BACKGROUND OF THE INVENTION
Field of the Invention

The present invention relates to a sliding member for a journal bearing. Particularly, the invention relates to a sliding member having a partially cylindrical shape and including a back metal layer and a sliding layer including synthetic resin and fibrous particles. The invention further relates to a journal bearing including the sliding member.

Description of the Related Art

A radial bearing has been used as a journal bearing for a rotation shaft of an exhaust turbine, a large-scale electrical generator or other devices. The radial bearing includes a plurality of sliding members having a bearing pad shape with a circular-arc cross section, which are arranged a rotation shaft (see e.g. JP-A-2004-156690). As the sliding member for the radial bearing, a sliding member including a resin sliding layer coated on a back metal layer has been known. JP-A-10-204282 and JP-A-2016-079391 disclose a resin composition including fibrous particles, such as glass fibrous particles, carbon fibrous particles or intermetallic compound fibrous particles, dispersed in synthetic resin to increase strength of the sliding layer. JP-A-2013-194204 discloses to disperse fibrous particles in a resin matrix in a non-oriented or isotropic manner, to prevent the fiber-reinforced resin composition from having anisotropy of strength.

SUMMARY OF THE INVENTION

During a steady operation of an exhaust turbine, a large-scale electrical generator or other devices, a lubricating fluid film, such as oil film, is formed between a surface of a shaft member and a sliding surface of a sliding member, thereby a direct contact between the shaft member and the sliding member is prevented. However, at the time of a start-up or other, the shaft starts to rotate from a stopping or stationary state and thus direct-contact occurs in the sliding, between the shaft member and the sliding member. When the sliding starts in this state, resin composition in the vicinity of the sliding surface in contact with the shaft member is drawn by the shaft member, and thus it elastically deforms toward a rotation direction of the shaft member. In the case, if the resin composition includes non-oriented or isotropically dispersed fibrous particles as disclosed in JP-A-2013-194204, the resin composition in the vicinity of the sliding surface is largely deformed, and damages such as cracking possibly occurs on the surface of the sliding layer. The damages also occur in the case where greater ratio of fibrous particles are dispersed such that a major axis thereof is directed perpendicular to the sliding surface.

On the contrary, if a greater ratio of fibrous particles are orientated in the sliding layer such that a major axis thereof is directed parallel to the sliding layer, the elastic deformation of the resin composition in the rotation direction of the shaft member decreases. Even then, the damages of the sliding layer can not be completely prevented, and furthermore another problem is raised that shearing is easily generated at an interface between the back metal layer and the sliding layer.

Accordingly, an object of the present invention is to overcomes the above problems of the conventional technologies, and provide a sliding member that is hardly subjected to damages such as cracking on a surface of a sliding layer at a startup of a bearing device, and also to shearing between the sliding layer and a back metal layer.

According to an aspect of the present invention, provided is a sliding member for a journal bearing, including a back metal layer and a sliding layer on the back metal layer. The sliding member has a shape of a partial cylinder. The sliding layer of the sliding member includes synthetic resin, and fibrous particles dispersed in the synthetic resin at a volume ratio of 10 to 35% of a volume of the sliding layer. The fibrous particles have an average particle size of 5 to 25 μm. The fibrous particles having a major axis length of not shorter than 20 μm are included at a volume ratio of not less than 10% in relation to a volume of total fibrous particles in a structure, when viewed in a cross section parallel to a circumferential direction of the sliding member and perpendicular to a sliding surface of the sliding layer (hereinafter referred to as “circumferential cross section”).

In the circumferential cross-sectional structure, a “sliding surface side area” is defined as an area from the sliding surface toward an interface between the sliding surface and the back metal layer, which has a thickness of 25% of a sliding layer thickness. An “interface side area” is defined as an area from the interface toward the sliding surface, which has a thickness of 25% of the sliding layer thickness. An “intermediate area” is defined as an area between the sliding surface side area and the interface side area. Then, in the sliding surface side area, the fibrous particles have a major axis length of not shorter than 20 μm have a dispersion index of 1.1 to 6. In the intermediate area, the fibrous particles having a major axis length of not shorter than 20 μm have the dispersion index of 0.1 to less than 1. In the interface side area, the fibrous particles having a major axis length of not shorter than 20 μm have the dispersion index of 1.1 to 6.

Here, the dispersion index is defined as an average of ratios X1/Y1 of the fibrous particles, where X1 is a length of a fibrous particle parallel to the sliding surface in the circumferential cross-sectional structure, and Y1 is a length of the fibrous particle perpendicular to the sliding surface in the circumferential cross-sectional structure.

According to an embodiment of the invention, the fibrous particles having a major axis length of not shorter than 20 μm in the circumferential cross-sectional structure preferably have an average aspect ratio of 1.5 to 10. Further preferably, the average aspect ratio is 5 to 10.

According to an embodiment, a volume ratio of the fibrous particles having a major axis length of not shorter than 20 μm is preferably not less than 30% in relation to the volume of total fibrous particles in the circumferential cross-sectional structure.

According to an embodiment, the fibrous particles are preferably one or more selected from a group consisting of glass fibrous particles, ceramic fibrous particles, carbon fibrous particles, aramid fibrous particles, acrylic fibrous particles, and polyvinyl alcohol fibrous particles.

