Patent Grant
8759431
1. Field of the Invention
The present invention generally relates to a durable polyoxymethylene composition and a ramp including a durable polyoxymethylene composition. In particular, the present invention is directed to a durable polyoxymethylene composition as well as a ramp including a durable polyoxymethylene composition with excellent micro-wear-resistant property and extremely small amount of wear debris under a high humidity and high temperature condition, or under a low humidity and low temperature condition.
2. Description of the Prior Art
A polyoxymethylene resin is a widely used engineering resin due to its well-balanced mechanical properties, remarkable chemical resistance and sliding properties as well as the good friction wear performance. Recently, attempts have been made to use such polyoxymethylene resin as material for a ramp in a hard disk drive. When other resins are added to increase the wear-resistant property of the polyoxymethylene resin, lamination or mold deposits often occurs and wear-resistant property accordingly is lowered due to low compatibility. To overcome these problems, it is necessary to clean the molds more frequently so the yield is lower. Addition of inorganic fillers may increase the surface hardness, but excess addition of inorganic fillers or micro-meter size inorganic fillers result in more wear debris that damages the metal parts or contaminates the parts in the hard drive, which in turn jeopardizes the durability. In view of the above, the lubricants and the additives in the polyoxymethylene resin currently have many problems such as compatibility and dispersibility.
For example, US 2008/0037175 discloses a ramp including a polyoxymethylene resin and a colorant for a hard disk drive. The ramp has an outgas level of 20 μg/g or less. U.S. Pat. No. 7,088,555 discloses a ramp having a surface hardness of 2.6 GPa or more.
However, in the aforementioned conventional technologies, no description is yet made to a polyoxymethylene resin with excellent micro-wear-resistant properties, and further, no proposal for attempting to reduce wear debris from a polyoxymethylene resin ramp is found.
The present invention has the properties of micro-wear resistance, high mechanical stability, high cleanliness and high injection moldability. The function of micro-wear resistance is to decrease the amount of energy necessary for loading/unloading, and also reduces the wear loss and the amount of debris caused when the lift feature of suspension arm rubs against the ramp surface.
The present invention in one aspect provides a durable polyoxymethylene composition. The durable polyoxymethylene composition of the present invention has excellent micro-wear-resistant property to lower the wear debris due to wear loss during the operation. The polyoxymethylene composition of the present invention in one aspect exhibits the micro-wear loss less than 10 μm2 wear area, or exhibits the micro-wear loss of 1 μm maximum wear depth under a condition of a load of 2.5 g, reciprocated 600,000 times, at a speed of 8 inch/sec and a low environmental humidity and a low environmental temperature.
The present invention in another aspect provides a durable polyoxymethylene composition. The durable polyoxymethylene composition of the present invention has excellent micro-wear-resistant property. The polyoxymethylene composition of the present invention in another aspect exhibits the micro-wear loss less than 10 μm2 wear area or exhibits the micro-wear loss of 1 μm maximum wear depth under a condition of a load of 2.5 g, reciprocated 600,000 times, at a speed of 8 inch/sec and a high environmental humidity and a high environmental temperature.
The present invention in another aspect provides a ramp including a durable polyoxymethylene composition. The ramp of the present invention may exhibit the micro-wear loss less than 10 μm2 wear area or exhibit the micro-wear loss of 1 μm maximum wear depth under a condition of a load of 2.5 g, reciprocated 600,000 times, at a speed of 8 inch/sec and a low environmental humidity and a low environmental temperature.
The present invention in another aspect provides a ramp including a durable polyoxymethylene composition. The ramp of the present invention may exhibit the micro-wear loss less than 10 μm2 wear area or exhibit the micro-wear loss of 1 μm maximum wear depth under a condition of a load of 2.5 g, reciprocated 600,000 times, at a speed of 8 inch/sec and a high environmental humidity and a high environmental temperature.
In one embodiment of the present invention, the condition of high humidity has a relative humidity in a range from 50% to 60%.
In another embodiment of the present invention, the condition of low humidity has a relative humidity in a range from 13% to 17%.
