS B0601 corresponding to ISO 4287) of 1 to 30 m, being obtained by vulcanization-molding of a rubber composition comprising 100 parts by weight of hydrogenated nitrile rubber or EPDM, 1 to 150 parts by weight of a reinforcing filler, 5 to 90 parts by weight of a non-reinforcing filler having an average particle diameter of 1 m or more, 0.1 to 5 parts by weight of a coupling agent, 1 to 15 parts by weight of a co-crosslinking agent, and 0.5 to 10 parts by weight of an organic peroxide.

2. The lip seal for water pump according to claim 1, wherein the hydrogenated nitrile rubber is a hydrogenated nitrile rubber that does not have a terminal functional group.

3. The lip seal for water pump according to claim 1, wherein the non-reinforcing filler is at least one member selected from a group consisting of aluminum silicate, magnesium silicate, calcium silicate, carbon fiber, iron oxide, titanium oxide, and diatomaceous earth.

4. The lip seal for water pump according to claim 1, wherein the non-reinforcing filler has an average particle diameter of 1 to 40 m.

5. The lip seal for water pump according to claim 1, wherein the non-reinforcing filler is used in an amount of 5 to 70 parts by weight.

6. The lip seal for water pump according to claim 1, wherein the reinforcing filler is carbon black or silica.

7. The lip seal for water pump according to claim 1, wherein the reinforcing filler is used in an amount of 30 to 70 parts by weight.

8. The lip seal for water pump according to claim 3, wherein the non-reinforcing filler has an average particle diameter of 1 to 40 m.

9. The lip seal for water pump according to claim 3, wherein the non-reinforcing filler is used in an amount of 5 to 70 parts by weight.

10. The lip seal for water pump according to claim 6, wherein the reinforcing filler is used in an amount of 30 to 70 parts by weight.

Description

EMBODIMENTS FOR CARRYING OUT THE INVENTION

(1) The rubber-like elastic material for forming the lip seal for water pump is at least one of any rubber-like elastic materials, such as hydrogenated nitrile rubber, EPDM, and fluororubber; among which hydrogenated nitrile rubber is preferably used. Here, hydrogenated nitrile rubber that does not have a terminal functional group is preferably used.

(2) Examples of the reinforcing filler include carbon black, silica, and the like. Moreover, the average particle diameter thereof is 5 nm to 150 m, preferably 5 nm to 50 m. The proportion of reinforcing filler is 1 to 150 parts by weight, preferably 30 to 70 parts by weight, based on 100 parts by weight of the rubber-like elastic material. When the proportion of reinforcing filler is less than this range, the required rubber physical properties are not obtained; whereas when the proportion is greater than this range, the sealing properties of the rubber decrease.

(3) The filler as other than a reinforcing filler, as non-reinforcing filler, may be any of various non-reinforcing fillers. Preferred examples thereof include silicates, such as aluminum silicate (Al.sub.2O.sub.3.SiO.sub.2), magnesium silicate (4SiO.sub.2.3MgO.H.sub.2O), and calcium silicate (CaSiO.sub.3); carbon fiber, iron oxide, titanium oxide, diatomaceous earth, or the like, that have an average particle diameter (a fiber diameter in the case of carbon fiber), as measured by laser analysis, of 1 m or more, preferably 1 to 40 m. The use of a non-reinforcing filler having such an average particle diameter can prevent softening and volume swelling caused by osmosis of LLC, while suppressing an increase in hardness. Moreover, due to the presence of such a filler in the sliding surface, deposits on the shaft generated when LLC containing phosphoric acid, or the like, is used can be cut to prevent deposition on a continuous basis.

(4) Furthermore, a roughness of about 1 to 30 m is imparted to the sliding surface, and a liquid membrane is formed by the action thereof to improve the lubrication state, thereby reducing torque and heat generation by sliding, and suppressing abrasion, etc. Imparting of a surface roughness Ra of about 1 to 30 m to the sliding surface is performed by adjusting the type and amount of filler. When Ra is lower than this range, the lubrication state of the sliding surface is worsened, and the cutting effect of deposits becomes low; as a result, deposits are formed on the sliding surface, thereby worsening the sealing properties. In contrast, when Ra is greater than this range, the gap of the sliding surface becomes large, thus worsening sealing properties.

(5) In contrast, when a non-reinforcing filler having an average particle diameter of less than 1 m is used, the cutting effect of deposits becomes low, and sealing properties cannot be ensured when LLC containing phosphoric acid, or the like, is used. Further, the liquid membrane forming ability is lowered, thereby leading to worsening of the lubrication state.

