JP2003083374A - Manufacturing method of friction member - Google Patents
Manufacturing method of friction memberInfo
- Publication number
- JP2003083374A JP2003083374A JP2001271568A JP2001271568A JP2003083374A JP 2003083374 A JP2003083374 A JP 2003083374A JP 2001271568 A JP2001271568 A JP 2001271568A JP 2001271568 A JP2001271568 A JP 2001271568A JP 2003083374 A JP2003083374 A JP 2003083374A
- Authority
- JP
- Japan
- Prior art keywords
- friction
- friction material
- temperature
- back metal
- manufacturing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、自動車や産業用機
械のブレーキ、クラッチ等に使用される摩擦部材の製造
方法に関し、さらに詳しくは、自動車や産業用機械のブ
レーキ、クラッチ等に使用されるディスクブレーキパッ
ド、ドラムブレーキシュー、或いはクラッチ板等、鉄系
などの金属製の裏金（バックプレート、裏板と称される
こともある）とその表面に一体に接合された非石綿系摩
擦材からなる摩擦部材の製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a friction member used for a brake or a clutch of an automobile or an industrial machine, and more specifically, it is used for a brake or a clutch of an automobile or an industrial machine. Disc brake pad, drum brake shoe, clutch plate, etc. made of metal such as ferrous metal (sometimes called back plate, back plate) and non-asbestos friction material integrally bonded to the surface And a method for manufacturing the friction member.
【０００２】[0002]
【従来の技術】自動車などのディスクブレーキ用摩擦パ
ッド、ブレーキシュー、クラッチ板等に使用される摩擦
部材は、摩擦材に、鉄系金属からなる裏金を一体に接合
して形成されている。これらの摩擦部材は、ディスクロ
ータや相手側のクラッチプレートとの間に押しつけられ
た状態で相対的な移動が加えられ、その際の摩擦力で自
動車を制動したり、エンジンの駆動力を車輪に伝達した
りする。そのため、摩擦材と裏金との間には、大きな剪
断力が加わる。したがって、摩擦材と裏金との間には、
この剪断力に耐えることができるような強い接合力（或
いは接着力）が必要となる。2. Description of the Related Art Friction members used for friction pads for disc brakes, brake shoes, clutch plates and the like of automobiles are formed by integrally joining a friction metal and a backing metal made of ferrous metal. These friction members are moved relative to each other while being pressed against the disc rotor and the clutch plate on the other side, and the friction force at that time brakes the automobile or the driving force of the engine to the wheels. To communicate. Therefore, a large shearing force is applied between the friction material and the back metal. Therefore, between the friction material and the back metal,
A strong bonding force (or adhesive force) that can withstand this shearing force is required.
【０００３】一般に、摩擦材と裏金とが接合された、デ
ィスクブレーキ用摩擦パッドなどの摩擦部材は、裏金に
摩擦材を密着させて加熱成形することにより製造され
る。さらに説明すると、摩擦材は、セラミック繊維、ス
チール繊維、銅繊維、アラミド繊維、チタン酸カリウム
繊維等の繊維基材、炭酸カルシウム、硫酸バリウム、ゴ
ム粉末、カシューダスト、黒鉛、二硫化モリブデン、銅
及びアルミニウム等の摩擦・摩耗調整剤も含む充填材お
よび全体を結合するフェノール樹脂等の結合材を含有し
ている。加熱成形時には、これら材料を混合撹拌した状
態で裏金に密着させ、あるいは混合撹拌するとともに予
め摩擦材の形状に予備成形して裏金に密着させ、これら
裏金及び摩擦材を金型に入れて熱及び圧力を加えること
により、結合材である樹脂を溶融、硬化させて摩擦材を
所定の形状・寸法に成形し、更に裏金に接着するのであ
る。また、摩擦部材の摩擦材と裏金との接合面の接着強
度を高めるために、裏金については、表面処理が行わ
れ、例えば、脱脂処理、ブラスト処理、化成被膜処理、
プライマー処理などが行われている。このようにして摩
擦部材は、製造されている。Generally, a friction member such as a friction pad for a disc brake, in which a friction material and a back metal are joined, is manufactured by bringing the friction material into close contact with the back metal and performing heat molding. To further explain, the friction material is a fiber material such as ceramic fiber, steel fiber, copper fiber, aramid fiber, potassium titanate fiber, calcium carbonate, barium sulfate, rubber powder, cashew dust, graphite, molybdenum disulfide, copper and It contains a filler that also contains a friction / wear modifier such as aluminum, and a binder such as a phenol resin that binds the whole. During heat molding, these materials are mixed and agitated to adhere to the back metal, or they are mixed and agitated and preformed into the shape of the friction material and adhered to the back metal in advance. By applying pressure, the resin as the binder is melted and hardened to form the friction material into a predetermined shape and size, and is further adhered to the backing metal. Further, in order to increase the adhesive strength of the joint surface between the friction material of the friction member and the back metal, the back metal is subjected to a surface treatment, for example, degreasing treatment, blast treatment, chemical conversion coating treatment,
Primer processing is performed. The friction member is manufactured in this manner.
【０００４】ところで、従来から、摩擦部材の摩擦材と
裏金との接着強度不足の原因として、例えば、セミメタ
リック材の断熱層の接着強度不足、すなわち断熱効率を
向上するため、断熱層の金属繊維成分量を少なくするこ
とによる高温強度の不足、あるいは異材質間の馴染み不
足による接着強度不足がある。また、非石綿系摩擦材の
接着強度不足、すなわち摩擦材中の結合材が少ないこと
による接着強度の不足、又は接着剤或いは接着剤及び接
合層と摩擦材との接着強度不足、すなわち異材質間の馴
染み不足や成形不良による接着強度不足などが挙げられ
ている。By the way, conventionally, as a cause of insufficient adhesion strength between the friction material of the friction member and the back metal, for example, insufficient adhesion strength of the heat insulating layer of the semi-metallic material, that is, in order to improve heat insulating efficiency, the metal fiber of the heat insulating layer is improved. There is a lack of high-temperature strength due to a decrease in the amount of components, or a lack of adhesive strength due to a lack of familiarity between different materials. Also, the adhesive strength of the non-asbestos-based friction material is insufficient, that is, the adhesive strength is insufficient due to the small amount of binder in the friction material, or the adhesive strength between the adhesive or the adhesive / bonding layer and the friction material is insufficient, that is, between different materials. Insufficient familiarity and insufficient adhesive strength due to defective molding are mentioned.
