JP2002021898A - Bonded structure of metallic material and friction material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide bonded structure wherein a metallic material and a friction material different in the coefficient of linear expansion or surface roughness from the metallic material can be firmly bonded without the possibility of separation. SOLUTION: In this bonded structure of the metallic material 1 and the friction material 2 different in the coefficient of linear expansion or surface roughness from the metallic material 1, an adhesive cushion layer 6 with an adhesive 5 impregnated in unwoven fabric 4 formed of short carbon fiber 3 or the like is interposed between adhesive faces 1a, 2a of the metallic material 1 and friction material 2, and pressure-bonded and hardened by heating. A friction material 24 formed of a carbon fiber reinforced carbon composite sheet material is stuck to an inner peripheral surface 23 of a metal ring 29 through the adhesive cushion layer 6 formed of the unwoven fabric 4 of short carbon fiber 3 or the like impregnated with a phenol resin adhesive 5, and the friction material 24 is pressed to the metal ring 29 side and hardened by heating while compressing the adhesive cushion layer 6, to form a synchronizer ring.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a bonding structure between a metal material and a friction material, and more particularly to a bonding structure between a metal material and a friction material having a different linear expansion coefficient or surface roughness from the metal material. .

[0002]

2. Description of the Related Art Metals, especially cast iron materials, are mainly used in automobile drive system parts (for example, transmission parts, etc.) which are required to be used in a harsh environment and have high strength and high durability. Since various required characteristics such as slidability and frictional characteristics are different for each part, required various characteristics are secured by material modification or joining of several kinds of materials having different characteristics.

As shown in FIG. 3, a synchronizer ring, which is one of transmission components, includes a metal (cast iron) ring portion 31 and a cone portion 32.
When the inner peripheral surface 33 of the cone portion 32 frictionally engages with the outer peripheral surface of the cone portion of the main gear (not shown) of the transmission, two gears (not shown) having different rotation speeds are synchronized.

Here, the frictional engagement surface (inner peripheral surface 33) of the cone portion 32 of the synchronizer ring 30 is the frictional engagement surface (cone outer peripheral surface) of the main gear of the transmission.
Therefore, it is necessary to have a sufficient friction coefficient and abrasion resistance. For this reason, a friction material (not shown) is usually provided on the friction engagement surface of the cone portion 32. As a conventional friction material, C is provided on a friction engagement surface of a cone portion.
Examples thereof include a u-Zn liner and a thermal spray coating of Mo.

In recent years, in addition to a synchronizer ring in which a friction material made of metal is joined to the friction engagement surface of the cone portion 32, a resin engagement surface of the cone portion 32 has (Made of phenolic resin) Friction material is joined (adhered) to provide higher strength adhesiveness, thermal expansion absorption, high temperature resistance,
Synchronizer rings that ensure high-performance surface characteristics such as oil resistance have been proposed. However, the transmission components, including the synchronizer ring, are immersed in the transmission oil and the transmission oil can be up to about 140 ° C during vehicle operation.
Also reach. Immediately after the start of the engine or when the lubricating oil does not rotate sufficiently, problems such as breakage of the friction material occur. Therefore, instead of a resin friction material, a carbon fiber reinforced carbon composite material (hereinafter referred to as C-
A friction material made of a C composite
It has been studied to join (adhere) to the frictional engagement surface of the.

[0006]

By the way, in a synchronizer ring in which a conventional metal friction material is joined, a metal material and a metal friction material (for example, Cu-Zn material or Mo material, etc.) are mutually connected (the same kind). (Material-to-material) bonding, there was almost no problem with differences in thermal characteristics and surface roughness between the two materials.

On the other hand, in a synchronizer ring using a friction material made of a CC composite, the difference between the thermal characteristics and the surface roughness of the two materials is caused by the adhesion between the metal material and the friction material between different materials. Problems due to the difference may occur.

That is, since the coefficient of linear expansion differs greatly between a metal material and a friction material made of a CC composite,
When the bond between the two materials is exposed to high temperatures, a shear stress acts on the bond interface. As a result, a phenomenon occurs in which the bonded portion is sheared and broken, and both materials are peeled off.

Further, since the processing accuracy of the surface treatment differs between the metal material and the friction material made of the CC composite,
The surface roughness of both materials is different. For this reason, microscopically, the clearance between the bonding surfaces becomes non-uniform,
There is a possibility that a problem such as poor bonding may occur on the bonding surface of both materials, and it is very difficult to firmly bond both materials.

An object of the present invention, which has been made in view of the above circumstances, is to firmly bond a metal material and a friction material having a different linear expansion coefficient or surface roughness from the metal material without fear of peeling. An object of the present invention is to provide a bonding structure and a bonding method thereof.

[0011]

In order to achieve the above object, the bonding structure of a metal material and a friction material according to the present invention comprises a metal material and a friction material having a different linear expansion coefficient or surface roughness from the metal material. In the adhesive structure, an adhesive cushion layer obtained by impregnating an adhesive into a nonwoven fabric made of short carbon fiber or the like is interposed between the adhesive surfaces of the metal material and the friction material, and is pressed and heat-cured.

Further, the metal material may be made of cast iron, and the friction material may be made of a carbon fiber reinforced carbon composite material.