According to an embodiment, the synthetic resin is preferably one or more selected from a group consisting of polyether ether ketone, polyether ketone, polyether sulfone, polyamide imide, polyimide, polybenzimidazole, nylon, phenol, epoxy, polyacetal, polyphenylene sulfide, polyethylene, and polyether imide.

According to an embodiment, it is preferable that the sliding layer further comprises one or more solid lubricants selected from a group consisting of graphite, molybdenum disulfide, tungsten disulfide, boron nitride, and polytetrafluoroethylene.

According to an embodiment, it is preferable that the sliding layer further comprises 1 to 10% by volume of one or more fillers selected from a group consisting of CaF₂, CaCo₃, talc, mica, mullite, iron oxide, calcium phosphate, potassium titanate, and Mo₂C (molybdenum carbide).

According to an embodiment, the back metal layer preferably comprises a porous metal portion on its surface at an interface between the back metal layer and the sliding layer.

According to another aspect of the present invention, a journal bearing including a plurality of the above sliding members is provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view depicting a circumferential cross section of a sliding member according to an embodiment of the present invention.

FIG. 1A is an enlarged view depicting a sliding surface side area of a sliding layer of the sliding member in FIG. 1.

FIG. 1B is an enlarged view depicting an intermediate surface area of the sliding layer of the sliding member in FIG. 1.

FIG. 1C is an enlarged view depicting an interface side area of the sliding layer of the sliding member in FIG. 1.

FIG. 2 is a view of a fibrous particle for explaining an aspect ratio (A).

FIG. 3 is a view of a fibrous particle for explaining a dispersion index (S).

FIG. 4 is a view depicting a circumferential cross section of a sliding member according to another embodiment of the present invention.

FIG. 5 is a view depicting a flow of molten resin.

FIG. 6 is a schematic view depicting a sliding member according to an embodiment of the present invention.

DESCRIPTION OF THE EMBODIMENT

FIG. 6 schematically depicts a partially cylindrical shaped sliding member 1 according to an embodiment of the present invention. The sliding member 1 has a shape of a partial cylinder. The partial cylinder is defined as a part obtained by cutting a cylinder along an axial direction (L direction) of the cylinder. An inner surface of the sliding member 1 constitutes a sliding surface for sliding against a shaft member during operation as a bearing. The sliding member 1 therefore includes a back metal layer 2 on an outer surface side, and a sliding layer 3 on an inner surface of the back metal layer 2. A sliding surface 30 corresponds to the inner surface of the sliding layer 3 and forms a concave surface. The sliding surface 30d has curvature designed to match with that of the opposed shaft member.

A circumferential direction of the cylindrical shape is referred to as a “circumferential direction” (C direction), that is a direction in which the partially cylindrical sliding member has a maximum curvature. An axial direction of the cylindrical shape is referred to as a “longitudinal direction” (L direction), that is a direction in which a straight line can be drawn on the partially cylindrical sliding member. The shaft member slides in the “circumferential direction” when it is used as a bearing. Thus the “circumferential direction” corresponds to a sliding direction.

FIG. 1 schematically depicts a circumferential cross section of the sliding member 1 according to an embodiment of the present invention. As described above, the circumferential cross section in this context is a cross section taken in the direction along the circumferential direction of the sliding layer 3 and perpendicular to the sliding surface 30.

The sliding member 1 includes a back metal layer 2, and a sliding layer 3 on the back metal layer 2. The sliding layer 3 includes 10 to 35 volume % of fibrous particles 5 dispersed in synthetic resin 4. The fibrous particles 5 have an average particle size of 5 to 25 μm. Fibrous particles 5 having a major axis length of not shorter than 20 μm occupy a volume ratio of not less than 10% in relation to a volume of total fibrous particles 5 when observed in a circumferential cross-sectional structure of the sliding member 1. The volume ratio is preferably not less than 30%. The “major axis length” in this context refers to a length of a fibrous particle along a direction in which the particle has maximum length.

The average particle size of the fibrous particles 5 of the sliding member 1 is determined as 5 to 25 μm for the following reason. When the average particle size is smaller than 5 μm, an effect of increasing strength (resistance to deformation) of the sliding layer 3 decreases. When the size exceeds 25 μm, shearing is easily generated in the fibrous particles 5 under a load applied to the sliding layer 3 from the shaft member.

The ratio of the fibrous particles 5 in the sliding layer 3 of the sliding member 1 is determined as 10 to 35 volume % for the following reason. When the ratio is smaller than 10%, strength (resistance to deformation) of the sliding layer 3 decreases. When the ratio exceeds 35%, the sliding layer 3 becomes brittle and thus an amount of abrasion easily increases during sliding.

The synthetic resin 4 is preferably one or more selected from polyether ether ketone, polyether ketone, polyether sulfone, polyamide imide, polyimide, polybenzimidazole, nylon, phenol, epoxy, polyacetal, polyphenylene sulfide, polyethylene, and polyether imide. The fibrous particles 5 are preferably one or more selected from glass fibrous particles, ceramic fibrous particles, carbon fibrous particles, aramid fibrous particles, acrylic fibrous particles, and polyvinyl alcohol fibrous particles. However, the synthetic resin 4 and the fibrous particles 5 may be of other materials.