【０００５】そのため、従来から改良された摩擦部材の
製造方法が種々提案されている。例えば、特許第２９０
４２４４号公報では、摩擦材と金属製の裏板とを含むデ
ィスクブレーキ用摩擦パッドの製造方法において、裏板
に摩擦材を密着させて加熱成形することにより摩擦部材
とするとともに裏板に固着する際に、裏板の摩擦材が密
着する側とは反対側の裏面を加熱する温度を、摩擦材の
裏板に密着する側とは反対側の表面を加熱する温度より
高くしたことを特徴とするディスクブレーキ用摩擦パッ
ドの製造方法が提案されている。すなわち、通常、摩擦
部材を成形する際には、金型温度は、全ての金型面（成
形面）で同じとするものであり、その結果、加圧・加熱
成形の際に、裏金側の摩擦材組成物の温度上昇が遅れる
とされるものであるが、この特許公報では、裏板の摩擦
材を密着させる側とは反対側の裏面を加熱する温度を高
くすることにより、裏板が摩擦材の表面側より速く加熱
され、摩擦材の裏板側部分の硬化が表面側部分に対して
遅れなく進行し、従って、硬化時に発生するガスは、摩
擦材の裏板側部分から少なくなり、その結果、摩擦材の
裏板側部分には、大きな気孔が少ないため強度が高くな
るというものを開示している。Therefore, various improved methods for manufacturing friction members have been proposed. For example, Japanese Patent No. 290
According to Japanese Patent No. 4244, in a method of manufacturing a friction pad for a disc brake including a friction material and a metal back plate, the friction material is adhered to the back plate and heat-molded to form a friction member and to be fixed to the back plate. At that time, the temperature of heating the back surface of the back plate on the side opposite to the side where the friction material adheres is set higher than the temperature of heating the surface of the friction material on the side opposite to the side that adheres to the back plate. A method for manufacturing a friction pad for a disc brake is proposed. That is, normally, when molding a friction member, the mold temperature is the same on all mold surfaces (molding surface), and as a result, the back metal side of the back metal side is subjected to pressure / heat molding. Although it is said that the temperature rise of the friction material composition is delayed, in this patent publication, by increasing the temperature for heating the back surface of the back plate on the side opposite to the side on which the friction material is adhered, the back plate is The friction material is heated faster than the front surface side, and the back plate side portion of the friction material cures without delay relative to the front surface side portion, so that the gas generated during curing is reduced from the back plate side portion of the friction material. As a result, it is disclosed that the back plate side portion of the friction material has a large number of large pores and thus has high strength.
【０００６】また、特許第３１４１５９８号公報では、
摩擦材を、裏金に密着させて加熱成形することにより摩
擦材とするとともに、裏金に固着させて製造されるディ
スクブレーキ用摩擦パッドの製造方法において、裏金を
予備加熱して裏金に予め余熱を与えた状態を維持しつ
つ、加熱成形を行うことを特徴とするディスクブレーキ
用摩擦パッドの製造方法が提案されている。すなわち、
この特許公報も、加熱成形の際に、接合層の温度上昇が
遅れるために内部欠陥が生じ易いとされる課題に対し
て、裏金側の摩擦材組成物の温度上昇が遅れる原因とさ
れる裏金を予備加熱して裏金に予め余熱を与えた状態を
維持しつつ、加熱成形を行うことにより、摩擦材の硬化
の最も遅い部分、すなわち強度の弱くなるおそれのある
部分が摩擦材の裏金近傍部分から離れ、その結果、摩擦
材の強度を上げることができ、耐久性に優れた摩擦パッ
ドを製造することができるというものを開示している。Further, in Japanese Patent No. 3141598,
The friction material is made into a friction material by closely adhering to the back metal to form a friction material, and in the method of manufacturing a friction pad for a disc brake manufactured by fixing the friction material to the back metal, the back metal is preheated to preheat the back metal. There has been proposed a method for manufacturing a friction pad for a disc brake, which is characterized by performing hot molding while maintaining the above state. That is,
Also in this patent publication, a back metal that causes a delay in the temperature rise of the friction material composition on the back metal side against the problem that internal defects are likely to occur due to a delay in the temperature rise of the bonding layer during heat molding. By preheating and preheating the back metal to maintain residual heat in advance, by performing heat molding, the slowest hardening part of the friction material, that is, the part where the strength may become weak, is the part near the back metal of the friction material. That is, the strength of the friction material can be increased as a result, and a friction pad having excellent durability can be manufactured.
【０００７】さらに、特開平１１−２５４４７３号公報
では、繊維状体、結合材及び摩擦調整剤を含む摩擦材の
材料を熱成形して摩擦材を製造する方法において、熱成
形に際して、その当初にあっては上型の温度を下型の温
度よりも低くし、熱成形の進行に伴って上型の温度を上
げて行くことを特徴とする摩擦材の製造方法が提案され
ている。すなわち、摩擦材側の上型の温度を熱成形の当
初、裏金側の下型の温度よりも低くすることなどによ
り、熱成形時に亀裂が発生することがないようにしたも
のを開示している。Further, in Japanese Patent Application Laid-Open No. 11-254473, in a method of manufacturing a friction material by thermoforming a material of a friction material containing a fibrous body, a binder and a friction modifier, at the beginning of the thermoforming, In that case, a method of manufacturing a friction material is proposed in which the temperature of the upper mold is set lower than the temperature of the lower mold, and the temperature of the upper mold is raised as the thermoforming progresses. That is, by disclosing the temperature of the upper mold on the friction material side lower than the temperature of the lower mold on the back metal side at the beginning of thermoforming, cracks do not occur during thermoforming. .
【０００８】しかしながら、これらの提案にも拘わら
ず、摩擦材と裏金とが接合された摩擦部材においては、
接着剤或いは接着剤及び接合層と摩擦材の境界面で剥離
したり、また、通常接合層の強度は、摩擦材の強度より
大であり、接合層を用いた摩擦部材の接着強度は、摩擦
材の剪断強度以上となるはずであるが、そうならない場
合もあり、さらに、接合層は、摩擦材より樹脂成分量が
多く良好な熱伝導性を持つため、接合層の硬化が早くな
り、それに比して、摩擦材の硬化が遅れるために摩擦材
に内部欠陥が生じる等、十分な接着強度が得られないと
いう恐れがあった。However, in spite of these proposals, in the friction member in which the friction material and the back metal are joined,
The adhesive or the adhesive / bonding layer peels off at the interface between the friction material and the friction material, and the strength of the normal bonding layer is higher than the strength of the friction material. It should be greater than the shear strength of the material, but in some cases it is not so.In addition, since the bonding layer has more resin components than the friction material and has good thermal conductivity, the bonding layer cures faster and On the other hand, there is a risk that sufficient adhesion strength cannot be obtained, such as internal defects occurring in the friction material due to delay in curing of the friction material.
【０００９】従って、摩擦材と裏金との間に、大きな剪
断力が加わわっても、この剪断力に耐えることができる
ような強い接着強度が得られる摩擦部材の製造方法が強
く求められている。Therefore, even if a large shearing force is applied between the friction material and the back metal, there is a strong demand for a method of manufacturing a friction member which can obtain a strong adhesive strength capable of withstanding the shearing force. .
【００１０】[0010]
【発明が解決しようとする課題】本発明の目的は、従来
技術の問題点に鑑み、摩擦材と裏金との間に強い接着強
度が得られ、耐久性に優れた摩擦部材の製造方法を提供
することにある。SUMMARY OF THE INVENTION In view of the problems of the prior art, an object of the present invention is to provide a method for producing a friction member having a strong adhesive strength between the friction material and the backing metal and having excellent durability. To do.