Furthermore, an adhesive layer made of an adhesive such as a phenolic resin may be previously formed on each of the adhesive surfaces of the metal material and the friction material, and an adhesive cushion layer may be interposed.

An adhesive such as a phenolic resin is previously applied to each of the bonding surfaces of the metal material and the friction material, and then the bonding cushion material is interposed between the bonding surfaces of the metal material and the friction material. You may let it.

Furthermore, the metal may be a synchronizer ring of a transmission.

Further, the friction material may be composed of a large number of carbon fiber reinforced carbon composite sheet pieces provided in a circumferential direction of an inner peripheral surface of the metal ring.

According to the above-described bonding structure, the bonding cushion layer provided between the bonding surfaces of the metal material and the friction material buffers the difference in elongation caused by the difference in the linear expansion coefficient between the two materials, or reduces the difference between the two materials. In order to absorb the uneven clearance between the bonding surfaces due to the difference in surface roughness, even if both materials have different linear expansion coefficients or surface roughness, both materials can be firmly bonded without fear of peeling. it can.

Further, by forming the friction material of the synchronizer ring with a CC composite having excellent heat resistance and wear resistance, the durability and reliability of the synchronizer ring are further improved. In addition, metal ring and friction material (C-
C composite) means that although the coefficient of linear expansion and the surface roughness are different, the adhesive cushion layer interposed between the metal ring and the friction material causes the elongation of the material due to the difference in the coefficient of linear expansion between the two materials. Buffers for differences and absorbs uneven clearance between the bonded surfaces due to differences in surface roughness between the two materials. Therefore, there is no possibility that the friction material is separated from the metal ring, and the metal ring and the friction material can be firmly bonded.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A preferred embodiment of the present invention will be described below with reference to the accompanying drawings.

Generally, when bonding between different materials (that is, bonding between a metal material and a friction material having a significantly different coefficient of linear expansion or surface roughness from the metal material), an adhesive having rubber-like elasticity is used. Or by increasing the thickness of the adhesive layer,
The above-described shear stress at the bonding interface can be reduced, and peeling of the material due to a difference in linear expansion coefficient can be prevented.

However, for example, a synchronizer
In a portion where a large stress is applied, such as a friction engagement surface of a ring, it is also important that the bonding portion has a sufficient bonding strength. For this reason, sufficient bonding strength cannot be obtained by bonding with an adhesive having rubber-like elasticity (generally, the bonding strength of the adhesive having rubber-like elasticity is low), and the bonding portion is sheared or broken. The adhesive layer itself may be broken. Also, even when the adhesive layer is formed thick using a low rubber-like elastic type hard adhesive,
Since the adhesive itself is brittle, there is a possibility that both materials will be peeled off as a result.

For this reason, in order to secure sufficient adhesive strength on the frictional engagement surface of the synchronizer ring having an adhesive portion between dissimilar materials, a low rubber-like elastic type hard adhesive is used and the adhesive layer is made thin. Need to be formed,
This is inconsistent with the bonding conditions between different materials described above.

An adhesive for adhering a friction material (for example, a C-C composite friction material) having a significantly different linear expansion coefficient or surface roughness from the metal ring material to the friction engagement surface of the synchronizer ring. Are required to have properties such as high-strength adhesiveness, thermal expansion absorption, clearance absorption, high-temperature resistance, and oil resistance. At present, there is a phenolic resin adhesive having excellent heat resistance and oil resistance as an adhesive used under conditions requiring high-strength adhesiveness and high temperature resistance. It has been studied to apply the present invention to adhesion between a metal material and a C-C composite friction material on a friction engagement surface of a ring. The phenolic resin adhesive generates gas (bubbles) at the time of heat curing, but if this gas is not released from the adhesive layer, the gas will destroy the adhesive layer, resulting in a decrease in adhesive strength. For this reason, usually, pressure is applied at about 5 to 15 kgf / cm ² during heat curing to degas.

Here, as described above, there is an uneven clearance between the bonding surfaces of the two materials due to the difference in the surface roughness. The role of filling (absorbing) the uneven clearance is also expected. However, in a phenolic resin-based adhesive, if the pressure at the time of heat curing is reduced to absorb the clearance, the adhesive strength will not be sufficiently exhibited, so that it is difficult to achieve both the clearance absorption and the high adhesive strength. Therefore, it has been difficult to apply the phenol resin-based adhesive as it is to the frictional engagement surface of the synchronizer ring.

The present inventors used a phenolic resin adhesive having excellent heat resistance and oil resistance as an adhesive for bonding a metal material and a friction material, and made the thickness of the adhesive layer as thin as possible. The adhesive layer buffers the difference in elongation caused by the difference in linear expansion coefficient between the metal material and the friction material, or absorbs the uneven clearance between the bonded surfaces caused by the difference in the surface roughness of both materials.・ Dedicated research was conducted to provide an absorption function.

FIG. 1 is a schematic cross-sectional view of a bonding structure between a metal material and a friction material according to the present invention. Here, FIG.
As shown in FIG. 1, the bonding structure of the metal material and the friction material according to the present invention, which is an enlarged view of the main part A of FIG. An adhesive cushion layer 6 impregnated with a system-based adhesive (or an acrylic resin-based adhesive) 5 is interposed between the bonding surfaces 1a and 2a of the metal material 1 and the friction material 2 and pressed and heat-cured (or cured). It was made.