In one embodiment of the present invention, the condition of high temperature has a temperature in a range from 22° C. to 60° C.
In one embodiment of the present invention, the condition of low temperature has a temperature in a range from 3° C. to 10° C.
The polyoxymethylene composition of the present invention includes:
In the polyoxymethylene composition of the present invention, the polyoxymethylene copolymer may have a tensile strength 60-65 Mpa (ISO 527) tensile strength and melt flow rate 20-35 g/10 min (ISO 1133) .
In the polyoxymethylene composition of the present invention, the composite lubricant may include various lubricants. For example, lubricants may be (A) a solid lubricant including the combination of one or more solid lubricant components and (B) a liquid lubricant including the combination of one or more liquid lubricant components. The composite lubricant may exhibit a synergistic effect of wear resistance, anti-scratch, low friction, high sliding, etc.
In the composite lubricant of the present invention, A) the solid lubricant is 70 wt % to 90 wt % of the total weight of the composite lubricant and (B) the liquid lubricant is 10 wt % to 30 wt % of the total weight of the composite lubricant.
In the composite lubricant of the present invention, the solid lubricant may be a polyamide resin or polyvinylidene difluoride (PVDF). The polyamide resin may be nylon-11 or nylon-12.
In the composite lubricant of the present invention, the liquid lubricant may be perfluoropolyether (PFPE), which mainly serves to improve processability, to lower the coefficient of friction and to reduce the wear loss due to sliding abrasion.
In the polyoxymethylene composition of the present invention, the compatilizer may be a maleic anhydride grafted styrene/low density ethylene copolymer, or an epoxy-containing styrene/acrylic copolymer, which mainly serves to reduce the interface energy of the polymers to increase the compatibility between the polyoxymethylene composition and the solid lubricant so that the solid lubricant can be uniformly dispersed in the polyoxymethylene composition to improve mechanical properties and wear-resistant properties.
In the polyoxymethylene composition of the present invention, the inorganic filler may be nano-grade zinc oxide particles with an average particle size of 100 nm or less, or other nano-grade inorganic fillers. The nano-grade inorganic filler can increase the surface hardness of polyoxymethylene to improve the wear-resistant property and dimensional stability.
In the polyoxymethylene composition of the present invention, the nucleating agent may be at least one of a sodium salt or a calcium salt of montanic acid and of a long chain, linear carboxylic acid to enhance the crystallinity of polyoxymethylene and to increase the mechanic properties. For example, the nucleating agent may be Licomont Cav 102 or Licomont Nav 101 from Clariant.
In the polyoxymethylene composition of the present invention, the stabilizer may be a mixture of IRGANOX 1010, IRGANOX 259 and IRGANOX 1098 from CIBA, MELAMINE, calcium stearate and PALMOWAX (specification EBS-SP).
In the polyoxymethylene composition of the present invention, the anti-static agent may be a glycerol monostearate or a polyether polyamide block polymer.
The polyoxymethylene composition of the present invention may further include an ultra high molecular weight polyethylene of molecular weight 2 million with average particle size 30 μm in a range of 3 wt % to 10 wt %.
The polyoxymethylene composition of the present invention may further include a low density polyethylene of 5 wt %.
The polyoxymethylene composition of the present invention may be in a form of pellets of 2mm by 3mm dimension.
The polyoxymethylene composition of the present invention may be in a form of a hollow column.
These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
The present invention generally relates to a durable polyoxymethylene composition as well as a load/unload ramp structure. Load/unload ramp structure is use to keep a magnetic head away from the rotating disk. A suspension arm holds a magnetic head for reading and writing of information from and to an information recording disk rotating at a high speed in a hard disk drive. In a recent hard disk drive, there is provided a ramp as a magnetic-head retraction location where the head is held as spaced from a recording disk when the disk is in its inoperable mode.