【００１１】[0011]
【課題を解決するための手段】本発明者らは、上記の目
的を達成するため鋭意検討した結果、摩擦部材の成形に
用いる金型の温度に注目し、従来提案されてきた裏金全
体、又は裏金の摩擦材側とは反対側の温度を高くするこ
ととは逆に、裏金の接する側の金型温度を摩擦材側の金
型温度より低くして成形することにより、驚くべきこと
に、接着剤や接合層の結合材の樹脂の硬化が遅くなり、
或いは接着剤や接合層と接している摩擦材中の結合材の
樹脂の硬化が遅くなり、接着剤や接合層と摩擦材の境界
面での摩擦材の樹脂とのなじみが良くなり、その結果、
境界面での剥離の恐れが減少し、接着強度が飛躍的に向
上することを見出した。本発明は、これらの知見に基づ
いて完成するに至ったものである。Means for Solving the Problems As a result of intensive studies to achieve the above-mentioned object, the present inventors have paid attention to the temperature of a mold used for molding a friction member, and have proposed the entire backing metal, or Contrary to increasing the temperature on the side opposite to the friction material side of the back metal, by molding with the mold temperature on the contact side of the back metal lower than the mold temperature on the friction material side, surprisingly, Curing of the adhesive or the resin of the binder of the bonding layer will slow down,
Alternatively, the resin of the binder in the friction material that is in contact with the adhesive or the joining layer slows to cure, and the interface between the adhesive or the joining layer and the friction material becomes better compatible with the resin of the friction material. ,
It was found that the risk of peeling at the boundary surface is reduced and the adhesive strength is dramatically improved. The present invention has been completed based on these findings.
【００１２】すなわち、本発明の第１の発明によれば、
金属製の裏金と、繊維基材、結合材及び充填材を主成分
とする摩擦材とを加熱加圧して一体に成形する摩擦部材
の製造方法において、裏金の摩擦材が接合される側とは
反対側の裏金に接する金型の温度を、摩擦部材の成形可
能な温度以上で、かつ摩擦材と接する他の金型の温度よ
り低くして成形することを特徴とする摩擦部材の製造方
法が提供される。また、本発明の第２の発明によれば、
第１の発明において、摩擦材は、セミメタリック材を除
く非石綿系摩擦材であることを特徴とする摩擦部材の製
造方法が提供される。さらに、本発明の第３の発明によ
れば、第１又は２の発明において、摩擦材は、裏金と接
合される側に、繊維基材、結合材及び充填材を主成分と
する接合層を有することを特徴とする摩擦部材の製造方
法が提供される。また、本発明の第４の発明によれば、
第３の発明において、接合層は、摩擦材に比較して結合
材の含有割合量が多いことを特徴とする摩擦部材の製造
方法が提供される。さらに、本発明の第５の発明によれ
ば、第１〜４のいずれかの発明において、裏金に接する
金型と、摩擦材と接する他の金型との温度差は、５〜５
０℃の範囲であることを特徴とする摩擦部材の製造方法
が提供される。That is, according to the first aspect of the present invention,
In the method of manufacturing a friction member in which a metal backing metal and a friction material mainly composed of a fiber base material, a binder and a filler are heated and pressed to be integrally molded, the side to which the friction material of the backing metal is joined is A method of manufacturing a friction member, characterized in that the temperature of a mold in contact with the back metal on the opposite side is equal to or higher than the moldable temperature of the friction member and lower than the temperature of another mold in contact with the friction material. Provided. According to the second aspect of the present invention,
In the first invention, there is provided a method of manufacturing a friction member, wherein the friction material is a non-asbestos friction material excluding a semimetallic material. Further, according to a third invention of the present invention, in the first or second invention, the friction material has a bonding layer containing a fiber base material, a binder and a filler as main components on the side to be bonded to the back metal. A method for manufacturing a friction member is provided. According to a fourth aspect of the present invention,
In a third aspect of the present invention, there is provided a method for manufacturing a friction member, wherein the joining layer has a larger content ratio of the binder than the friction material. Further, according to a fifth aspect of the present invention, in any one of the first to fourth aspects, the temperature difference between the die contacting the back metal and the other die contacting the friction material is 5 to 5
A method for manufacturing a friction member is provided which is in the range of 0 ° C.
【００１３】本発明は、上記した如く、金属製の裏金と
摩擦材とを加熱加圧して一体に成形する摩擦部材の製造
方法において、裏金の摩擦材が接合される側とは反対側
の裏金に接する金型の温度を、摩擦部材の成形可能な温
度以上、かつ摩擦材と接する他の金型の温度より低くし
て成形することを特徴とする摩擦部材の製造方法などに
係るものであるが、その好ましい態様としては、次のも
のが包含される。
（１）裏金と摩擦材との接合層は、摩擦材に比較して高
い熱伝導率を有することを特徴とする上記のいずれかの
摩擦部材の製造方法。
（２）接着剤は、熱硬化性樹脂接着剤であることを特徴
とする上記のいずれかの摩擦部材の製造方法。
（３）第５の発明において、温度差は、１０〜３０℃の
範囲であることを特徴とする摩擦部材の製造方法。As described above, the present invention is a method of manufacturing a friction member in which a metal backing and a friction material are heated and pressed to be integrally molded, and in the backing on the side opposite to the side to which the friction material of the backing is joined. The present invention relates to a method for manufacturing a friction member, characterized in that the temperature of the mold in contact with the friction member is higher than the moldable temperature of the friction member and lower than the temperature of another mold in contact with the friction material. However, the preferred embodiments include the following. (1) The method for manufacturing a friction member as described above, wherein the joining layer between the backing metal and the friction material has a higher thermal conductivity than the friction material. (2) The method for producing a friction member as described above, wherein the adhesive is a thermosetting resin adhesive. (3) In the fifth invention, the temperature difference is in the range of 10 to 30 ° C., and the method for manufacturing the friction member.
【００１４】[0014]
【発明の実施の形態】以下、本発明について項目毎に詳
細に説明する。本発明の摩擦部材の製造方法では、金属
製の裏金と摩擦材とを加熱加圧して一体に成形する際
に、裏金の摩擦材が接合される側とは反対側の裏金に接
する金型の温度を、摩擦材と接する他の金型の温度より
低くして成形することにより、接合層と、摩擦材の境界
面での摩擦材の樹脂とのなじみが良くなり、その結果、
境界面での剥離が減少し、接着強度が飛躍的に向上する
ことに最大の特徴がある。BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in detail for each item. In the method for manufacturing a friction member of the present invention, when the metal back metal and the friction material are heated and pressed to be integrally molded, a mold contacting the back metal on the side opposite to the side where the friction material of the back metal is bonded is formed. By molding at a temperature lower than the temperature of other molds that come into contact with the friction material, the bonding layer and the resin of the friction material at the boundary surface of the friction material become more compatible, and as a result,
The greatest feature is that peeling at the boundary surface is reduced and the adhesive strength is dramatically improved.
