Composite bearing with enhanced wear and machinability
A self-lubricating composite material is disclosed. The self-lubricating composite material can include discontinuous polymer fiber segments dispersed within a woven matrix of semi-continuous thermoplastic fiber. The woven matrix can be embedded within a thermosetting resin. Also disclosed are methods of manufacturing the self-lubricating composite material.
1. A self-lubricating composite material comprising:
a woven matrix of semi-continuous thermoplastic fibers;
discontinuous polymer fiber segments dispersed throughout the woven matrix, wherein each discontinuous polymer fiber segment has a length in the range of from 0.5 mm to 3.0 mm and, wherein:
the discontinuous polymer fiber segments are formed by:
winding a continuous polymer fiber onto a supporting mandrel, and
stretch breaking the continuous polymer fiber, which was wound onto the supporting mandrel, to form the discontinuous polymer fiber segments; and
a thermosetting resin in which the woven matrix is embedded.
2. The material of claim 1 , wherein the semi-continuous thermoplastic fiber comprises polyester.
3. The material of claim 1 , wherein the discontinuous polymer fiber segments comprise PTFE.
4. The material of claim 1 , wherein the thermosetting resin comprises an epoxy resin.
5. The material of claim 4 , wherein the epoxy resin further comprises one or more self-lubricants selected from the group consisting of boron nitride particulates, PTFE particulates, and graphite particulates.
6. The material of claim 1 , wherein each discontinuous polymer fiber segment has an aspect ratio in the range of from 10 to 40.