Each of the bonding surfaces 1 of the metal material 1 and the friction material 2
An adhesive layer (not shown) made of a phenol resin-based adhesive (or an acrylic resin-based adhesive) may be formed in advance on a and 2a, and the adhesive cushion layer 6 may be interposed.

Here, the metal material 1 is not particularly limited, and may be, for example, Fe alloy, Al or Al alloy, T
Although i or Ti alloy is mentioned, cast iron is particularly preferable.

The friction material 2 may be either a metal material or a non-metal material as long as the material has a different linear expansion coefficient from the metal material 1. However, the friction material 2 is a C--C material having excellent heat resistance and wear resistance. Composites are particularly preferred.

When a CC composite is used as the friction material 2, the carbon fiber (carbon long fiber) constituting the CC composite is not particularly limited in fiber length, but has a fiber diameter D of 0.002-0. 010 mm, preferably 0.00
One having a thickness of 5 to 0.007 mm is exemplified. Also, C-C
The orientation of the carbon fibers in the composite is appropriately set in accordance with the desired coefficient of friction, and is not particularly limited.
It is possible to arbitrarily adjust the friction coefficient of the -C composite.

The short carbon fiber (or short glass fiber) 3 is not particularly limited as long as it is a fiber capable of forming a nonwoven fabric. However, considering the clearance absorbency, the fiber length L is preferably 10 to 20 mm, and more preferably 10 to 20 mm. 14 to 16 mm, fiber diameter D is 0.5 to 1.0 μm, preferably 0.6 to 0.8
μm.

If the thickness of the nonwoven fabric 4 is too small, it is impossible to impregnate the phenolic resin adhesive (or the acrylic resin adhesive) 5, and if it is too thick, the thickness of the adhesive cushion layer 6 is too large. Therefore, the thickness is preferably 1.5 to 2.5 mm, and particularly preferably about 2 mm. On the other hand, if the density of the nonwoven fabric 4 is too low, the impregnation of the phenolic resin adhesive 5 is impossible, and if the density is too high, the impregnation of the phenolic resin adhesive 5 becomes difficult. 3.5m
g / cm ² is preferred.

The adhesive 5 to be impregnated into the nonwoven fabric 4 may be a phenol resin-based, epoxy resin-based, polyester resin-based, or acrylic resin-based adhesive. Is preferably a phenolic resin adhesive.

Next, a method of bonding a metal material and a friction material according to the present invention will be described with reference to FIG.

The nonwoven fabric 4 of the short carbon fiber 3 shown in FIG.
Is impregnated with a phenolic resin-based adhesive 5 to form an adhesive cushion material (not shown) in advance. This adhesive cushion material is heated at a temperature of 60 to 100 ° C. × 10 to 60 min, preferably 70 to 90 ° C. × 20 to 40 min to perform pre-curing, thereby evaporating the solvent in the phenolic resin adhesive 5.

The adhesive cushion material after the pre-curing is interposed between the metal material 1 and the adhesive surfaces 1a, 2a of the friction material 2 having a significantly different linear expansion coefficient or surface roughness from the metal material 1. Prior to this interposition, it is preferable to apply a phenol resin-based adhesive to each of the bonding surfaces 1a and 2a of the metal material 1 and the friction material 2 in advance, and to perform preliminary curing. The phenolic resin-based adhesive applied to each of the bonding surfaces 1a and 2a of both materials 1 and 2 is preferably one having a higher viscosity than the phenolic resin-based adhesive 5 impregnated in the adhesive cushioning material.

After that, the metal material 1 and the friction material 2 are
The phenolic resin-based adhesive 5 is pressed at 130 to 230 ° C. × 30 to 90 min, preferably 160 to 200 ° C. × 40 to 40 mm while compressing the adhesive cushion material by pressing at a pressure of 1.5 to 1.5 MPa (5 to 15 kgf / cm ² ). Heat and cure under a temperature condition of 80 min. As a result, as shown in FIG. 1A, the metal material 1 and the friction material 2
Glued through.

Here, when the adhesive cushion layer 6 is viewed microscopically, the short carbon fibers 3a, 3b, 3c shown in FIG.
The region B surrounded by is very small.
Are filled with a phenol resin-based adhesive 5 which is a hard adhesive, and are randomly arranged in the horizontal direction and the layer thickness direction of the adhesive cushion layer 6. From another point of view, since the minute region B can be regarded as a minute adhesive region made of a hard adhesive, the short carbon fibers 3 in the adhesive cushion layer 6 are strongly adhered to each other by the phenol resin adhesive 5 ( As a result, both materials 1 and 2 are firmly bonded. On the other hand, macroscopically, the adhesive cushion layer 6 is slightly reinforced in all directions because the adhesive layer of the phenolic resin-based adhesive 5 is fiber-reinforced by the short carbon fiber 3 group. It is a hard and “flexible” (high toughness) layer that has room for movement (expansion and contraction).