【００１５】１．摩擦部材
本発明の摩擦部材の製造方法に係る摩擦部材は、貫通孔
が穿孔された金属製裏金と、非石綿系摩擦材とからな
る。この摩擦材と金属製裏金とは、接着剤を介して接合
されている。1. Friction Member The friction member according to the method for manufacturing a friction member of the present invention includes a metal backing metal having through holes formed therein and a non-asbestos-based friction material. The friction material and the metal backing metal are joined together via an adhesive.
【００１６】（１）非石綿系摩擦材
本発明に係る非石綿系摩擦材は、繊維基材、結合材及び
充填材とを主成分とするものである。繊維基材として、
石綿（アスベスト）以外の摩擦材に通常用いられる無機
質繊維、有機質繊維などが挙げられる。このような繊維
基材として、比較的硬いものとしては、例えば、セラミ
ック繊維、天然鉱物繊維、ガラス繊維、金属繊維などが
挙げられ、比較的柔らかいものとしては、例えば、アラ
ミド繊維、炭素繊維、セルロース繊維、アクリル繊維、
チタン酸カリウム繊維などが挙げられ、これらの１種を
単独で又は２種以上を組み合わせて用いることができ
る。中でも好ましいのは、アラミド繊維やチタン酸カリ
ウム繊維などが挙げられる。(1) Non-asbestos-based friction material The non-asbestos-based friction material according to the present invention is mainly composed of a fiber base material, a binder and a filler. As a fiber substrate,
Inorganic fibers and organic fibers that are usually used for friction materials other than asbestos (asbestos) can be mentioned. As such a fiber base material, relatively hard materials include, for example, ceramic fibers, natural mineral fibers, glass fibers, metal fibers, and the like, and relatively soft materials include, for example, aramid fibers, carbon fibers, and cellulose. Fiber, acrylic fiber,
Examples thereof include potassium titanate fiber, and these can be used alone or in combination of two or more. Of these, aramid fibers and potassium titanate fibers are preferable.
【００１７】具体的には、セラミック繊維としては、例
えばアルミナ、シリカを主成分とするセラミック繊維、
アルミナ、シリカ、ジルコニアを主成分とするセラミッ
ク繊維、シリカ、酸化カルシウム、酸化マグネシウムを
主成分とするセラミック繊維等が挙げられる。天然鉱物
繊維としては、例えばウオラストナイト、セピオライト
等が挙げられる。金属繊維としては、例えば、ステンレ
ス、青銅、銅、真鍮、アルミニウム等の各種金属の繊維
等が挙げらる。Specifically, as the ceramic fiber, for example, a ceramic fiber containing alumina or silica as a main component,
Examples thereof include ceramic fibers containing alumina, silica and zirconia as main components, and ceramic fibers containing silica, calcium oxide and magnesium oxide as main components. Examples of natural mineral fibers include wollastonite and sepiolite. Examples of the metal fibers include fibers of various metals such as stainless steel, bronze, copper, brass and aluminum.
【００１８】本発明においては、繊維基材は、短繊維
状、パルプ状、粉末状で用いられ、繊維成分の含有量
は、特に制限されず、非石綿系摩擦材全量基準で、用い
る繊維基材成分の種類により、適宜選ばれ、通常、５〜
９０体積％程度、好ましくは２０〜７０体積％である。In the present invention, the fiber base material is used in the form of short fibers, pulp or powder, and the content of the fiber component is not particularly limited, and the fiber base used on the basis of the total amount of non-asbestos-based friction material. It is appropriately selected depending on the type of material component, and is usually 5
It is about 90% by volume, preferably 20 to 70% by volume.
【００１９】また、本発明において用いられる結合材に
は、通常摩擦材に用いられる公知のものを使用すること
ができ、例えばフェノール樹脂、エポキシ樹脂、尿素樹
脂、メラミン樹脂またはそれらの変成樹脂のような熱硬
化性樹脂や、ポリアセタール、芳香族ポリイミド樹脂、
フッ素樹脂等の耐熱性樹脂、又はＮＢＲなどが挙げられ
る。これらの１種を単独で、或いは２種以上を組み合わ
せて用いることができる。本発明においては、金型の温
度差で顕著な効果を発揮する点から結合材には、熱硬化
性樹脂が好ましい。As the binder used in the present invention, known binders usually used for friction materials can be used. For example, a phenol resin, an epoxy resin, a urea resin, a melamine resin or a modified resin thereof can be used. Thermosetting resin, polyacetal, aromatic polyimide resin,
A heat resistant resin such as a fluororesin or NBR may be used. These 1 type can be used individually or in combination of 2 or more types. In the present invention, a thermosetting resin is preferable as the binder because it exhibits a remarkable effect due to the temperature difference between the molds.
【００２０】さらに、結合材の含有量は、特に制限され
ず、非石綿系摩擦材全量基準で、用いる結合材成分の種
類により、適宜選ばれ、通常、５〜５０体積％程度、好
ましくは１０〜２５体積％である。Further, the content of the binder is not particularly limited and is appropriately selected depending on the kind of the binder component used on the basis of the total amount of the non-asbestos friction material, and is usually about 5 to 50% by volume, preferably 10%. ~ 25% by volume.
【００２１】本発明に係る非石綿系摩擦材において、充
填材成分として使用されるものは、有機系でも無機系で
もよく、通常摩擦材に用いられる公知のものを使用する
ことができ、例えば二硫化モリブデン、三硫化アンチモ
ン、炭酸カルシウム、硫酸バリウム、酸化マグネシウ
ム、カシューダスト、黒鉛、水酸化カルシウム、フッ化
カルシウム、タルク、三酸化モリブデン、三酸化アンチ
モン、ケイ酸ジルコニウム、酸化鉄、雲母、硫化鉄、酸
化ジルコニウム、金属粉末、石英、酸化ケイ素、ゴム粉
末、アルミナ、酸化クロム、バーミキュライトなどが挙
げられる。中でも二硫化モリブデン、三硫化アンチモ
ン、カシューダスト、黒鉛、三酸化アンチモンのような
潤滑性のあるものは、耐摩耗性の向上や対面攻撃性の減
少に寄与する。逆に、珪酸ジルコニウム、酸化鉄、酸化
ジルコニウム、石英、酸化珪素、アルミナ、酸化クロム
のような研磨作用のあるものは、摩擦特性の向上に寄与
する。これらの１種を単独で又は２種以上を組み合わせ
て用いることができる。In the non-asbestos-based friction material according to the present invention, the filler component may be organic or inorganic, and known ones commonly used in friction materials can be used. Molybdenum sulfide, antimony trisulfide, calcium carbonate, barium sulfate, magnesium oxide, cashew dust, graphite, calcium hydroxide, calcium fluoride, talc, molybdenum trioxide, antimony trioxide, zirconium silicate, iron oxide, mica, iron sulfide , Zirconium oxide, metal powder, quartz, silicon oxide, rubber powder, alumina, chromium oxide, vermiculite and the like. Among them, those having lubricity such as molybdenum disulfide, antimony trisulfide, cashew dust, graphite and antimony trioxide contribute to the improvement of wear resistance and the reduction of face-to-face attack. On the other hand, zirconium silicate, iron oxide, zirconium oxide, quartz, silicon oxide, alumina, chromium oxide, etc. having a polishing action contribute to the improvement of friction characteristics. These 1 type can be used individually or in combination of 2 or more types.
