Nonwoven material for low friction bearing surfaces
View Patent ↗The present invention relates to a saturable nonwoven material comprising fluoropolymer floc and aramid floc, which can be used as a substrate for a liner for self-lubricating bearings and for other applications.
1. A prepreg comprising a matrix resin and a saturable nonwoven material comprising a resin impregnatable structure including a mixture dispersed therein of at least one fluoropolymer floc; at least one wettable structural organic floc; and a binder wherein the binder is up to about 20% by weight of the saturable nonwoven material; and wherein the material has a basis weight of about 17 g/m 2 to about 810 g/m 2 and a thickness of about 0.02 mm to about 8.2 mm.
2. A self-lubricating bearing comprising a saturable nonwoven material comprising a resin impregnatable structure including a mixture dispersed therein of at least one fluoropolymer floc; at least one wettable structural organic floc; and a binder wherein the binder is up to about 20% by weight of the saturable nonwoven material; and wherein the material has a basis weight of about 17 g/m 2 to about 810 g/m 2 and a thickness of about 0.02 mm to about 8.2 mm.
3. A process for making a saturable nonwoven material comprising a resin impregnatable structure including a mixture dispersed therein of a least one fluoropolymer floc; at least one wettable structural organic floc; and a binder wherein the binder is up to about 20% by weight of the saturable nonwoven material; and wherein the material has a basis weight of about 17 g/m 2 to about 810 g/m 2 and a thickness of about 0.02 mm to about 8.2 mm comprising the steps of:
a) delivering an aqueous dispersion of a mixture comprising the wettable structural organic floc, fluoropolymer floc and binder onto a screen of a papermaking device;
b) withdrawing water from the aqueous dispersion to leave a wet paper felt; and
c) drying the wet paper felt.
4. The process according to claim 3 , further comprising calendering the dried nonwoven material for further densification of the material.