Usually, since the adhesive layer of the phenolic resin adhesive 5 is hard and very brittle, a thick adhesive layer formed only of the phenolic resin adhesive 5 is used for the frictional engagement surface of the synchronizer ring. However, it is difficult to apply the method to a part where a large stress is applied as described above. On the contrary,
Although the adhesive cushion layer 6 is thick as much as it includes the short carbon fiber 3 group, it is hard as described above,
And since it is a layer with high toughness, there is no possibility of breakage even when a large stress is applied. In addition, since the layer thickness is large, the shear stress caused by the difference in the linear expansion coefficient between the two materials 1 and 2 can be dispersed throughout the adhesive cushion layer 6, thereby preventing a peeling phenomenon that is a concern at the time of joining dissimilar materials. It becomes possible.

The bonding surfaces 1a, 2a of the two materials 1, 2
Is bonded by interposing an adhesive cushion material, and is heated and cured while being pressed with a sufficient pressure, so that a sufficient bonding strength can be obtained.

Further, since the surface of the adhesive cushion material can be freely deformed within a predetermined range by applying a surface pressure, even if the pressure is applied under a sufficient pressure as described above,
The bonding cushion material is used as the bonding surface 1a, 2a
The adhesive cushion material is not deformed so as to fill (absorb) the uneven clearance therebetween and the compression stiffness of the short carbon fiber 3 itself exceeds a predetermined range. For this reason, between the bonding surfaces 1a, 2a of both materials 1, 2,
Even if there is uneven clearance due to the difference in surface roughness between the two materials 1 and 2, the metal material 1 and the adhesive cushion layer 6
And between the friction material 2 and the adhesive cushion layer 6, there is no possibility of a problem such as poor adhesion.

Further, as a combination of the metal material 1 and the friction material 2, both of the metal materials 1 made of a metal material having a rough surface are used.
And friction material 2, metal material 1 made of metal material having a rough surface and C-
The friction material 2 made of a C composite may be used. In this case, since the surface treatment of the metal material 1 or the friction material 2 becomes unnecessary, the manufacturing process can be simplified and the manufacturing cost can be reduced.

As described above, according to the bonding structure of the metal material and the friction material and the method of bonding the metal material and the friction material, the metal material and the friction material can be firmly bonded without fear of damage or peeling.

In this embodiment, the case where the phenol resin-based adhesive is used has been described. However, it is needless to say that substantially the same effect can be obtained by using the acrylic resin-based adhesive.

Next, another embodiment of the present invention will be described with reference to the accompanying drawings.

FIG. 2 is a perspective view of a preferred embodiment of the synchronizer ring according to the present invention.

As shown in FIG. 2, the synchronizer ring 20 according to the present invention comprises a metal (cast iron) ring portion 2.
Ring body (metal ring) provided with 1 and cone portion 22
29, an adhesive cushion layer 6 made of a nonwoven fabric 4 of carbon short fibers (or glass short fibers) 3 impregnated with the phenolic resin adhesive 5 shown in FIG. A friction material 24 made of a carbon fiber reinforced carbon composite sheet (hereinafter, referred to as a CC sheet) material is adhered, and the friction material 24 is pressed toward the cone portion 22 to be heated and cured while compressing the adhesive cushion layer 6. It is a thing.

The friction material 24 is composed of a large number of CC sheet pieces 25 provided over the inner peripheral surface of the cone portion 22 in the circumferential direction. −
It is provided with a predetermined interval from the C sheet piece 25.
The friction material 24 may be provided in multiple stages in the axial direction (vertical direction in FIG. 2) as needed (two stages in FIG. 2).
Here, an oil cut groove (not shown) is formed on the non-sticking surface (friction engagement surface) of each CC sheet piece 25 along the circumferential direction of the inner peripheral surface of the cone portion 22.

Next, a method of manufacturing the synchronizer ring 20 according to the present invention will be described with reference to FIG.

First, a C-C manufactured using a known method or the like is used.
A large number of CC sheet pieces 25 are cut out of the C composite block using a diamond cutter or the like. Also,
A nonwoven fabric 4 of short carbon fibers 3 shown in FIG. 1B is impregnated with a phenolic resin-based adhesive 5 to form an adhesive cushion material (not shown).

Next, a phenol resin-based adhesive having a relatively high viscosity is applied to the attachment surface of each CC sheet piece 25 and the inner peripheral surface 23 of the cone portion 22 of the ring main body 29, and then, an adhesive cushion material, Each of the CC sheet pieces 25 and the ring main body 29 are placed in a furnace and heated under a predetermined temperature condition, and the phenol resin-based adhesive is pre-cured, thereby evaporating the solvent in the phenol resin-based adhesive.

After pre-curing, the adhesive cushioning material was replaced with CC
The sheet piece 25 is cut into the same shape. After that, each CC sheet piece 25 is attached via an adhesive cushion material over the circumferential direction of the inner peripheral surface 23 of the cone portion 22.

Thereafter, a mold pin (not shown) is fitted into the inner peripheral surface 23 of the cone portion 22, and each of the C-
The C sheet piece 25 is pressed against the inner peripheral surface 23 of the cone portion 22 with a predetermined pressure. In this state, the ring main body 29 is placed in a furnace and heated under a predetermined temperature condition to heat and harden the phenol resin-based adhesive. At this time, the adhesive cushion material is deformed so as to fill (absorb) the clearance between the inner peripheral surface 23 of the cone portion 22 and the adhesive surface of the CC sheet piece 25, and the compression rigidity of the short carbon fiber 3 itself. As a result, the adhesive cushion material is not compressed and deformed beyond a predetermined range. For this reason, the inner peripheral surface 23 of the cone portion 22 and the CC sheet piece 25
The non-uniform clearance between the bonding surfaces can be completely filled with the bonding cushion material.