【００２２】また、充填材の含有量は、特に制限され
ず、非石綿系摩擦材全量基準で、用いる充填材成分の種
類により、適宜選ばれ、通常、５〜６０体積％程度、好
ましくは１０〜４０体積％である。The content of the filler is not particularly limited and is appropriately selected based on the total amount of the non-asbestos friction material, depending on the type of the filler component used, and usually about 5 to 60% by volume, preferably 10%. -40% by volume.
【００２３】本発明において、非石綿系摩擦材には、本
発明の目的を損なわない範囲で、上記の繊維基材、結合
材及び充填材以外の、摩擦材に通常用いられる任意材料
を適宜添加することができる。例えば、コークス、リン
系潤滑剤等が挙げられるが、任意材料はこれらに限定さ
れるものではない。また、本発明に係る非石綿系摩擦材
の製造方法においては、上記の繊維基材、結合材及び充
填材などをヘンシェルミキサー、レディゲミキサー、ア
イリッヒミキサー等の混合機を用いて均一に混合し、成
形用粉体を得、この粉体を加圧型内で予備成形するもの
である。In the present invention, the non-asbestos-based friction material is appropriately added with any material commonly used in friction materials other than the above-mentioned fiber base material, binder and filler, as long as the object of the present invention is not impaired. can do. For example, coke, phosphorus-based lubricant and the like can be mentioned, but the optional material is not limited to these. Further, in the method for producing a non-asbestos-based friction material according to the present invention, the above fibrous base material, binder, filler and the like are uniformly mixed using a mixer such as a Henschel mixer, a Loedige mixer, and an Eichrich mixer. Then, a molding powder is obtained, and this powder is preformed in a pressure mold.
【００２４】（２）裏金
本発明に係る摩擦部材の裏金には、図２に示すように、
裏金の製造工程で得られた裏金が用いられるが、特に限
定されるものではない。本発明に係る摩擦部材は、裏金
の製造工程で得られた裏金と、別の摩擦材の製造（予備
成形）工程で得られた摩擦材とを、接着剤或いは接着剤
及び接合層を介して接合して、加熱・加圧成形し、次い
で、焼成工程、仕上げ工程とを経て、摩擦材と裏金が一
体となった摩擦部材が製造されるものである。(2) Back metal As shown in FIG. 2, the back metal of the friction member according to the present invention is as follows.
The back metal obtained in the manufacturing process of the back metal is used, but is not particularly limited. The friction member according to the present invention comprises a backing metal obtained in the backing metal manufacturing step and a friction material obtained in another friction material manufacturing (preforming) step through an adhesive or an adhesive and a bonding layer. A friction member in which a friction material and a backing metal are integrated is manufactured by joining, heating / pressurizing, and then performing a firing process and a finishing process.
【００２５】通常、裏金の製造工程は、次の（Ａ）〜
（Ｆ）工程からなる。
（Ａ）板金プレス成形工程：鋼板などを、プレスの打ち
抜き加工などによって成形する工程。この工程により、
貫通孔が穿孔された金属製裏金の原形物が得られる。
（Ｂ）脱脂処理工程：工程Ａで得られた、貫通孔が穿孔
された裏金を、アルカリ水溶液などにより、脱脂処理す
る工程。脱脂処理工程は、油分などが接合力低下の原因
となるので取り除くために実施される。
（Ｃ）ブラスト加工表面処理工程：工程Ｂの脱脂処理工
程の次に、或いは同時に、裏金の表面をブラストにより
加工する工程。この工程は、裏金と摩擦材との接着強度
を高めるために、すなわち、裏金の面粗度を上げるため
に、裏金に向けて粒状物、例えば、砥粒を含む水（スラ
リー又はブラスト液）を噴射し、ブラスト加工するもの
である。
（Ｄ）化成被膜処理工程：工程Ｃで得られた表面処理し
た裏金を、さらに、化成被膜処理する工程。この工程
は、裏金の防錆のために、裏金表面に化成被膜を形成す
る防錆被膜処理の工程である。
（Ｅ）プライマー処理工程：工程Ｄで得られた化成被膜
処理した裏金を、裏金の防錆性と接着剤の接着性とを向
上させるために、プライマー処理（裏金にプライマー剤
を塗布、乾燥、焼き付け）する工程。
（Ｆ）接着剤塗布工程：別に予備成形された摩擦材と接
合させるために、工程Ｅで得られた裏金に、接着剤を塗
布・乾燥する工程。Usually, the manufacturing process of the back metal is as follows.
(F) Step. (A) Sheet metal press forming step: a step of forming a steel plate or the like by punching with a press or the like. By this process,
An original metal backing metal having through holes is obtained. (B) Degreasing treatment step: a step of degreasing the back metal obtained in step A and having through holes with an alkaline aqueous solution or the like. The degreasing process is performed to remove oil and the like because it causes a decrease in bonding strength. (C) Blasting surface treatment step: a step of blasting the surface of the back metal after or simultaneously with the degreasing treatment step of step B. In this step, in order to increase the adhesive strength between the back metal and the friction material, that is, in order to increase the surface roughness of the back metal, a granular material, for example, water containing abrasive grains (slurry or blast liquid) is directed toward the back metal. It is sprayed and blasted. (D) Chemical conversion coating treatment step: a step of further subjecting the surface-treated back metal obtained in step C to a conversion coating treatment. This step is a step of a rust preventive film treatment for forming a chemical conversion film on the surface of the back metal for rust prevention of the back metal. (E) Primer treatment step: The chemical conversion film-treated back metal obtained in step D is subjected to a primer treatment (coating the primer metal on the back metal, drying, in order to improve the rust prevention of the metal back and the adhesiveness of the adhesive). Step of baking). (F) Adhesive applying step: a step of applying and drying an adhesive on the backing metal obtained in step E in order to bond it with the separately preformed friction material.