(6) The proportion of non-reinforcing filler is 5 to 90 parts by weight, preferably 5 to 70 parts by weight, based on 100 parts by weight of the rubber-like elastic material. When the proportion of filler is less than this range, the desired effect of the present invention cannot be obtained; whereas when the proportion is greater than this range, the physical property evaluation (elongation at break) is low.

(7) The coupling agent may be a silane-, titanium-, zirconium- or aluminum-based coupling agent; among which a silane-based coupling agent is preferably used. The presence of the coupling agent strengthens adhesion between the rubber and the filler, and suppresses a phenomenon in which LLC is collected in the rubber/filler interface because of osmosis of LLC. As a result, softening and swelling are suppressed. Moreover, since the volume effect of the filler relatively reduces the volume of the swollen rubber polymer, swelling is also suppressed in this respect.

(8) Examples of silane-based coupling agents include vinyl-, glycidoxy-, methacryloxy-, and amino-based silane coupling agents, such as vinyltrichlorosilane, vinyltrimethoxysilane, vinylethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropylmethyldiethoxysilane, p-styryltrimethoxysilane, 3-methacryloxypropylmethyldimethoxysilane, 3-methacryloxypropyltrimethoxysilane, N-2-(aminoethyl)-3-aminopropylmethyldimethoxysilane, 3-aminopropyltrimethoxysilane, and N-phenyl-3-aminopropyltrimethoxysilane.

(9) Examples of titanium-based coupling agents include titanium diisopropoxybis(triethanolaminate), titanium lactate ammonium salt, titanium lactate, titanium dioctyloxybis(octyleneglycolate), and the like. Examples of zirconium-based coupling agents include zirconium tetra-n-butoxide, zirconium tetraacetylacetonate, zirconium tributoxymonoacetylacetonate, zirconium monobutoxy acetylacetonatebis(ethylacetoacetate), zirconium butoxybis(ethylacetoacetate), zirconium tetraacetylacetonate, zirconium tributoxymonostearate, and the like. Moreover, examples of aluminum-based coupling agents include acetoalkoxy aluminum diisopropylate, and the like.

(10) The proportion of coupling agent is 0.1 to 5 parts by weight, preferably 0.5 to 3 parts by weight, based on 100 parts by weight of the rubber-like elastic material. When the proportion of coupling agent is less than this range, the dipping test will show inferior results; whereas when the proportion is greater than this range, physical properties, such as elongation at break, decrease.

(11) Examples of the organic peroxide include t-butyl peroxide, dicumyl peroxide, t-butylcumyl peroxide, 1,1-di(t-butylperoxy)-3,3,5-trimethylcyclohexane, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, 2,5-dimethyl-2,5-di(t-butylperoxy)hexyne-3, 1,3-di(t-butylperoxyisopropyl)benzene, 2,5-dimethyl-2,5-di(benzolyperoxy)hexane, t-butylperoxy benzoate, t-butylperoxy isopropyl dicarbonate, n-butyl-4,4-di(t-butylperoxy)valerate, and the like. The proportion of organic peroxide is 0.5 to 10 parts by weight, preferably 1 to 8 parts by weight, based on 100 parts by weight of the rubber-like elastic material.

(12) When performing organic peroxide crosslinking, a polyfunctional unsaturated compound, such as triallyl isocyanurate, triallyl cyanurate, triallyl trimellitate, trimethylolpropane trimethacrylate, or N,N-m-phenylenebismaleimide, is used as a co-crosslinking agent. The proportion of co-crosslinking agent is 1 to 15 parts by weight, preferably 2 to 10 parts by weight, based on 100 parts by weight of the rubber-like elastic material. The use of a co-crosslinking agent leads to tight crosslinking, and suppresses softening and swelling caused by osmosis of LLC. When the proportion of co-crosslinking agent is less than this range, the dipping test will show inferior results, that is, softening and swelling cannot be sufficiently suppressed. In contrast, when the proportion is greater than this range, the evaluation of physical properties, such as elongation at break, will be inferior.

(13) The composition comprising the above components may suitably contain processing aids, such as stearic acid, palmitic acid, and paraffin wax; acid acceptors, such as zinc oxide, magnesium oxide, and hydrotalcite; antioxidants; plasticizers; and other compounding agents that are generally used in the rubber industry, if necessary.

