Tribological materials and structures and methods for making the same

Abstract

An article having a bearing surface with improved wear characteristics is provided. The article may be formed from a composition that includes a polymeric material, a lubricious and reinforcing additive, and a solid lubricant. Methods for forming the compositions and structures are also provided.

1 . A plastic article having a bearing surface, comprising: 
 a polymeric matrix material; and    a first additive that is a lubricious reinforcing fiber having a thermal conductivity of at least about 50 W/m° K.    
     
     
         2 . The plastic article of  claim 1 , wherein the first additive has a tensile strength of at least about 200 KSI.  
     
     
         3 . The plastic article of  claim 1 , wherein the first additive has a tensile modulus of at least about 100 MSI.  
     
     
         4 . The plastic article of  claim 1 , wherein the first additive has a coefficient of thermal expansion of about −1.4 parts per million/° C.  
     
     
         5 . (canceled)  
     
     
         6 . The plastic article of  claim 1 , wherein the first additive has a thermal conductivity ranging from about 200 to about 1000 W/m° K.  
     
     
         7 . (canceled)  
     
     
         8 . The plastic article of  claim 1 , wherein the article comprises from about 5 percent to about 70 percent by weight of the first additive based on the total weight of the article.  
     
     
         9 . The plastic article of  claim 1 , wherein the article comprises from about 30 percent to about 60 percent by weight of the first additive, based on the total weight of the article.  
     
     
         10 . The plastic article of  claim 1 , wherein the article comprises from about 35 percent to about 55 percent by weight of the first additive, based on the total weight of the article.  
     
     
         11 .- 17 . (canceled)  
     
     
         18 . The plastic article of  claim 1 , wherein the polymeric matrix material is selected from the group consisting of polyamideimide, polyetherimide, polyimide, polyetheretherketone, polyphenylene sulfide, liquid crystal polymer, and combinations thereof.  
     
     
         19 . The plastic article of  claim 1 , wherein the lubricious reinforcing fiber is selected from the group consisting of Thermalgraph DKD fibers, Thermalgraph DKA fibers, Dialead K223HG fibers, and combinations thereof.  
     
     
         20 . The plastic article of  claim 1 , further comprising a second additive that is lubricious.  
     
     
         21 .- 27 . (canceled)  
     
     
         28 . The plastic article of  claim 20 , wherein the article comprises from about 2 percent to about 75 percent by weight of the first additive and about 2 percent to about 75 percent by weight of the second additive, based on the total weight of the article.  
     
     
         29 . The plastic article of  claim 20 , wherein the article comprises from about 20 percent to about 60 percent by weight of the first additive and about 20 percent to about 60 percent by weight of the second additive, based on the total weight of the article.  
     
     
         30 . The plastic article of  claim 29 , wherein the article comprises from about 15 percent to about 40 percent by weight of the first additive and about 15 percent to about 40 percent by weight of the second additive, based on the total weight of the article.  
     
     
         31 . The plastic article of  claim 20 , wherein the polymeric matrix material is selected from the group consisting of polyamideimide, polyetherimide, polyimide, polyetheretherketone, polyphenylene sulfide; liquid crystal polymer, and combinations thereof.  
     
     
         32 . The plastic article of  claim 20 , wherein the first additive is selected from the group consisting of Thermalgraph DKD fibers, Thermalgraph DKA fibers, Dialead K223HG fibers, and combinations thereof.  
     
     
         33 . The plastic article of  claim 20 , wherein the second additive is selected from the group consisting of boron nitride, carbon, graphite, molybdenum disulfide, talc, tetrafluoroethylene, and combinations thereof.  
     
     
         34 . The plastic article of  claim 20 , wherein the plastic article comprises about 60 percent by weight of the first additive, and about 10 percent by weight of the second additive, based on the total weight of the article.  
     
     
         35 . The plastic article of  claim 34 , wherein the first additive is DKD, the second additive is boron nitride platelets, and the polymeric matrix material is selected from the group consisting of polyamideimide, polyetherimide, polyimide, polyetheretherketone, polyphenylene sulfide, liquid crystal polymer, and combinations thereof.  
     
     
         36 . The plastic article of  claim 34 , wherein the first additive is DKD, the second additive is tetrafluoroethylene, and the polymeric matrix material is selected from the group consisting of polyamideimide, polyetherimide, polyimide, polyetheretherketone, polyphenylene sulfide, liquid crystal polymer, and combinations thereof.  
     
     
         37 . A plastic article having a bearing surface, comprising: 
 a polymeric matrix material; and    about 5 percent to about 75 percent by weight of a first additive having a density of at least about 2.0 gm/cm 3 ;    wherein the plastic article has a wear factor of less than about 200 under a load of about 200 psi and a velocity of about 50 feet per minute.    
     
     
         38 . The plastic article of  claim 37 , wherein the polymeric matrix material is selected from the group consisting of polyamideimide, polyetherimide, polyimide, polyetheretherketone, polyphenylene sulfide, liquid crystal polymer, and combinations thereof.  
     
     
         39 . The plastic article of  claim 38 , wherein a first additive is selected from the group consisting of Thermalgraph DKD fibers, Thermalgraph DKA fibers, Dialead K223HG fibers, and combinations thereof.  
     
     
         40 . A plastic article having a bearing surface, comprising: 
 a polymeric matrix material selected from the group consisting of polyamideimide, polyetherimide, polyimide, polyetheretherketone, polyphenylene sulfide, liquid crystal polymer, and combinations thereof; and    about 5 percent to about 75 percent by weight of a first additive selected from the group consisting of Thermalgraph DKD fibers, Thermalgraph DKA fibers, Dialead K223HG fibers, and combinations thereof;    wherein the plastic article has a wear factor of less than about 200 under a load of about 200 psi and a velocity of about 50 feet per minute.    
     
     
         41 . A plastic article having a bearing surface, comprising: 
 a polymeric matrix material;    about 2 percent to about 75 percent by weight of a first additive having a density of at least about 2.0 gm/cm 3 ; and    about 2 percent to about 75 percent by weight of a second additive,    wherein the plastic article has a wear factor of less than about 200 under a load of about 200 psi and a velocity of about 50 feet per minute.    
     
     
         42 . The plastic article of  claim 41 , wherein the polymeric matrix material is selected from the group consisting of polyamideimide, polyetherimide, polyimide, polyetheretherketone, polyphenylene sulfide—liquid crystal polymer, and combinations thereof.  
     
     
         43 . The plastic article of  claim 42 , wherein the first additive is selected from the group consisting of Thermalgraph DKD fibers, Thermalgraph DKA fibers, Dialead K223HG fibers, and combinations thereof.  
     
     
         44 . The plastic article of  claim 43 , wherein the second additive is selected from the group consisting of boron nitride, carbon, graphite, molybdenum disulfide, talc, tetrafluoroethylene, and combinations thereof.  
     
     
         45 .- 82 . (canceled)  
     
     
         83 . A plastic article having a bearing surface, comprising: 
 a polymeric matrix material; and    a first additive that is a lubricious carbon fiber having a thermal conductivity of at least about 50 W/m° K.    
     
     
         84 .- 85 . (canceled)