【００２６】（３）接合層
本発明に係る摩擦部材において、裏金と摩擦材との間の
接合層には、前記の接着剤塗布工程で用いられる接着剤
の層、或いは接着剤の層に加えて繊維基材、結合材及び
充填材を主成分とする接合層が形成されており、その接
着剤には、ブレーキをかけたときの摩擦熱が１５０℃以
上の高温になるために、耐熱性を必要とし、そのために
熱硬化性接着剤や合成ゴム系接着剤が用いられる。この
ような熱硬化性接着剤や合成ゴム系接着剤としては、例
えば、アクリルニトリル−ブタジエンゴム（ＮＢＲ）等
のゴム系接着剤や、ニトリルゴムに対し少なくとも２倍
以上のフェノールレジンを配合したニトリルゴムフェノ
ール系接着剤、或いはフェノール系やエポキシ系樹脂の
熱硬化性接着剤を挙げることができる。(3) Bonding Layer In the friction member according to the present invention, the bonding layer between the backing metal and the friction material is added to the adhesive layer used in the above-mentioned adhesive applying step or the adhesive layer. Is formed with a fibrous base material, a binder and a filler as main components, and the adhesive has a heat resistance of 150 ° C or higher because the frictional heat when braking is high. Therefore, a thermosetting adhesive or a synthetic rubber adhesive is used for that purpose. Examples of such thermosetting adhesives and synthetic rubber adhesives include rubber adhesives such as acrylonitrile-butadiene rubber (NBR), and nitriles containing at least twice as much phenol resin as nitrile rubber. Examples thereof include rubber phenol adhesives, and thermosetting adhesives of phenolic or epoxy resins.
【００２７】さらに、本発明において、必須の構成要件
ではないものの、裏金と摩擦材との間の接合層には、上
記の接着剤層と摩擦材との間に、繊維基材、結合材及び
充填材を主成分とする接合層を有することが望ましい。
接合層に用いられる繊維基材、結合材及び充填材は、摩
擦材に用いられたものと概略類似のものが用いられ、接
合層の剪断強度又は接着強度を上げるために、摩擦材と
比較すると、摩擦材より結合材の含有比率（割合）が大
であることが望ましい。また、摩擦材に比較して高い熱
伝導率を有することも、望ましい。裏金と摩擦材との間
に、上記の接合層を有することにより、裏金の接する側
の金型温度を摩擦材側の金型温度より下げて成形するこ
との本発明の効果が、更に、発揮される。その理由とし
ては、接合層の結合材の樹脂の硬化が遅くなり、或いは
接合層と接している摩擦材（結合材）の樹脂の硬化が遅
くなり、接合層と摩擦材の境界面での摩擦材（結合材）
の樹脂とのなじみが良くなり、その結果、境界面での剥
離の恐れが減少することなどが挙げられている。尚、接
合層の厚さは、０．２〜５ｍｍ程度である。Further, in the present invention, although not essential, the joining layer between the backing metal and the friction material has a fiber base material, a binder and a bonding material between the adhesive layer and the friction material. It is desirable to have a bonding layer containing a filler as a main component.
The fibrous base material, binder and filler used in the joining layer are similar to those used in the friction material. Compared with the friction material to increase the shear strength or adhesive strength of the joining layer, It is desirable that the binder content ratio is higher than that of the friction material. It is also desirable to have a higher thermal conductivity than the friction material. By having the above-mentioned bonding layer between the back metal and the friction material, the effect of the present invention of molding by lowering the mold temperature of the contacting side of the back metal below the mold temperature of the friction material is further exerted. To be done. The reason for this is that the hardening of the resin of the binder of the joining layer becomes slower, or the hardening of the resin of the friction material (bonding material) in contact with the joining layer becomes slower, causing friction at the interface between the joining layer and the friction material. Material (bond material)
It has been mentioned that the resin becomes better compatible with the resin, and as a result, the risk of peeling at the interface decreases. The thickness of the bonding layer is about 0.2 to 5 mm.
【００２８】２．摩擦部材の製造方法
本発明に係る摩擦部材の製造方法は、前記したように、
裏金の製造工程で得られた裏金と、耐熱性有機繊維や無
機繊維、金属繊維等の繊維基材と、無機や有機の充填材
及び結合材である熱硬化性樹脂バインダ等の粉末原料と
を配合し、攪拌により十分に均質化した原材料を常温に
て所定の圧力で成形する摩擦材の製造（予備成形）工程
で得られた摩擦材とを、接着剤或いは接着剤及び接合層
を介して接合して、加熱・加圧成形し、次いで、焼成工
程、仕上げ工程とを経て、摩擦材と裏金が一体となった
摩擦部材が製造されるものである。2. Method for manufacturing friction member The method for manufacturing a friction member according to the present invention, as described above,
The backing metal obtained in the manufacturing process of the backing metal, the fiber base material such as the heat-resistant organic fiber, the inorganic fiber, the metal fiber, and the powder raw material such as the thermosetting resin binder which is the inorganic or organic filler and the binder. The raw material, which is blended and sufficiently homogenized by stirring, is molded at a predetermined pressure at room temperature with the friction material obtained in the manufacturing (preforming) step of the friction material through an adhesive or an adhesive and a bonding layer. A friction member in which a friction material and a backing metal are integrated is manufactured by joining, heating / pressurizing, and then performing a firing process and a finishing process.
【００２９】本発明は、特に、摩擦部材の製造工程の中
の加熱・加圧成形工程に関するものであり、その加熱・
加圧成形工程において、図１に示すような熱プレス装置
を用いることができる。本発明においては、金属製の裏
金（７）と、繊維基材、結合材及び充填材を主成分とす
る摩擦材（９）とを加熱加圧して一体に成形する摩擦部
材の製造方法において、裏金に接する金型（１）の温度
（温度センサー：８）を、摩擦材と接する他の金型（２
や３）の温度（温度センサー：８’）より低くして成形
する。その場合、裏金に接する金型（１）と、摩擦材と
接する他の金型（２や３）とは、それぞれの温度を別々
に制御できるようにすることが好ましい。その温度制御
のためには、各金型に、ヒーター（１１）を有する熱盤
（４〜６）などの加熱装置や、温度センサー（８や
８’、８’’）を設ける。The present invention particularly relates to the heating / pressurizing step in the manufacturing process of the friction member.
In the pressure molding step, a hot press machine as shown in Fig. 1 can be used. In the present invention, in a method of manufacturing a friction member, a metal backing metal (7) and a friction material (9) containing a fiber base material, a binder and a filler as main components are heated and pressed to be integrally molded, The temperature of the mold (1) in contact with the back metal (temperature sensor: 8) is changed to the other mold (2) in contact with the friction material.
And the temperature of 3) (temperature sensor: 8 ') is used for molding. In that case, it is preferable that the mold (1) contacting the back metal and the other molds (2 and 3) contacting the friction material can be controlled in temperature separately. In order to control the temperature, each mold is provided with a heating device such as a heating plate (4 to 6) having a heater (11) and temperature sensors (8, 8 ′, 8 ″).