By bonding each CC sheet piece 25 to the inner peripheral surface 23 of the cone portion 22 via an adhesive cushion material,
The synchronizer ring 20 having the friction material 24 on the inner peripheral surface 23 of the cone portion 22 is obtained.

According to the synchronizer ring according to the present embodiment, the friction material 24 of the synchronizer ring 20 is used.
Is made of a C-C composite having excellent heat resistance and wear resistance, and exhibits excellent wear resistance stably even in high-temperature oil after long-term use.
Superior in durability and reliability compared to rings.

Further, an adhesive cushion material is interposed between the ring body 29 and the friction material 24, and the adhesive cushion material is press-bonded at a predetermined pressure and is cured by heating under a predetermined temperature condition. And the friction material 24 can be bonded through the bonding cushion layer 6 with a sufficient bonding strength. Further, as described above, the adhesive cushion layer 6 is an adhesive layer of the phenol resin-based adhesive 5 fiber-reinforced with the short carbon fiber 3 group, and is a hard and highly tough layer. Therefore, even if a large stress due to frictional engagement is applied to the adhesive cushion layer 6, the layer is not likely to be damaged.

Further, a ring body 29 made of cast iron and C
The friction material 24 made of a C-composite is a dissimilar material and has a large difference in linear expansion coefficient and surface roughness. The difference in elongation caused by the difference in expansion coefficient can be buffered, and the uneven clearance between the bonding surfaces caused by the difference in surface roughness between the ring main body 29 and the friction material 24 can be absorbed. For this reason, the ring body 2
Even if a shear stress caused by a difference in linear expansion coefficient is applied to the bonding surface between the friction material 9 and the friction material 24, there is no possibility that the friction material 24 is separated from the ring main body 29. Further, the uneven clearance between the bonding surfaces of the ring main body 29 and the friction material 24 is completely filled with the adhesive cushion material.
There is no risk that poor adhesion will occur between the adhesive cushion layer 6 and the friction material 24 and the adhesive cushion layer 6.

[0058]

EXAMPLE In order to confirm the adhesive strength between a metal material made of cast iron and a friction material made of a C-C composite, and the adhesive strength between metal materials made of cast iron, the shear strength is measured using a tensile tester. Here, when measuring the shear strength of a bonded metal material and a friction material, when the friction material is pulled with a tensile tester, the friction material is damaged because the C-C composite is a very brittle material. Thus, a tensile test cannot be performed on a metal material and a friction material bonded together. Therefore, in this case, the friction material was sandwiched between metal materials and bonded, and subjected to a tensile test to pull the metal materials together.

<Test 1> Width 25 mm, thickness 0.8 mm,
After preparing two cast iron materials (SPCC-SD (JIS standard)) with a length of 100 mm, the surface of the bonded part of each cast iron material is carburized, and then the surface of the bonded part is adjusted by shot blasting, and the surface roughness is adjusted. The degree is 50 μRz. Among these cast iron materials, one of the cast iron materials is bent in a V-shape in the width direction,
As shown in FIG. 4, a bent first member 41 and a straight second member 42 are manufactured. Here, the maximum depth of the valley-side surface 41a of the first member 41 was set to 0.5 mm to provide an uneven clearance.

The fiber diameter D is 0.006 mm (6 μm).
m) forming a CC composite using the carbon fibers of
Slice this C-C composite, 25mm in length,
A friction material 43 having a width of 25 mm and a thickness of 0.7 mm (see FIGS. 5 and 6)
Reference). Since the surface of the friction material cannot be polished, the surface roughness is considerably large (the surface roughness cannot be measured and has large variations).

Further, a non-woven fabric having a thickness of 2 mm and a basis weight of 3.0 × 10 ⁻³ g / cm ² is prepared using short carbon fibers having a fiber length L of 15 mm and a fiber diameter D of 0.8 μm. A phenolic resin adhesive (hamatite A-344) is applied to this nonwoven fabric.
-B (Yokohama Rubber Co., Ltd.)), 25 mm long,
Adhesive cushion material 44 25mm wide and 2.0mm thick
(See FIG. 5).

(Example 1) As shown in FIG. 5, the surfaces of the bonding portions of the first member 41 and the second member 42 and the friction 43
Phenolic resin-based adhesive (hamatite Y-
After applying 3600 (manufactured by Yokohama Rubber Co., Ltd.) 45, the first member 41, the second member 42, the friction material 43, and the adhesive cushioning material 44 are heated under a temperature condition of 80 ° C. × 30 min to form a phenol resin-based material. The phenol resin-based adhesive impregnated in the adhesive 45 and the adhesive cushioning material 44 is pre-cured.

Next, when the surfaces of the bonding portions of the first member 41 and the second member 42 are overlapped with each other,
A friction material 43 sandwiched between adhesive cushioning materials 44, 44 is interposed.

Then, the first member 41 and the second member 42 are pressed at a pressure of 0.98 MPa (10 kgf / cm ² ) and heated at a temperature of 180 ° C. × 60 min.
Phenolic resin adhesive 45 and adhesive cushioning material 44
The phenol resin-based adhesive impregnated in the sample is cured by heating to prepare a sample 1.