The present invention in a first aspect provides a durable polyoxymethylene composition. The durable polyoxymethylene composition of the present invention has excellent micro-wear-resistant property. The polyoxymethylene composition of the present invention in one aspect exhibits the micro-wear loss less than 10 μm2 wear area or 1 μm maximum wear depth under a condition of a load of 2.5 g, reciprocated 600,000 times, at a speed of 8 inch/sec and a low environmental humidity and a low environmental temperature, or generates extreme low wear debris.
In another embodiment of the present invention, the condition of low humidity has a relative humidity in a range from 13% to 17%. In another embodiment of the present invention, the condition of low temperature has a temperature in a range from 3° C. to 10° C. In one preferred embodiment of the present invention, the polyoxymethylene composition forms a ramp for use in a hard drive.
The present invention in another aspect provides another durable polyoxymethylene composition. The durable polyoxymethylene composition of the present invention also has excellent micro-wear-resistant property. The polyoxymethylene composition of the present invention in another aspect exhibits the micro-wear loss less than 10 μm2 wear area or 1 μm maximum wear depth under a condition of a load of 2.5 g, reciprocated 600,000 times, at a speed of 8 inch/sec and a high environmental humidity and a high environmental temperature, or generates extreme low wear debris.
In one embodiment of the present invention, the condition of high humidity has a relative humidity in a range from 50% to 60%. In another embodiment of the present invention, the condition of high temperature has a temperature in a range from 22° C. to 60° C. In one preferred embodiment of the present invention, the polyoxymethylene composition forms a ramp for use in a hard drive.
The polyoxymethylene composition of the present invention includes some components, such as a polyoxymethylene copolymer, an inorganic filler, a composite lubricant, a compatilizer, a nucleating agent, a stabilizer, and an anti-static agent. The polyoxymethylene composition includes the polyoxymethylene copolymer of 80 wt % to 95 wt % including 1.0-3.3 wt % of 1,3-dioxolane as a comonomer. For example, the polyoxymethylene copolymer may have a tensile strength 60-65 Mpa (ISO 527) and melt flow rate 20-35 g/10min (ISO 1133).
The polyoxymethylene composition may include a composite lubricant of 1.0 wt % to 10.0 wt %. For example, the lubricant may be a solid lubricant such as a polyamide resin, for example nylon-11 or nylon-12, or polyvinylidene difluoride (PVDF). The liquid lubricant may be perfluoropolyether (PFPE). The polyoxymethylene composition of the present invention may further include a low density polyethylene with a melt flow rate 22 g/10 min. In addition, the polyoxymethylene composition of the present invention may further include an ultra high molecular weight polyethylene of molecular weight 2 million with average particle size 30 μm in a range of 3 wt % to 10 wt %.
The polyoxymethylene composition of the present invention may include a compatilizer of 1.0 wt % to 10 wt %, such as a maleic anhydride grafted styrene/low density ethylene copolymer, or an epoxy-containing styrene/acrylic copolymer.
There may be various and different inorganic fillers. For example, one suitable inorganic filler may be nano-grade zinc oxide particles of 0.1 wt % to 3.0 wt % with an average particle size of 100 nm or less or other nano-grade inorganic fillers.
The polyoxymethylene composition includes the nucleating agent of 0.1 wt % to 3.0 wt %. For example, the nucleating agent may be at least one of a sodium salt or a calcium salt of montanic acid and one of a sodium salt or a calcium salt of a long chain, linear carboxylic acid. For example, the nucleating agent may be Licomont Cav 102, Licomont Nav 101 or the combination thereof from Clariant.
The polyoxymethylene composition includes the stabilizer of 0.5 wt % to 1.0 wt %, such as at least one of an antioxidant and an acid scavenger. For example, the stabilizer may be a mixture of IRGANOX 1010, IRGANOX 259 and IRGANOX 1098 from CIBA, MELAMINE, calcium stearate and PALMOWAX (specification EBS-SP).
The polyoxymethylene composition includes the anti-static agent of 0.5 wt % to 5.0 wt %. For example, the anti-static agent may be a glycerol monostearate.