(14) The preparation of the rubber composition is carried out by kneading the components by using open rolls or a kneading machine such as intermix, kneader, or Banbury mixer. Crosslinking of the kneaded product is generally carried out by heating at about 150 to 200 C. for about 3 to 60 minutes using an injection molding machine, compression molding machine, vulcanizing press, or the like, optionally followed by secondary crosslinking by heating at about 100 to 200 C. for about 1 to 24 hours.

(15) Due to the presence of the filler having an average particle diameter of 1 m or more, the sliding surface of the vulcanization-molded lip seal has concave-convex portions with a surface roughness Ra (arithmetic average roughness defined by JIS B 0601) of 1 to 30 m. Therefore, when the lip seal is used as a lip seal made of a rubber-like elastic material, fixed to a housing as a fixed side and in sliding contact with a shaft rotating relative to the housing, the aforementioned various effects can be obtained.

EXAMPLES

(16) The following describes the present invention with reference to Examples.

Example 1

(17) TABLE-US-00001 Hydrogenated nitrile rubber (Zetpol 2011, 100 parts by weight produced by Zeon Corporation) [HNBR] Carbon black (G-SO, produced by Tokai Rubber 45 parts by weight Industries, Ltd.) [CB] Aluminum silicate (No. 5 Clay, produced by 15 parts by weight Takehara Kagaku Kogyo Co., Ltd.; average particle diameter: 5.3 m) Silane-based coupling agent (KBM602, produced 0.5 parts by weight by Shin-Etsu Chemical Co., Ltd.) Co-crosslinking agent A (Acryester ED, produced 6 parts by weight by Mitsubishi Rayon Co., Ltd.; ethyleneglycol dimethacrylate) Antioxidant (Antage 6C, produced by Kawaguchi 3 parts by weight Chemical Industry Co., Ltd.; N- 1,3-dimethylbutyl-N-phenyl-p-phenylenediamine) Organic peroxide A (Perbutyl P, produced by 3 parts by weight NOF Corporation; ,-di(t-butylperoxy)diisopropylbenzene)
The above components were kneaded by 10-inch rolls, and the knead product was subjected to primary vulcanization at 180 C. for 5 minutes and oven vulcanization (secondary vulcanization) at 150 C. for 1 hour, thereby vulcanization-molding a rubber sheet (thickness: 2 mm) and a lip seal.

(18) The obtained crosslinked products were measured by the following items. Regarding test pieces, the rubber sheet was used in the physical property evaluation and the dipping test, and the lip seal was used in the torque test and the deposition test. Physical property evaluation: Elongation at break was measured according to JIS K6251 corresponding to ISO 37 and evaluated as follows: 150% or more: ; and less than 150%: Torque test: Using water as a sealing fluid, torque was measured by rotating a 15-mm-diameter shaft at a rotational speed of 0 to 5,000 rpm and evaluated as follows: torque lower than that of Comparative Example 1: ; and torque equal to or greater than that of Comparative Example 1: Dipping test: According to JIS K6258 corresponding to ISO 1817, the test piece was dipped in an aqueous solution of organic acid-adding LLC (concentration: 30 volume %) under conditions of 120 C., atmospheric pressure (natural temperature rising), and for 2,000 hours, and the volume change after dipping was evaluated as follows: less than +10%: ; and +10% or more: Deposition test: Using an aqueous solution of phosphoric acid-adding LLC (concentration: 30 volume %) as a sealing fluid, a rotation test was performed under conditions of 6,000 rpm, 120 C., 0.15 MPa, and for 50 hours, and the results were evaluated as follows: no deposition in the sliding part of the shaft after the test: ; and deposition occurred: Surface roughness: The arithmetic average roughness Ra (3 times) of the sliding surface of the lip seal was measured according to JIS B0601 corresponding to ISO 4287 Sealing properties: The leakage rate (ml/hr) of an LLC aqueous solution during the Deposition test was measured and evaluated as follows: leakage rate of less than 0.2 ml/hr: ; and leakage rate of 0.2 ml/hr or more:

Example 2

(19) In Example 1, the amount of aluminum silicate was changed to 5 parts by weight.

Example 3

(20) In Example 1, the amount of aluminum silicate was changed to 70 parts by weight.

Example 4

(21) In Example 1, the amount of aluminum silicate was changed to 30 parts by weight, and 15 parts by weight of carbon fiber (Donacarbo S-241, produced by Osaka Gas Chemicals Co., Ltd.; fiber diameter: 13 m, fiber length: 130 m) was further used.

Example 5

(22) In Example 1, the same amount (100 parts by weight) of EPDM (EPT3045, produced by Mitsui Chemicals, Inc.) was used in place of hydrogenated nitrile rubber.