(Comparative Example 1) As shown in FIG. 6, a phenol resin-based adhesive (hamatite Y-3600) was applied to the surface of each of the bonding portions of the first member 41, the second member 42, and the friction material 43.
After applying (Yokohama Rubber Co., Ltd.) 45, the first member 4
1, the second member 42 and the friction material 43 are set at 80 ° C. × 30 mi.
Heating is performed under the temperature condition of n, and the phenol resin-based adhesive 45 is pre-cured.

Next, when the surfaces of the bonding portions of the first member 41 and the second member 42 are superposed on each other, a friction material 43 is interposed between the surfaces of the bonding portions. Thereafter, the first member 41 and the second
The member 42 is pressed under a pressure of 0.98 MPa (10 kgf / cm ² ) and heated under a temperature condition of 180 ° C. × 60 min to heat and cure the phenolic resin-based adhesive 45 to prepare a sample 2.

<Test 2> In the same manner as in Test 1, a first member 41 and a second member 42 are manufactured. In addition, the nonwoven fabric prepared in the same manner as in Test 1 was impregnated with an acrylic resin-based adhesive (Hard Rock G55 (manufactured by Denki Kagaku Co., Ltd.)) to provide an adhesive cushion material having a length of 25 mm, a width of 25 mm, and a thickness of 2.0 mm. 74 (see FIG. 7).

(Embodiment 2) As shown in FIG. 7, when the surfaces of the bonding portions of the first member 41 and the second member 42 face each other, an adhesive cushion member 74 is interposed between the surfaces of the bonding portions. .

Thereafter, the first member 41 and the second member 42 are fixed with clips and left at room temperature for 24 hours to cure the acrylic resin-based adhesive impregnated in the adhesive cushion material 74, thereby preparing the sample 3.

Comparative Example 2 As shown in FIG. 8, an acrylic resin-based adhesive (Hard Rock G55 (manufactured by Denki Kagaku Co., Ltd.))
After 81 is applied, the surfaces of the bonding portions of the first member 41 and the second member 42 are overlapped so as to face each other. Then, the first member 41
And fix the second member 42 with a clip and
The sample 4 is prepared by allowing the acrylic resin-based adhesive 81 to cure for 4 hours.

Here, from a different point of view, Samples 3 and 4 are:
It can be seen as a bonding structure between a metal material and a friction material having the same linear expansion coefficient as the metal material but different surface roughness.

<Test 3> 25 mm wide, 0.8 mm thick,
After preparing two cast iron materials (SPCC-SD (JIS standard)) with a length of 100 mm, the surface of the bonded part of each cast iron material is carburized, and then the surface of the bonded part is adjusted by shot blasting, and the surface roughness is adjusted. The degree is 50 μRz. Of this cast iron material, the adhesive part of one cast iron material is bent into an arch shape in the width direction,
As shown in FIG. 9, a bent first member 91 and a straight second member 92 are manufactured. Here, the maximum depth of the concave surface 91a of the first member 91 is 0.5 mm.

Other than the above, the friction material 43 was made in the same manner as in Test 1.
(See FIGS. 10 and 11) and an adhesive cushion material 44 (see FIG. 10).

(Embodiment 3) As shown in FIG. 10, the surfaces of the bonding portions of the first member 91 and the second member 92 and the friction
A phenolic resin-based adhesive (hamatite Y
-3600 (produced by Yokohama Rubber Co., Ltd.) 45
The first member 91, the second member 92, the friction material 43, and the adhesive cushion material 44 are heated at a temperature of 80 ° C. × 30 min to impregnate the phenol resin adhesive 45 and the adhesive cushion material 44 with the phenol resin adhesive. Pre-curing agent.

Next, when the surfaces of the bonding portions of the first member 91 and the second member 92 are overlapped with each other,
A friction material 43 sandwiched between adhesive cushioning materials 44, 44 is interposed.

Then, the first member 91 and the second member 92 are pressed at a pressure of 0.98 MPa (10 kgf / cm ² ) and heated at a temperature of 180 ° C. × 60 min.
Phenolic resin adhesive 45 and adhesive cushioning material 44
The sample 5 is prepared by heating and curing the phenol resin-based adhesive impregnated in the resin.

(Comparative Example 3) As shown in FIG. 11, a phenolic resin-based adhesive (hamatite Y-3600) was applied to the surfaces of the first member 91, the second member 92, and the friction material 43 at the respective bonding portions.
(Yokohama Rubber Co., Ltd.) After applying 45, the first member 9
1. The second member 92 and the friction material 43 were heated at 80 ° C. × 30 mi.
Heating is performed under the temperature condition of n, and the phenol resin-based adhesive 45 is pre-cured.

Next, when the surfaces of the bonding portions of the first member 91 and the second member 92 are superposed on each other, the friction material 43 is interposed between the surfaces of the bonding portions. Thereafter, the first member 91 and the second
The member 92 is pressed under a pressure of 0.98 MPa (10 kgf / cm ² ) and heated under a temperature condition of 180 ° C. × 60 min to heat and cure the phenolic resin adhesive 45 to prepare a sample 6.

<Test 4> In the same manner as in Test 3, a first member 91 and a second member 92 (see FIGS. 12 and 13) and an adhesive cushion material 44 (see FIG. 12) are manufactured.