【００３０】本発明において、裏金に接する金型の温度
を、摩擦材と接する他の金型の温度より低くする程度
は、裏金に接する金型の温度が、摩擦材及び接合層の結
合材或いは接着剤が溶融、熱硬化を開始する温度以上、
すなわち摩擦部材の成形可能な温度以上であれば、特に
限定されないが、接着剤又は結合材の熱硬化特性の点か
ら、温度差が５〜５０℃程度の範囲が好ましく、特に１
０〜３０℃程度の範囲がより好ましい。温度差が５℃未
満であると、本発明の効果が発揮されず、一方、５０℃
を超えると、摩擦材側の結合材の硬化が進み、接着剤又
は接合層の結合材が摩擦材側に沁み込む量が少なくな
り、境界層の強度が充分でなくなる恐れが生じる。In the present invention, the temperature of the mold contacting the back metal is lower than the temperature of the other mold contacting the friction material, as long as the temperature of the mold contacting the back metal is the friction material and the bonding material of the bonding layer. Above the temperature at which the adhesive melts and begins to heat cure,
That is, the temperature is not particularly limited as long as it is at least the temperature at which the friction member can be molded, but from the viewpoint of the thermosetting property of the adhesive or the binder, the temperature difference is preferably in the range of 5 to 50 ° C., and particularly 1
The range of about 0 to 30 ° C is more preferable. If the temperature difference is less than 5 ° C, the effect of the present invention will not be exhibited, while on the other hand, 50 ° C
If it exceeds, the binder on the friction material side will be hardened, the amount of the adhesive or the binder of the bonding layer penetrating to the friction material side will decrease, and the strength of the boundary layer may become insufficient.
【００３１】また、本発明において、上記以外の加熱・
加圧成形条件としては、通常、例えば２００〜５００ｋ
ｇｆ／ｃｍ２、１３０〜２００℃、３〜１５分であり、
続いて焼成条件としては、１８０〜２３０℃、１〜１０
時間である。In addition, in the present invention, heating other than the above
The pressure molding condition is usually, for example, 200 to 500 k.
gf / cm 2 , 130 to 200 ° C., 3 to 15 minutes,
Subsequently, the firing conditions are 180 to 230 ° C. and 1 to 10
It's time.
【００３２】次に、得られた成形品を１４０〜２５０℃
の温度で２〜４８時間熱処理（後硬化）し、必要に応じ
てスプレー塗装、焼き付け、研磨処理を施して完成品が
得られる。Next, the obtained molded product is heated to 140 to 250 ° C.
Heat treatment (post-curing) at the temperature of 2 to 48 hours and, if necessary, spray coating, baking, and polishing treatment to obtain a finished product.
【００３３】本発明に係る摩擦部材は、自動車、大型ト
ラック、鉄道車両、各種産業機械等のディスクブレーキ
用摩擦パッド、ブレーキシュー、クラッチプレートなど
の各種用途に好適に用いることができる。The friction member according to the present invention can be suitably used for various applications such as friction pads for disc brakes of automobiles, heavy trucks, railway vehicles, various industrial machines, brake shoes, clutch plates and the like.
【００３４】[0034]
【実施例】本発明について、実施例及び比較例により、
さらに詳細に説明するが、本発明は、これらの実施例に
特に限定されるものではない。[Examples] The present invention will be described with reference to Examples and Comparative Examples.
Although described in more detail, the present invention is not particularly limited to these examples.
【００３５】［実施例１〜４及び比較例１〜３］実施例
１〜４及び比較例１〜３は、図１に示すような、摩擦材
に接した金型の上型（２）、摩擦材と裏金に接した金型
の中型（３）、裏金に接した金型の下型（１）、金型の
上型に接しヒーター（１１）を内蔵した上熱盤（４）、
金型の中型に接しヒーター（１１）を内蔵した中熱盤
（５）及び金型の下型に接しヒーター（１１）を内蔵し
た下熱盤（６）を有し、各型が、独立して温度が制御で
きる構造の摩擦材熱成形用金型及び熱盤にて作成した。
その金型の材質は、鉄系材料（ＳＫＤ６１）を焼き入れ
の上、クロムメッキを施して用いた。また、ヒーターの
熱容量は十分に余裕を持たせた。[Examples 1 to 4 and Comparative Examples 1 to 3] In Examples 1 to 4 and Comparative Examples 1 to 3, as shown in FIG. 1, the upper mold (2) of the mold in contact with the friction material, A medium mold (3) in contact with the friction material and the back metal, a lower mold (1) in contact with the back metal, an upper heating plate (4) in contact with the upper mold and containing a heater (11),
It has an intermediate heating plate (5) in contact with the middle mold of the mold and having a built-in heater (11) and a lower heating plate (6) in contact with the lower mold of the mold and having a heater (11), and each mold is independent. It was created with a friction material thermoforming mold and a heating plate with a structure in which the temperature can be controlled by the temperature.
As the material of the mold, an iron material (SKD61) was quenched and then used for chrome plating. In addition, the heat capacity of the heater has a sufficient margin.
【００３６】実施例１では、表１に示すように、繊維基
材、結合材及び充填材などの組成（成分）を配合した、
摩擦材ＡとＣ及び接合層の結合材が主に異なる接合層
Ｂ、Ｄ、Ｅとの計５種の配合品を、夫々レディゲミキサ
ーを用いて均一に混合し、加圧型内で１００ｋｇ／ｃｍ
２で１分間加圧して予備成形した。この予備成形物を、
金型の温度条件を変えた４条件につき、例えば、摩擦材
Ａと接合層Ｂの組み合わせでは、裏金に接した金型の下
型（１）の成形温度１４０℃、摩擦材に接した金型の上
型（２）の成形温度１５０℃、及び摩擦材と裏金に接し
た金型の中型（３）の成形温度１４５℃、成形圧力２５
０ｋｇ／ｃｍ２の条件下で１０分間成形し、その後、２
００℃で５時間熱処理（後硬化）を行った。このように
して、４種の摩擦部材を製造した。In Example 1, as shown in Table 1, compositions (components) such as a fiber base material, a binder and a filler were blended,
Friction materials A and C and bonding layers B, D, and E, which are mainly different in bonding material, were uniformly mixed using a Loedige mixer, and 100 kg / in a pressure mold. cm
It was pressed at 2 for 1 minute and preformed. This preform,
Regarding the four conditions in which the temperature conditions of the mold are changed, for example, in the case of the combination of the friction material A and the bonding layer B, the molding temperature of the lower mold (1) of the mold in contact with the back metal is 140 ° C., the mold in contact with the friction material is Molding temperature of the upper mold (2) of 150 ° C, and molding temperature of the middle mold (3) of the mold in contact with the friction material and the back metal, 145 ° C, molding pressure of 25
Molded under 0 kg / cm 2 for 10 minutes, then 2
Heat treatment (post-curing) was performed at 00 ° C. for 5 hours. In this way, four types of friction members were manufactured.
【００３７】実施例２〜４及び比較例１〜３も、実施例
１と同様に、表１に示すような条件で、各実施例、比較
例につき、４種の摩擦部材を製造した。In Examples 2 to 4 and Comparative Examples 1 to 3, four kinds of friction members were manufactured for each Example and Comparative Example under the conditions shown in Table 1 as in Example 1.