The sliding layer 3 may further include one or more solid lubricants selected from graphite, molybdenum disulfide, tungsten disulfide, boron nitride, and polytetrafluoroethylene. The solid lubricant/lubricants can improve sliding properties of the sliding layer 3. The sliding layer 3 may further include 1 to 10 volume % of one or more fillers selected from CaF₂, CaCo₃, talc, mica, mullite, iron oxide, calcium phosphate, potassium titanate, and Mo₂C (molybdenum carbide). The filler/fillers can improve abrasion resistance of the sliding layer 3.

The sliding layer 3 preferably has a thickness of 0.5 to 6 mm where the thickness of the sliding member is defined as a distance from the sliding surface 30 to the interface 7 between the sliding layer 3 and the back metal layer 2 in a direction perpendicular to the sliding surface 30.

The sliding layer 3 is divided in following three regions in the circumferential cross-sectional structure of the sliding member 1:

a “sliding surface side area 31” extending from the sliding surface 30 toward the interface 7 by a length of 25% of the thickness T, where T is a thickness of the sliding layer 3;

an “interface side area 33” extending from the interface 7 toward the sliding surface 30 by a length of 25% of the thickness T; and

an “intermediate area 32” positioned between the “sliding surface side area 31” and the “interface side area 33”.

Then, the “fibrous particles 5 having a major axis length of not shorter than 20 μm” dispersed in the sliding surface side area 31 have a dispersion index S of 1.1 to 6. The “fibrous particles 5 having a major axis length of not shorter than 20 μm” dispersed in the intermediate area 32 have a dispersion index S of not less than 0.1 to less than 1, preferably 0.1 to 0.9. The “fibrous particles 5 having a major axis length of not shorter than 20 μm” dispersed in the interface side area 33 have a dispersion index S of 1.1 to 6.

Here, the dispersion indexes S is defined as an average ratio X1/Y1 of the fibrous particles 5, where, X1 is a length of a fibrous particle 5 parallel to the sliding surface 30 in the cross-sectional structure, and Y1 is a length of the fibrous particle 5 perpendicular to the sliding surface 30 in the cross-sectional structure.

FIGS. 1A through 1C schematically illustrate the cross section of the respective areas.

According to the embodiment of the present invention, the fibrous particles 5 having a major axis length of not shorter than 20 μn occupy a volume ratio of not less than 10% in relation to a volume of total fibrous particles 5. The “fibrous particles having a major axis length of not shorter than 20 μm” have a large effect in increasing a strength, or resistance to deformation, of the sliding layer 3. When the volume ratio of the “fibrous particles having a major axis length of not shorter than 20 μm” in relation to the volume of the total fibrous particles 5 is not less than 10%, the strength or the resistance to deformation is increased in a direction where major axes of the “fibrous particles having a major axis length of not shorter than 20 μm” orient in the sliding surface side area 31, the intermediate area 32, and the interface side area 33.

The dispersion index S of the fibrous particles 5 is 1.1 to 6 in the sliding surface side area 31 of the sliding layer 3 in the circumferential cross-sectional structure. The value of the dispersion index indicates that a large percentage of the fibrous particles 5 are orientated such that the major axis thereof is directed along the sliding surface 30. Thus, the sliding surface side area 31 therefore exhibits such an anisotropic property that it has higher strength (high resistance to deformation) to a load applied parallel to the sliding surface 30, while it has lower strength (low resistance to deformation) to a load applied perpendicular to the sliding surface 30.

On the other hand, the dispersion index S of the fibrous particles 5 is 01 to less than 1 in the intermediate area 32 of the sliding layer 3, more preferably 0.1 to 0.9. Thus, a large percentage of the fibrous particles 5 are orientated such that the major axis thereof is perpendicular to the sliding surface 30. Accordingly, the intermediate area 32 has an anisotropic property in a different direction from that of the sliding surface side area 31. Thus, the intermediate area 32 exhibits such a property that it has lower strength (lower resistance to deformation) to a load applied parallel to the sliding surface 30, and it has higher strength (high resistance to deformation) to a load applied perpendicular to the sliding surface 30.

The dispersion index S of the fibrous particles 5 in the interface side area 33 of the sliding layer 3 is 1.1 to 6. This index indicates that a larger ratio of the fibrous particles 5 are orientated such that the major axis thereof is directed along the sliding surface 30, similarly to the sliding surface side area 31. Accordingly, the interface side area 33 of the sliding layer 3 also has such a property that it has higher strength (high resistance to deformation) to a load applied parallel to the sliding surface 30, and it has lower strength (lower resistance to deformation) to a load perpendicular to the sliding surface 30.

Since the fibrous particles 5 have the above orientations, the resistance to deformation of the sliding surface side area 31 increases to a load applied parallel to the sliding surface 30, while the resistance to deformation of the intermediate area 32 to the load decreases. At the time of startup of the bearing device, even though the shaft member and the sliding surface 30 of the sliding layer 3 slide with each other in direct contact therebetween, the intermediate area 32 elastically deforms in the direction parallel to the sliding surface 30. Accordingly, the resin composition in the vicinity of the sliding surface of the sliding surface side area 31 of the sliding layer 3 does not subjected to excessive elastic deformation in the sliding direction, i.e., in the circumferential direction. As a result, the sliding surface 30 is prevented from cracking.