(Embodiment 4) As shown in FIG. 12, a phenolic resin-based adhesive (Hamatite Y-3600 (manufactured by Yokohama Rubber Co., Ltd.)) was applied to the surface of each of the bonding portions of the first member 91 and the second member 92. 45, the first member 91, the second member 92, and the adhesive cushioning material 44 were heated to 80 ° C. × 30 m
in phenol resin adhesive 45
Then, the phenol resin adhesive impregnated in the adhesive cushion material 44 is pre-cured.

Next, when the surfaces of the bonding portions of the first member 91 and the second member 92 are overlapped with each other,
An adhesive cushion member 44 is interposed. Then, Example 3
In the same manner as in the above, the phenol resin-based adhesive 45 and the phenol resin-based adhesive impregnated in the adhesive cushioning material 44 are cured by heating to prepare a sample 7.

(Comparative Example 4) As shown in FIG. 13, a phenolic resin-based adhesive (Hamatite Y-3600 (manufactured by Yokohama Rubber Co., Ltd.)) was applied to the surfaces of the bonded portions of the first member 91 and the second member 92. After applying 45, the first member 91 and the second member 92 are heated under a temperature condition of 80 ° C. × 30 minutes to pre-cure the phenolic resin-based adhesive 45.

Next, after the surfaces of the bonding portions of the first member 91 and the second member 92 are superposed on each other, the first member 91 and the second member 92 are pressed at a pressure of 0.98 MPa (10 kgf / cm ² ). The sample 8 is produced by pressure bonding and heating at a temperature of 180 ° C. × 60 min to heat and cure the phenolic resin adhesive 45.

Here, from a different point of view, Samples 3 and 4 are:
It can be seen as a bonding structure between a metal material and a friction material having the same linear expansion coefficient as the metal material but different surface roughness.

For the samples 1 to 8 obtained in Examples 1 to 4 and Comparative Examples 1 to 4, the first members 41 and 91 and the second members 42 and 92 were subjected to an Instron type tensile tester.
Pulling was performed in the direction of the arrow shown in FIGS. 4 and 9, and the shear strength in the air at room temperature was measured.

In Samples 2 and 6 of Comparative Examples 1 and 3 having a conventional structure of bonding a metal material and a friction material, the friction members 43 between the first members 41 and 91 and the friction material 43 and the friction members 43 and the second members 42 and 92 were used. 4
And the phenolic resin-based adhesive 45
Is an adhesive layer. Since this adhesive layer is a hard and brittle layer, the allowable range when the adhesive layer is deformed due to tension is narrow (small). The adhesive layer needs to be pressurized in order to develop adhesive strength. However, when pressure is applied during the bonding, the pressure between the first members 41 and 91 and the friction material 43 and the second
The uneven clearance between the members 42 and 92 and the friction material 43 cannot be absorbed. Therefore, between the first members 41 and 91 and the friction material 43 and between the second members 42 and 9
Adhesion failure occurs between the friction material 2 and the friction material 43. For these reasons, the shear strength (adhesive strength) of Samples 2 and 6
Is as low as 5 MPa.

On the other hand, in the samples 1 and 5 of Examples 1 and 3 having the bonding structure of the metal material and the friction material of the present invention, the first
Between the members 41 and 91 and the friction material 43 and the second member 4
An adhesive cushion layer is interposed between the friction members 43 and the friction members 43. Since this adhesive cushion layer is a layer that is hard and has high toughness, the allowable range when the adhesive cushion layer is deformed due to tension is wide (large). Also, even if pressure is applied to develop the adhesive strength of the phenolic resin-based adhesive, the adhesive cushion layer is not compressed beyond a certain range, so that the first members 41 and 91 are not compressed. Between the friction member 43 and the second members 42, 9
The uneven clearance between the friction material 2 and the friction material 43 can be almost completely absorbed. For this reason, the first members 41, 9
There is no risk of poor adhesion between the first member and the friction member 43 and between the second members 42 and 92 and the friction member 43. For these reasons, the shear strength (adhesive strength) of samples 1 and 3
Is a very high value of 17 MPa, which is three times or more that of the samples 2 and 6.

Samples 3 and 7 of Examples 2 and 4 and Samples 4 and 8 of Comparative Examples 2 and 4 are adhesives between the same materials, and therefore, the first members 41 and 91 and the second members 42 and 92 are used. No distortion occurs between the first members 41 and 91 after bonding.
And the second members 42 and 92 can be regarded as substantially integral.

For this reason, in Samples 4 and 8 of Comparative Examples 2 and 4 having a conventional structure of bonding a metal material and a friction material, Samples 2 and 6
, The first members 41 and 91 and the second members 42 and 9
Although the shear strength (adhesive strength) is slightly higher because there is no distortion between the two, the shear strength (adhesive strength) is still low at 7 MPa for the same reason as in Samples 2 and 6.

On the other hand, in the samples 3 and 7 of Examples 2 and 4 having the bonding structure of the metal material and the friction material according to the present invention, the shear strength (adhesion strength) was reduced for the same reason as in the samples 1 and 3. This is a very high value of 21 MPa, which is three times that of Samples 4 and 8.

That is, it was confirmed that the adhesive having the structure of bonding a metal material and a friction material according to the present invention greatly improved the adhesive strength as compared with the conventional structure having an adhesion structure of a metal material and a friction material. did it.