In addition to being processed to form a ramp, the polyoxymethylene composition of the present invention may also be processed to form pellets. For example, the pellets may be hollow columns of 2 mm by 3 mm dimension. The pellets are advantageous for use in transportation or in storage. The pellets may be later processed to form ramps when needed.
Some examples are given here to demonstrate the steps to formulate and to form the micro-wear-resistant and few-amount-of-wear-debris polyoxymethylene composition of the present invention.
Materials (A) polyoxymethylene copolymer (88.7 wt. %); (B) a lubricant of LDPE of 5.0 wt. %; (B-4) perfluoropolyether (1.0 wt. %) and (C) a compatilizer (3.0 wt. %); (D) an inorganic filler of nano-grade zinc oxide (0.5 wt. %); (E) a nucleating agent Licomont Cav 102 from Clariant (0.3 wt %) and (F) a stabilizer IRGANOX 1010, IRGANOX 259 and IRGANOX 1098 from CIBA, MELAMINE, calcium stearate and PALMOWAX (0.5 wt %) and (G) an anti-static agent (1 wt. %) were well mixed in a high speed vertical mixer for 2 min. The mixed materials (5 KG) were placed in a raw material tank after mixing.
The mixed materials were fed into a twin screw extruders (φ=44 mm) by a feeder. The feeding was set to be 35 kg/hr. The extruder barrel was adjusted to 160-220° C. The vacuum was adjusted to 10-30 cm Hg. The melted composition were cooled and cut to be pellets in the form of 3 mm*2 mm, then dried by a hot blow dryer at 130° C. for 4 hours. The pellets were injected to form ramps of 0.17 g, 11.6×6.2×5.2 mm each piece and the results are tested and shown in TABLE 1. The ramps were washed in an ultrasonic cleaner (first stage in a 1% surfactant VALTRON® DP97031, second to fifth stages in deionized water, 8 min in each stage). The wet ramps were dried in a cyclone type oven at 85° C. for 8 min., then dried in a dry oven at 85° C. for 1 hour. The ramps were subject to various tests. The results were listed in TABLE 2.
Methods, materials and ratios which are similar to those of Example 1 were used except that (B-1) a solid lubricant of polyvinylidene difluoride (5.0 wt. %). The results are tested and shown in TABLE 1 and the ramps were subject to various tests. The results were also listed in TABLE 2.
Methods, materials and ratios which are similar to those of Example 1 were used except that (B-2) a lubricant of UHMWPE (molecular weight 2 million(ASTM D4020) with average particle size 30 μm) (5.0 wt. %). The results are tested and shown in TABLE 1 and the ramps were subject to various tests. The results were also listed in TABLE 2.
Methods which are similar to those of Example 1 were used except that (A) polyoxymethylene copolymer (89.2 wt. %) ; (B-3) nylon-12 (5.0 wt. %); (B-4) perfluoropolyether (1.0 wt. %); (C) a compatilizer (3.0 wt. %); (D) an inorganic filler of nano-grade zinc oxide (0.0 wt. %); (E) a nucleating agent Licomont Cav 102 from Clariant (0.3 wt %) and (F) a stabilizer IRGANOX 1010, IRGANOX 259 and IRGANOX 1098 from CIBA, MELAMINE, calcium stearate and PALMOWAX (0.5 wt %) with (G) an anti-static agent of 1.0 wt %. The results are tested and shown in TABLE 1. The ramps were subject to various tests. The results were also listed in TABLE 2.
Methods which are similar to those of Example 1 were used except that (A) polyoxymethylene copolymer (91.7 wt. %); (B-3) nylon-12 (5.0 wt. %); (B-4) perfluoropolyether (1.0 wt. %); (C) a compatilizer (0.0 wt. %); (D) an inorganic filler of nano-grade zinc oxide (0.5 wt. %); (E) a nucleating agent Licomont Cav 102 from Clariant (0.3 wt %) and (F) a stabilizer IRGANOX 1010, IRGANOX 259 and IRGANOX 1098 from CIBA, MELAMINE, calcium stearate and PALMOWAX (0.5 wt %) with (G) an anti-static agent of 1.0 wt %. The results are tested and shown in TABLE 1. The ramps were subject to various tests. The results were also listed in TABLE 2.