As well, the resistance to deformation of the interface side area 33 of the sliding layer 3 in the direction parallel to the sliding surface 30 is larger than that of the intermediate area 32. Thus, the load applied from the shaft member to the sliding layer 3 elastically deforms the intermediate area 32, and therefore the load does not reach an area around the interface between the interface side area 33 and the back metal layer 2. Even when a slight load, or stress, is transmitted to the interface, the stress causes only small deformation at the interface side area 33 since it has higher strength (higher resistance to deformation) in the direction parallel to the sliding surface 30. Accordingly, shearing is hardly generated between the back metal layer 2 and the resin composition of the interface in the vicinity of the area in contact with the back metal layer 2 due to different elastic deformations.

The above mechanism therefore prevents the surface of the sliding layer 3 of the sliding member 1 from damages such as cracking, even when direct contact may occur between the sliding surface 30 and the opposed shaft surface immediately after the startup of the device including the sliding member 1.

A substantially same amount of the fibrous particles 5 may be included in the sliding surface side area 31, the intermediate area 32, and the interface side area 33 of the sliding layer 3. Similarly, a substantially same amount of the “fibrous particles having a major axis length of not shorter than 20 μm” may be included in the respective areas 31 to 33.

The dispersion index of the “fibrous particles having a major axis length shorter than 20 μm” dispersed in the sliding surface side area 31, the intermediate area 32, and the interface side area 33 of the sliding layer 3 may be substantially equivalent to the dispersion index of the “fibrous particles having a major axis length of not shorter than 20 μm” dispersed in the respective areas 31 to 33.

Unlike the configuration of the embodiment of the present invention described above, in a conventional sliding member including fibrous particles dispersed in a non-oriented or isotropic manner throughout a sliding layer, the situation differs from that of the invention. In the conventional sliding member, a resin composition in the vicinity of the sliding layer surface in contact with the shaft member is drawn by the surface of the shaft member so that elastic deformation of the resin composition in the rotation direction of the shaft member increases and damages, such as cracking leading to abrasion, are generated on the surface of the sliding layer, when the sliding surface of the sliding member and the opposed shaft member are in direct contact immediately after a start-up of a bearing device.

Moreover, in a conventional sliding member which including a sliding layer including fibrous particles, of which major axis are oriented substantially in parallel to the sliding surface throughout the sliding layer, strength parallel to the sliding surface increases throughout the sliding layer. In this case, a load from the shaft member applied to the surface of the sliding layer reaches the interface between the sliding layer and the back metal layer. Thus, a shearing force is generated by an elastic deformation difference between the back metal layer made of a metal and the sliding layer made of synthetic resin. When a small shearing is generated, shearing expends from this start point, leading to exfoliation in some cases.

The “fibrous particles having a major axis length of not shorter than 20 μm” in the circumferential cross-sectional structure of the sliding member 1 according to the embodiment of the present invention preferably have an average aspect ratio of 1.5 to 10, more preferably 5 to 10, and further more preferably 7 to 10. When the average aspect ratio is smaller than 1.5, the effect of increasing the strength (resistance to deformation) of the resin layer 3 decreases. In this case, the anisotropic difference in the resistance to deformation is more likely to become insufficient for producing the effect even when the above three areas may have different orientations of the “fibrous particles having a major axis length of not shorter than 20 μm”. When the average aspect ratio exceeds 10, the fibrous particles 5 may be subjected to shearing when a load is applied to the sliding layer 3 from the shaft member.

The back metal layer 2 may include a porous metal portion 6 on its surface that is an interface between the back metal layer 2 and the sliding layer 3. FIG. 4 schematically depicts a circumferential cross section of the sliding member 1 in an embodiment in which the back metal layer 2 includes the porous metal portion 6. When the porous metal portion 6 is formed on the surface of the back metal layer 2, bonding strength between the sliding layer 3 and the back metal layer 2 increases. More specifically, the porous metal portion 6 increases a bonding force between the back metal layer 2 and the sliding layer 3 by an anchor effect, that is, a material of the sliding layer 3 impregnates in pores of the porous metal portion 6.

The porous metal portion 6 may be produced by sintering a metal powder such as Cu, Cu alloy, Fe, or an Fe alloy on a surface of a metal plate, a strip or the like. The porous metal portion 6 may have porosity of approximately 20 to 60%. The porous metal portion 6 may have a thickness of approximately 50 to 500 μm. In this case, the sliding layer 3 coated on a surface of the porous metal portion 6 may have a thickness of 0.5 to 6 mm. However, these dimensions are mere examples, and other dimensions may be adopted.

The above sliding member may be used for e.g. a journal bearing (radial bearing). For example, this bearing includes a housing defining a cylindrical inner cavity. The housing is composed of one or more of housing elements, typically two elements. A plurality of the sliding members are arranged on an inner circumferential surface in the inner cavity along a circumferential direction to support a shaft member on the sliding members. The sliding member has a partially cylindrical shape. The shape (e.g., curvature and size) is designed to match with the inner cavity and the shaft member. However, the sliding member may be also used for other bearings or for other sliding applications.

The present invention is also directed to a journal bearing including a plurality of sliding members.

A process of manufacturing the above sliding member is described in detailed hereinafter.

(1) Preparation of Fibrous Particle Material

Examples of the material of the fibrous particles include artificially produced inorganic fibrous particles (e.g., glass fibrous particles or ceramic fibrous particles), and organic fibrous particles (e.g., carbon fibrous particles, aramid fibers, acrylic fibrous particles, or polyvinyl alcohol fibrous particles).