As described above, the embodiments of the present invention are not limited to the above-described embodiments, and it is needless to say that various other embodiments are also conceivable.

[0093] The bonding structure of the metal material and the friction material according to the present invention is not limited to the synchronizer ring as described above, but may be applied to other frictional parts to which a large amount of stress is applied. It goes without saying that a brake shoe, a brake pad, a cylinder liner, and the like are assumed, of course.

[0094]

In summary, according to the present invention, a phenolic resin is applied to a nonwoven fabric made of short carbon fibers or the like between a metal material and a friction material having a greatly different linear expansion coefficient or surface roughness from the metal material. An excellent effect that the metal material and the friction material can be firmly adhered to each other by interposing the adhesive cushion layer impregnated with the adhesive or the acrylic resin adhesive, and pressing and curing the adhesive material. .

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view of a bonding structure between a metal material and a friction material according to the present invention.

FIG. 2 is a perspective view showing a preferred embodiment of a synchronizer ring according to the present invention.

FIG. 3 is a perspective view showing an embodiment of a conventional synchronizer ring.

FIG. 4 is a perspective view of a first member and a second member used in tests 1 and 2.

FIG. 5 is a sectional view of a bonding portion of a sample 1 in Example 1.

FIG. 6 is a cross-sectional view of a bonding portion of Sample 2 in Comparative Example 1.

FIG. 7 is a sectional view of a bonding portion of a sample 3 in Example 2.

FIG. 8 is a cross-sectional view of a bonding portion of Sample 4 in Comparative Example 2.

FIG. 9 is a perspective view of a first member and a second member used in tests 3 and 4.

FIG. 10 is a cross-sectional view of a bonding portion of a sample 5 according to a third embodiment.

11 is a cross-sectional view of a bonding portion of a sample 6 in Comparative Example 3. FIG.

FIG. 12 is a sectional view of a bonded portion of a sample 7 in Example 4.

FIG. 13 is a cross-sectional view of a bonding portion of Sample 8 in Comparative Example 4.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Metal material 2 Friction material 3 Short carbon fiber (or short glass fiber) 4 Nonwoven fabric 5 Phenol resin adhesive (or acrylic resin adhesive) 6 Adhesive cushion layer 20 Synchronizer ring 21 Ring part (metal ring) 22 Cone part (Metal ring) 23 Inner peripheral surface of cone part (Inner peripheral surface of metal ring) 24 Friction material 25 CC sheet piece (Carbon fiber reinforced carbon composite sheet piece) 29 Ring body (Metal ring)

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Toshiyuki Kanasaka 8 Dosana, Fujisawa-shi, Kanagawa Prefecture Isuzu Motors Fujisawa Plant Co., Ltd. (72) Inventor Tokiko Hashimoto 8 Isuzu-Mura, Fujisawa City, Kanagawa Prefecture Isuzu Motors Fujisawa Plant, Inc. (72) Inventor Eiichi Kijima 8 Tozai, Fujisawa-shi, Kanagawa Prefecture Isuzu Motors Fujisawa Co., Ltd. (72) Inventor Takuoka Tsuruoka 3- 25-1, Tonomachi, Kawasaki-ku, Kawasaki-shi, Kanagawa Prefecture Isuzu Motors Kawasaki Plant (72) Inventor Takashi Suzuki 3-25-1, Tonomachi, Kawasaki-ku, Kawasaki-shi, Kanagawa Prefecture F-term in the Kawasaki Plant of Isuzu Motor Co., Ltd. (Reference) 3J056 AA14 AA53 AA61 BA02 BC01 BE01 BE17 CA03 CA12 EA03 EA26 EA30 FA07 GA05 GA12 3J058 BA47 DD13 GA03 GA27 GA42 GA55 GA68 GA93 GA94 4F100 AB01A AB08A AD11B AD11C AK33C BA03 BA07 BA10A BA1 0B CB00C DC21B DG01B DG01C DG15C EC012 EC182 EJ082 EJ422 GB32 JK16B JL11

Claims (6)

[Claims] In a bonding structure of a metal material and a friction material having a different linear expansion coefficient from the metal material, an adhesive cushion layer obtained by impregnating an adhesive into a non-woven fabric made of short carbon fiber or the like is provided with the metal material and the friction material. An adhesive structure between a metal material and a friction material, wherein the metal material and the friction material are interposed between the adhesive surfaces and are pressed and heat-cured. 2. The bonding structure according to claim 1, wherein said adhesive is a phenolic resin adhesive. 3. The bonding structure between a metal material and a friction material according to claim 1, wherein the metal material is cast iron, and the friction material is a carbon fiber reinforced carbon composite material. 4. The method according to claim 1, wherein an adhesive layer made of a phenolic resin adhesive is previously formed on each of the adhesive surfaces of the metal material and the friction material, and an adhesive cushion layer is interposed therebetween. Adhesion structure of metal material and friction material. 5. The bonding structure between a metal material and a friction material according to claim 1, wherein the metal is a synchronizer ring of a transmission. 6. The metal material and the friction material according to claim 5, wherein the friction material is constituted by a plurality of carbon fiber reinforced carbon composite sheet pieces provided in a circumferential direction of an inner peripheral surface of the metal ring. Adhesive structure.