Example 6

(23) TABLE-US-00002 Fluororubber (Daiel G901 , produced by Daikin 100 parts by weight Industries, Ltd.) Carbon black (G-SO) 45 parts by weight Aluminum silicate (No. 5 Clay) 15 parts by weight Silane-based coupling agent (KBM-602) 0.5 parts by weight Co-crosslinking agent B (Taic WH-60, produced 3 parts by weight by Nippon Kasei Chemical Co., Ltd.; triallyl isocyanurate) Organic peroxide B (Perhexa 25B40, produced 2 parts by weight by NOF Corporation; 2,5-dimethyl-2,5- di(t-butylperoxy)hexane; purity: 40%)
Using the above components, kneading, vulcanization-molding, and measurement were performed in the same manner as in Example 1.

Example 7

(24) In Example 1, the same amount (15 parts by weight) of calcium silicate (NYAD 1250, produced by NYCO Minerals, Inc.; average particle diameter: 4.5 m) was used in place of aluminum silicate.

Example 8

(25) In Example 4, the same amount (30 parts by weight) of calcium silicate (NYAD 1250) was used in place of aluminum silicate.

Example 9

(26) In Example 1, 40 parts by weight of carbon fiber (Donacarbo S-341, produced by Osaka Gas Chemicals Co., Ltd.; fiber diameter: 18 m, fiber length: 180 m) was used in place of aluminum silicate.

(27) Table 1 below shows the evaluation results obtained in the Examples, together with the amount of each component (unit: part by weight).

(28) TABLE-US-00003 TABLE 1 Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 Ex. 7 Ex. 8 Ex. 9 [Composition component] HNBR 100 100 100 100 100 100 100 EPDM 100 Fluororubber 100 CB 45 45 45 45 45 45 45 45 45 Al silicate (particle 15 5 70 30 15 15 diameter: 5.3 m) Ca silicate (particle 15 30 diameter: 4.5 m) Carbon fiber (fiber 15 15 diameter: 13 m) Carbon fiber (fiber 40 diameter: 18 m) Si coupling agent 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Co-crosslinking 6 6 6 6 6 6 6 6 agent A Co-crosslinking 6 agent B Antioxidant 3 3 3 3 3 3 3 3 3 Organic peroxide A 3 3 3 3 3 3 3 3 Organic peroxide B 3 [Evaluation results] Physical property evaluation Torque test Dipping test Deposition test Surface roughness 4.0 1.5 4.8 8.2 4.1 4.3 4.0 5.6 20.0 Ra (m) Sealing properties

Comparative Example 1

(29) In Example 1, the same amount (15 parts by weight) of clay (Hydrite, produced by Takehara Kagaku Kogyo Co., Ltd.; average particle diameter: 0.68 m) was used in place of aluminum silicate.

Comparative Example 2

(30) In Example 1, the amount of aluminum silicate was changed to 100 parts by weight.

Comparative Example 3

(31) In Example 1, the amount of co-crosslinking agent A was changed to 20 parts by weight.

Comparative Example 4

(32) In Example 1, no silane-based coupling agent was used.

Comparative Example 5

(33) In Example 1, no co-crosslinking agent A was used.

Comparative Example 6

(34) In Example 1, none of aluminum silicate, silane-based coupling agent, and co-crosslinking agent A was used.

Comparative Example 7

(35) In Comparative Example 1, 30 parts by weight of mica powder (MC-120W, produced by Hayashi-Kasei Co., Ltd.; particle diameter: 53.3 m) was used in place of clay.

(36) Table 2 below shows the evaluation results obtained in the Comparative Examples, together with the amount of each component (unit: part by weight).

(37) TABLE-US-00004 TABLE 2 Comp. Comp. Comp. Comp. Comp. Comp. Comp. Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 Ex. 7 [Composition component] HNBR 100 100 100 100 100 100 100 CB 45 45 45 45 45 45 45 Al silicate (particle 100 15 15 15 diameter: 5.3 m) Clay (particle 15 diameter: 0.68 m) Mica powder (particle 30 diameter: 53.3 m) Si coupling agent 0.5 0.5 0.5 0.5 0.5 Co-crosslinking 6 6 20 6 6 agent A Antioxidant 3 3 3 3 3 3 3 Organic peroxide A 3 3 3 3 3 3 3 [Evaluation results] Physical property X X X evaluation Torque test X X Dipping test X X X Deposition test X X Surface roughness 0.5 5.1 3.9 3.8 4.2 0.3 41.2 Ra (m) Sealing properties X X X