(2) Preparation of Synthetic Resin Material Particles

Particles having an average particle size of 7 to 30 μm and an aspect ratio of 5 to 100 are preferable for the synthetic resin material. The synthetic resin may be one or more selected from polyether ether ketone, polyether ketone, polyether sulfone, polyamide imide, polyimide, polybenzimidazole, nylon, phenol, epoxy, polyacetal, polyphenylene sulfide, polyethylene, and polyether imide.

(3) Manufacture of Resin Composition Sheet

A resin composition sheet is produced from the above materials or other with use of a melt-kneading machine, a supply mold, a sheet forming mold, and drawing rolls.

“Melt-Kneading Machine”

The melt-kneading machine mixes the synthetic resin material particles, the fibrous particle material, and other optional materials, such as solid lubricant o filler, while heating the materials at a temperature of 185 to 370° C. to produce a resin composition in a molten state. The molten resin composition is extruded from the melt-kneading machine under fixed pressure.

“Supply Mold”

The molten resin composition extruded from the melt-kneading machine is constantly supplied to the sheet forming mold via the supply mold in an constant amount. The supply mold has a heater to heat the resin composition passing through the supply mold at 175 to 360° C. to maintain the resin composition in a molten state.

“Sheet Forming Mold”

The resin composition is formed into a sheet shape by the sheet forming mold. The sheet forming mold includes a cooling fluid passage inside a mold wall of the mold to cool the sheet-shaped resin composition. The molten resin composition supplied from the supply mold to the sheet forming mold is formed into a sheet shape, and then cooled while the sheet moves toward an outlet of the sheet forming mold. Accordingly, the resin composition gradually increasing its viscosity and starts to solidify, and the sheet is completely solidified before drawn out through the outlet of the forming mold. An example of a thickness of the sheet is 1 to 7 mm.

“Drawing Rolls”

The resin composition sheet is successively drawn out from the “sheet forming mold” with use of the drawing rolls. As the rolls, at least a pair of rolls moves the resin composition sheet with pressing it from both sides of the sheet. The drawing rolls are rotated in a controllable manner by an electric motor.

The completed resin composition sheet is cut in a size matched with the size of back metal used in a coating step described below.

(4) Back Metal

As the back metal layer, a metal plate made of an Fe alloy such as a hypoeutectoid steel or a stainless steel, Cu, a Cu alloy or the like may be used. A porous metal portion may be formed on a surface of the back metal layer, i.e., on the side facing an interface between the back metal layer and the sliding layer. The porous metal portion may have a same composition as the back metal layer. Alternatively, the porous metal portion may have a different composition from the back metal layer.

(5) Coating and Molding Step

The resin composition sheet is bonded to one surface of the back metal layer, or to the porous metal portion of the back metal. Subsequently, the back metal with the resin composition sheet is molded in a shape for use, such as a partial cylinder, by pressing. Then, a surface of the sliding layer and the back metal are processed or cut to make a thickness of the composition uniform. The molding is performed such that a drawn direction of the resin composition sheet in the sheet forming step becomes a circumferential direction of the partial cylinder.

Structure Control

A structure control method for controlling orientations of the fibrous particles is hereinafter described. The control is conducted by cyclically varying a drawing speed of a resin composition sheet by the drawing rolls during the manufacturing step of the resin composition sheet. At a minimum speed in this control, the molten resin composition is sufficiently supplied from the melt-kneading machine to fill the sheet forming mold at a supply pressure (or at an extrusion pressure). At a maximum speed, a slight shortage of the supply of the molten resin composition occurs for filling the sheet forming mold. For example, when a volume rate of the molten resin composition completely filling the sheet forming mold at the supply pressure is assumed to be 100, the maximum speed is determined such that the volume ratio of the resin composition sheet drawn out from the mold is approximately 120.

The cycle from the minimum to the maximum speed should be varied depending on an internal volume of the sheet forming mold, that corresponds to a volume of the molten resin within the mold. For example, when the resin composition sheet has a thickness of 1 to 7 mm and a width of 150 to 800 mm, the cycle may be approximately 5 to 10 seconds.

When the drawing speed changes from a lower speed to a higher speed and reaches close to the maximum speed, a solidified portion of the resin composition sheet moves ahead toward an outlet of the mold, while molten or semi-molten portion delays. Thus, a slight gap is produced between the solidified portion and the molten or semi-molten portion. In a subsequent change from the higher to the lower speed, molten or semi-molten resin composition is extruded from the melt-kneading machine at a fixed supply pressure and flows toward the outlet, and catches up with the solidified portion of the resin composition having gone ahead. As a result, the gap is disappears. During the molten or semi-molten resin composition flows in the gap and hit the solidified portion, disturbance of the flow of the resin composition is generated.

FIG. 5 schematically illustrates this situation. The resin composition sheet is drawn out in the direction from the right to the left in the figure (drawing direction is designated by reference “10”). The flow of the molten or semi-molten resin composition 11 is indicated by arrows. The molten or semi-molten resin composition 11 flows from the supply mold (flowing from the right side in the figure) collides with a solidified resin composition 12, and further flows toward a surface of the sheet along the solidified portion 12 while producing disturbance. At the surface area, the molted or semi-molten resin composition 11 flows along a surface of the sheet forming mold 13 and solidifies. Therefore, disturbance is hardly produced in the surface area. Accordingly, the fibrous particles in a central area of the sheet in a thickness direction is likely to have an orientation that the major axis thereof directs perpendicular to the surface of the sheet. In a surface area, however, the major axis of the fibrous particles is likely to oriented parallel to the surface of the sheet.