Methods which are similar to those of Example 1 were used except that (A) polyoxymethylene copolymer (89.7 wt. %); (B-3) nylon-12 (5.0 wt. %); (B-4) perfluoropolyether (0.0 wt. %); (C) a compatilizer (3.0 wt. %); (D) an inorganic filler of nano-grade zinc oxide (0.5 wt. %); (E) a nucleating agent Licomont Cav 102 from Clariant (0.3 wt %) and (F) a stabilizer IRGANOX 1010, IRGANOX 259 and IRGANOX 1098 from CIBA, MELAMINE, calcium stearate and PALMOWAX (0.5 wt %) with (G) an anti-static agent of 1.0 wt %. The results are tested and shown in TABLE 1. The ramps were subject to various tests. The results were also listed in TABLE 2.
Methods which are similar to those of Example 1 were used except that (A) polyoxymethylene copolymer (88.7 wt. %); (B-3) nylon-12 (5.0 wt. %); (B-4) perfluoropolyether (1.0 wt. %); (C) a compatilizer (3.0 wt. %); (D) an inorganic filler of nano-grade zinc oxide (0.5wt. %); (E) a nucleating agent Licomont Cav 102 from Clariant (0.3 wt %) and (F) a stabilizer IRGANOX 1010, IRGANOX 259 and IRGANOX 1098 from CIBA, MELAMINE, calcium stearate and PALMOWAX (0.5 wt %) with (G) an anti-static agent of 1.0 wt %. The results are tested and shown in TABLE 1. The ramps were subject to various tests. The results were also listed in TABLE 2.
A raw material, polyoxymethylene resin pellets (Polyplastics-Duracon M9044) were dried at 100° C. for 4 hrs. The pellets were injected to form ramps of 0.41 g, 13.5×8.8×8.6 mm each piece. The ramps were washed in an ultrasonic cleaner (first stage in a 1% surfactant VALTRON® DP97031, second to fifth stages in deionized water, 8 min in each stage). The wet ramps were dried in a cyclone type oven at 85° C. for 8 min., then dried in a dry oven at 85° C. for 1 hour. The ramps were subject to various tests. The results were listed in TABLE 3.
A raw material, polyoxymethylene resin pellets (DuPont-Derlin 500P) were dried at 100° C. for 4 hrs. The pellets were injected to form ramps of 0.17 g, 11.6×6.2×5.2 mm each piece. The ramps were washed in an ultrasonic cleaner (first stage in a 1% surfactant VALTRON® DP97031, second to fifth stages in deionized water, 8 min in each stage). The wet ramps were dried in a cyclone type oven at 85° C. for 8 min., then dried in a dry oven at 85° C. for 1 hour. The ramps were subject to various tests. The results were listed in TABLE 3.
The following test results are carried out under a condition of after being reciprocated 600,000 times:
Example 1 demonstrates a primary evaluation of the polyoxymethylene composition of the present invention. Example 2-4 are further modified and improved in accordance with Example 1. Example 5 demonstrates excellent micro-wear-resistant properties in comparison to the comparative examples. Example 5 exhibits excellent micro-wear-resistant properties in both (A) low humidity/low temperature condition, (B) high humidity/high temperature condition and (C) room temperature. Example 5 also generates least wear debris to show excellent micro-wear-resistant properties in (A) low humidity/low temperature condition, (B) high humidity/high temperature condition and (C) room temperature.
Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
This application is a continuation-in-part application of the application Ser. No. 12/820,145, filed Jun. 22, 2010, which claims the benefit of U.S. Provisional Application No. 61/318,784, filed Mar. 29, 2010.
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| Number | Date | Country | |
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| 20120238680 A1 | Sep 2012 | US |
| Number | Date | Country | |
|---|---|---|---|
| 61318784 | Mar 2010 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12820145 | Jun 2010 | US |
| Child | 13484239 | US |