In a conventional method, the drawing speed of the resin composition sheet by the drawing rolls is kept constant. Thus, the molten resin composition constantly flows in one direction toward the outlet of the sheet forming mold. Accordingly, the fibrous particles have the major axis orientated parallel to a surface of the sheet throughout the sheet.

When the resin composition sheet is manufactured by a conventional injection molding, the molten resin composition is injected in a moment from a supply port of the sheet forming mold. In this case, collision and junction of the molten resin composition occur at various positions within the mold. The collision and junction of the resin composition produce a difference of the orientation between a portion where the resin composition flows in one direction and a portion where the collision occurs. As a result, the resin composition sheet has a mixture of portions where the fibrous particles are orientated parallel to the surface of the sheet and portions where the fibrous particles are oriented at random (weld portions) as viewed from the surface.

When a resin composition sheet is manufactured from a resin composition including synthetic resin, cross-linking promotor, and fibrous particles by injection molding as described in JP-A-2013-194204, the fibrous particles are dispersed in a non-oriented (isotropic) manner.

Measuring Method

The average particle size of the fibrous particles is measured as follows. Electron images of a plurality of positions in a circumferential cross section of the sliding member are taken with use of an electronic microscope at 200 magnifications. More specifically, the average particle size of the fibrous particles is obtained by measuring an area of each fibrous particle from the electron images by a typical image analysis method (analysis software: Image-Pro Plus (version 4.5) manufactured by Planetron Inc.), and a diameter of a circle having the measured area is calculated (equivalent circle diameter) and an average is obtained. However, the magnification is not limited to 200 and other magnification may be used.

Next, measuring of a volume ratio of fibrous particles having a major axis length of not shorter than 20 μm in relation to the total volume of the fibrous particles in the sliding layer is explained below. The fibrous particles in the above images are classified into a group of fibrous particles having a major axis length of not shorter than 20 μm and a group of the other fibrous particles with use of a typical image analysis method (e.g., analysis software: Image-Pro Plus (version 4.5) manufactured by Planetron Inc.). A total area of all the fibrous particles observed in the images, and a total area of the fibrous particles having a major axis length of not shorter than 20 μm in the images are measured. Thus, a ratio of the total area of the fibrous particles having a major axis length of not shorter than 20 μm in relation to the total area of all fibrous particles is obtained. Please note that the area ratio represent a volume ratio.

Next, a method for sectioning the sliding layer into the sliding surface side area, the intermediate area, and the interface side area is explained. A thickness T of the sliding layer in the direction perpendicular to the sliding surface is measured from the above electron images. A virtual line UL is drawn in parallel to the sliding surface, such that the line UL positions at a distance of 25% of the thickness T (that is, ¼*T) from the sliding surface toward the back metal layer. A virtual line LL is also drawn in parallel to the sliding surface such that the line LL positions at a distance of 25% of the thickness T (that is, ¼*T) from the interface toward the sliding surface. An area between the sliding surface of the sliding layer and the virtual line UL is defined as a “sliding surface side area”, while an area between the virtual line LL and the interface is defined as an “interface side area”. An area between the virtual line UL and the virtual line LL is defined as an “intermediate area”. The virtual lines UL and LL are depicted by dotted lines in FIG. 1.

When the back metal layer includes a porous portion on its surface, the surface of the back metal layer has recesses and protrusions. In this case, the interface between the sliding layer and the back metal layer is assumed as a virtual line in parallel to the sliding surface, which passes through a top portion of a protrusion of the surface of the back metal layer (that is the porous portion) closest to the sliding surface.

The average aspect ratio A is obtained as an average ratio of a major axis length L to a minor axis length S (major axis length L/minor axis length S) of the fibrous particles having a major axis length of not shorter than 20 μm from the electron images taken by the above method (see FIG. 2) The major axis length L of the fibrous particle indicates a length measured in a first direction in which the particle has a maximum length in the electron image, while the minor axis length S indicates a maximum length measured in a second direction perpendicular to the first direction.

The dispersion index S of the fibrous particles is obtained by measuring a length X1 of the fibrous particle having a major axis length of not shorter than 20 μm in the direction parallel to the sliding surface, and the length Y1 of the fibrous particle in the direction perpendicular to the sliding surface, and calculating an average ratio of X1/Y1 based on the electron images (see FIG. 3). As the dispersion index S of the fibrous particles indicates a value closer to zero, the dispersed fibrous particles are more oriented in the direction perpendicular to the sliding surface. As the dispersion index S indicates a larger value greater than 1.1, the major axis is more oriented in the direction parallel to the sliding surface.

EXAMPLES

For the sliding members including a back metal layer and a sliding layer, Examples 1 to 10 according to the invention and Comparative Examples 11 to 17 were produced as follows. Table 1 shows compositions of sliding layer of sliding member of Examples 1 to 10 and Comparative Examples 11 to 17.

TABLE 1

Composition (volume %)
Fibrous particle

Fibrous particle

Cross-
Average
Average

Synthetic resin
Carbon
Glass
Solid lubricant
Filler
linking
particle
aspect

Sample
PEEK
PF
fiber
fiber
Gr
MoS2
CaF2
promotor
size (μm)
ratio (A)

Example
1
90
—
10
—
—
—
—
—
5
1.4

of the
2
80
—
—
20
—
—
—
—
25
3.2

invention
3
70
—
30
—
—
—
—
—
10
3.8

4
75
—
20
—
—
—
5
—
20
5.5

5
70
—
25
—
—
5
—
—
22
6.2

6
65
—
35
—
5
—
5
—
23
7.1

7
60
—
—
20
—
10
10
—
21
9.1

8
70
—
15
—
5
—
10
—
20
10

9
75
—
—
15
—
5
5
—
20
5.9

10
—
75
—
25
—
—
—
—
5
1.7

Compar-
11
70
—
—
30
—
—
—
—
3
1.3

ative
12
70
—
—
30
—
—
—
—
30
3.2

Example
13
95
—
5
—
—
—
—
—
20
3.1

14
60
—
40
—
—
—
—
—
15
3.8

15
70
—
—
30
—
—
—
—
15
3.4

16
75
—
25
—
—
—
—
—
25
3.3

17
—
70
25
—
—
—
—
5
10
3

Fibrous particle

Dispersion index (S)

Evaluation

Sliding surface
Intermediate
Interface
Volume

Shearing in
Abrasion

Sample
side area
area
side area
ratio (%)
Cracking
interface
(μm)

Example
1
3.2
0.9
3.9
12
Absence
Absence
15.2

of the
2
4.3
0.8
4.4
29
Absence
Absence
7.2

invention
3
4.5
0.8
5.2
27
Absence
Absence
6.8

4
5.2
0.5
4.9
35
Absence
Absence
5.1

5
5.5
0.7
5.3
38
Absence
Absence
5.5

6
5.4
0.6
5.7
42
Absence
Absence
4.2

7
4.8
0.3
5.1
34
Absence
Absence
4.9

8
5.1
0.7
4.8
33
Absence
Absence
4.8

9
5.6
0.1
4.4
39
Absence
Absence
5.4

10
3.6
0.8
3.2
11
Absence
Absence
13.9

Compar-
11
3.5
1.2
3.8
8
Presence
Presence
32.3

ative
12
3.5
1.1
3.2
25
Presence
Presence
21.6

Example
13
3.3
1.2
3.2
24
Presence
Presence
26.9

14
4.2
0.9
5.1
27
Presence
Presence
20.4

15
5.2
5.1
5.5
29
Presence
Presence
23.8

16
8.3
2.8
9.7
28
Presence
Presence
19.3

17
1.1
1.2
1.3
23
Presence
Absence
36.7

Material particles for the fibrous particles used in Examples 1 to 10 and Comparative Examples 11 to 17 in Table 1 have an average particle size of 7 to 35 μm, and an average aspect ratio (major axis length/minor axis length) of 5 to 100.

The material for the synthetic resin used in Examples 1 to 10 and Comparative Examples 11 to 17 were polyether ether ketone (PEEK) particles or phenol (PF) particles. These particles had an average size of 125% of that of the material of the fibrous particles.

The material particles for the solid lubricant (MoS₂, Gr) used in Examples 5 to 9 have an average size of 30% of that of the material of the fibrous particles, while the material particles for the filler (CaF₂) have an average size of 25% of that of the material of the fibrous particles. The material particles for the cross-linking promotor used in Comparative Example 17 have an average size of 25% of that of the material of the fibrous particles.

The materials were mixed at the ratios in Table 1. The composition was pressed in a pellet. The pellets were charged in a melt-kneading machine, and then subjected to the supply mold, sheet forming mold, and drawing rolls to produce a resin composition sheet. For Examples 1 to 9 and Comparative Examples 11 to 16, the heating temperature in the melt-kneading machine was set at 350 to 390° C., while the temperature was 230° C. to 250° C. for Example 10. The resin composition sheet was drawn out by the drawing rolls at cyclically varied speed (5 to 10 seconds intervals) for Examples 1 to 10 and Comparative Examples 11 to 14 and 16, while the sheet was drawn out at a constant speed for Comparative Example 15. The resin composition sheet for Comparative Example 17 was produced by injection molding as disclosed in JP-A-2013-194204.

Subsequently, the produced resin composition sheet was coated on one surface of the back metal layer made of an Fe alloy, and then processed into a shape of a partial cylinder, which was then cut so that the composition on the back metal layer has a predetermined thickness. While the back metal layer in Examples 1 to 9 and Comparative Examples 11 to 17 was made of an Fe alloy, that of Example 10 includes a porous sintered portion made of Cu alloy on a surface of the Fe alloy. The processing of Examples 1 to 10 and Comparative Examples 11 to 16 was conducted so that the drawn direction of the resin composite sheet is parallel to the circumferential direction of the partial cylinder.

The sliding layer of the sliding member of Examples 1 to 10 and Comparative Examples 11 to 17 had a thickness of 3 mm and the back metal layer had a thickness of 10 mm.

An average particle size of the fibrous particles dispersed in the sliding layer of the sliding member of Examples and Comparative Examples are measured as explained above and the results were shown in the column “average particle size” in Table 1. Also, an average aspect ratio (A) of the “fibrous particles having a major axis length of not shorter than 20 μm” was measured as explained above and the results were shown in the column “average aspect ratio (A)” in Table 1. Each dispersion index (S) of the “fibrous particles having a major axis length of not shorter than 20 μm” dispersed in the sliding surface side area, the intermediate area, and the interface side area of the sliding layer were measured as the above and the results were shown in the column “dispersion index (S)” in Table 1. A volume ratio of the fibrous particles having a major axis length of not shorter than 20 μm in relation to the total volume of the fibrous particles dispersed in the sliding layer was measured and the results were shown in the column “volume ratio” in Table 1.

A plurality of the sliding members in a shape of a partial cylinder were combined into a cylindrical shape and a sliding test was conducted under conditions in Table 2. An amount of abrasion of the sliding layer after the sliding test for Examples and Comparative Examples were shown in the column “abrasion (μm)” in Table 1. The surface of the sliding layer was detected at a plurality of positions with a roughness tester to evaluate if any defects were generated after the sliding test for Examples and Comparative Examples. The “presence or absence of cracking” column in Table 1 shows “presence” when a defect having a depth of not less than 5 μm was measured on the surface of the sliding layer, or “absence” when no defect was measured. A test piece after the sliding test was cut in the direction parallel to the circumferential direction of the sliding member and perpendicular to the sliding surface to check if any shearing occurred at the interface between the sliding layer and the back metal with an optical microscope. The “presence or absence of shearing in interface” column in Table 1 shows “presence” when the “shearing” was detected at the interface, or “absence” when no “shearing” was detected.

TABLE 2

Testing machine
Journal sliding tester

Load
25
MPa

Rotation speed
1500
rpm

Drive mode
Repeating 0.5-minute sliding and

subsequent 5-minute stop

Number of cycles
25
cycles

Oil
VG46

Oil feeding rate
100
cc/min

Oil feeding temperature
50°
C.

Opposed shaft
SUJ2

Roughness of opposed shaft
0.2
Ra

As seen from the results shown in Table 1, an amount of abrasion after the sliding test of Examples 1 to 10 was smaller than that of Comparative Examples 11 to 17. Particularly, the abrasion was considerably reduced in Examples 4 to 9, of which an average aspect ratio (A) of the fibrous particles is 5 to 10. The abrasion of Examples 4 to 9 was smaller than that of Examples 1 to 3, since Examples 4 to 9 included the fibrous particles “having a major axis length of not shorter than 20 μm” and having an average aspect ratio of 1.5 to 10 at a volume ratio of not less than 30% while Examples 1 to 3 include these particles at a volume ratio smaller than 30%. It is considered that strength (resistance to deformation) of the sliding layer is more increased for Examples 4 to 9 as described above.

Furthermore, no cracking on the surface of the sliding layer and no shearing at the interface were detected after the sliding test in each of Examples of the invention. It is considered that cracking was prevented by the varied dispersion indexes between the sliding surface side area, the intermediate area, and the interface side area of the sliding layer as described above.

In Comparative Example 15, on the other hand, the fibrous particles in the sliding layer have the same orientation (orientation in parallel to sliding surface) between the sliding surface side area, the intermediate area, and the interface side area, and thus the cracking and the shearing were easily generated. In the case, the sliding layer was easily worn and an amount of abrasion increased.

In Comparative Example 11, since the fibrous particles have an average size smaller than 5 μm, it is considered that the effect of increasing the strength (resistance to deformation) of the sliding layer decreased. Thus, cracking on the surface of the sliding layer occurred, leading to increase of abrasion.

In the sliding layer in Comparative Example 12, since the fibrous particles have a large average size of 30 μm, it is considered that the fibrous particles itself broke by shearing when a load was applied to the sliding layer from the shaft member. Thus, cracking on the surface of the sliding layer was generated, leading to increase of abrasion and shearing was generated at the interface between the sliding layer and the back metal.

In Comparative Example 13, since the volume ratio of the fibrous particles in the sliding layer is smaller than 10%, it is considered that the strength (resistance to deformation) of the sliding layer decreased. Thus, cracking occurred on the sliding surface, leading to leading to increase of abrasion, and shearing was generated at the interface between the sliding layer and the back metal.

In Comparative Example 14, the volume ratio of the fibrous particles in the sliding layer exceeds 35%, the sliding layer became brittle. It is therefore considered that cracking occurred in the sliding surface, leading to leading to increase of abrasion, and shearing was generated at the interface between the sliding layer and the back metal.

In Comparative Example 15, since the drawing speed during the drawing step in manufacturing the resin composition sheet was kept constant, the fibrous particles orientated substantially in parallel to the sliding surface of the sliding layer (that is, great dispersion index), in the sliding surface side area, the intermediate area, and the interface side area. Thus, cracking occurred on the sliding surface, leading to leading to increase of abrasion, and shearing was generated at the interface between the sliding layer and the back metal.

In Comparative Example 16, the dispersion index of the fibrous particles in the sliding surface side area and the interface side area of the sliding layer exceeds 6, and the dispersion index of the intermediate area also exceeds 2. It is considered that the effect of in the intermediate area for releasing a load applied from the shaft member to the sliding surface decreased. Thus, cracking occurred on the sliding surface, leading to leading to increase of abrasion and shearing was generated at the interface between the sliding layer and the back metal.

In Comparative Example 17, since the resin composition sheet was produced by injection molding, the dispersion index of the fibrous particles in the sliding layer indicates non-orientation throughout the sliding layer. Thus, cracking occurred on the sliding surface, leading to increase of abrasion, when a load was applied from the shaft member.