【００３８】得られた実施例、比較例の２８種の摩擦部
材につき、次に示す評価方法に基づき、接着強度、成形
性、及び耐亀裂性を評価した。その評価結果を表１に示
す。接着強度は、「ＪＡＳＯ Ｃ４３７−７６」に準拠
し、測定した。接着強度の高いもの程、良好である。成
形性の評価は、製品の外観検査を目視により実施し、そ
の評価基準としては、良好なもの（問題なし）を○、若
干シワがあるが、問題ないものを△、亀裂又は浮き発生
したものを×で示した。耐亀裂性の評価は、「ＪＡＳＯ
Ｃ４０６−８７」に準拠して、常用ブレーキのダイナ
モメータ性能試験を実施した後に、外観検査を目視によ
り実施し、その評価基準としては、亀裂が認められなく
良好なものを○、長さが３ｍｍ未満の微小な亀裂が認め
られるものの問題ないものを△、長さが３ｍｍ以上で、
かつ０．５ｍｍの厚さ計（シックネスゲージ）が入る亀
裂が認められるものを×で示した。The 28 types of friction members obtained in Examples and Comparative Examples were evaluated for adhesive strength, moldability, and crack resistance based on the following evaluation methods. The evaluation results are shown in Table 1. The adhesive strength was measured according to "JASO C437-76". The higher the adhesive strength, the better. The moldability was evaluated by visually inspecting the appearance of the product, and the evaluation criteria were good (no problem) ○, slightly wrinkled, but no problem △, cracks or buoyancy occurred. Is indicated by x. The crack resistance is evaluated by "JASO
In accordance with C406-87 ", after performing a dynamometer performance test of a service brake, a visual inspection is visually performed. As the evaluation criteria, a good one without cracks is ◯, and a length is 3 mm. △ that there is no problem, but the length is 3mm or more,
Moreover, the thing which the crack which a 0.5-mm thickness gauge (thickness gauge) enters is recognized is shown by x.
【００３９】[0039]
【表１】 [Table 1]
【００４０】本方法により成形した実施例１〜４の摩擦
部材は、比較例１〜３の摩擦部材に比べて、接合層と摩
擦材の境界面での摩擦材の樹脂とのなじみが良くなり、
その結果、境界面での剥離が減少し、接着強度が飛躍的
に向上することが確認された。また、成形性、耐亀裂性
も良好である。一方、比較例１〜３の摩擦部材は、例え
ば、裏金に接する金型の温度と摩擦材と接する他の金型
の温度が等しい比較例１では、成形性は良好なものの接
着強度は低く、また耐亀裂性もそれ程良好となっていな
い。The friction members of Examples 1 to 4 molded by this method have better compatibility with the resin of the friction material at the interface between the joining layer and the friction material than the friction members of Comparative Examples 1 to 3. ,
As a result, it was confirmed that peeling at the boundary surface was reduced and the adhesive strength was dramatically improved. Also, the moldability and crack resistance are good. On the other hand, in the friction members of Comparative Examples 1 to 3, for example, in Comparative Example 1 in which the temperature of the mold contacting the back metal and the temperature of the other mold contacting the friction material are equal, the moldability is good but the adhesive strength is low, Also, the crack resistance is not so good.
【００４１】[0041]
【発明の効果】本発明の摩擦部材の製造方法により得ら
れた摩擦部材は、摩擦材と裏金との間に、大きな剪断力
が加わわっても、接着剤或いは接着剤及び接合層と摩擦
材の境界面で剥離や破壊が起きずに、この剪断力に耐え
ることができるような強い接着強度が得られ、耐久性に
優れるという顕著な効果を発揮する。そのため、自動
車、大型トラック、鉄道車両及び各種産業用機械のブレ
ーキ、クラッチ等に好適に用いられる。The friction member obtained by the method for producing a friction member of the present invention has the adhesive or the adhesive and the bonding layer and the friction material even if a large shearing force is applied between the friction material and the back metal. A strong adhesive strength that can withstand this shearing force can be obtained without peeling or breakage at the boundary surface of, and a remarkable effect of excellent durability is exhibited. Therefore, it is suitably used for brakes, clutches, etc. of automobiles, large trucks, railway vehicles and various industrial machines.
【図面の簡単な説明】[Brief description of drawings]
【図１】本発明の摩擦部材の製造方法に係る加熱・加圧
成形工程に用いる熱プレス装置の概略の縦断面図であ
る。FIG. 1 is a schematic vertical cross-sectional view of a hot press machine used in a heating / pressurizing step according to a method for manufacturing a friction member of the present invention.
【図２】摩擦部材の製造工程を示す図である。FIG. 2 is a diagram showing a manufacturing process of a friction member.
１ 成形下型（裏金側金型） ２ 成形上型（摩擦材側金型） ３ 成形中型（摩擦材枠型） ４ 上熱盤 ５ 中熱盤 ６ 下熱盤 ７ 裏金 ８，８’，８’’ 温度センサー ９ 摩擦材 １０ 接合層 １１ ヒーター 1 Molding lower mold (back side metal mold) 2 Molding upper mold (friction material side mold) 3 Molding medium size (friction material frame type) 4 Upper heating plate 5 Middle heat plate 6 lower heating plate 7 Back money 8,8 ', 8 "temperature sensor 9 Friction material 10 Bonding layer 11 heater
Claims (5)
充填材を主成分とする摩擦材とを加熱加圧して一体に成
形する摩擦部材の製造方法において、裏金の摩擦材が接
合される側とは反対側の裏金に接する金型の温度を、摩
擦部材の成形可能な温度以上で、かつ摩擦材と接する他
の金型の温度より低くして成形することを特徴とする摩
擦部材の製造方法。1. A method of manufacturing a friction member in which a metal backing and a friction material containing a fibrous base material, a binder and a filler as main components are heated and pressed to integrally form the friction material of the backing. Characterized in that the temperature of the mold contacting the back metal on the side opposite to the side to be molded is higher than the moldable temperature of the friction member and lower than the temperature of other molds in contact with the friction material. A method of manufacturing a member.
綿系摩擦材であることを特徴とする請求項１記載の摩擦
部材の製造方法。2. The method for producing a friction member according to claim 1, wherein the friction material is a non-asbestos friction material excluding a semimetallic material.
基材、結合材及び充填材を主成分とする接合層を有する
ことを特徴とする請求項１又は２記載の摩擦部材の製造
方法。3. The friction member according to claim 1, wherein the friction material has a bonding layer containing a fiber base material, a binder and a filler as main components on the side bonded to the back metal. Production method.
有割合量が多いことを特徴とする請求項３記載の摩擦部
材の製造方法。4. The method for manufacturing a friction member according to claim 3, wherein the joining layer has a larger content ratio of the binder than the friction material.
の金型との温度差は、５〜５０℃の範囲であることを特
徴とする請求項１〜４のいずれかに記載の摩擦部材の製
造方法。5. The temperature difference between the mold contacting the back metal and the other mold contacting the friction material is in the range of 5 to 50 ° C., according to claim 1. Method for manufacturing friction member.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001271568A JP4458724B2 (en) | 2001-09-07 | 2001-09-07 | Method for manufacturing friction member |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001271568A JP4458724B2 (en) | 2001-09-07 | 2001-09-07 | Method for manufacturing friction member |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2003083374A true JP2003083374A (en) | 2003-03-19 |
| JP4458724B2 JP4458724B2 (en) | 2010-04-28 |
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ID=19097059
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2001271568A Expired - Fee Related JP4458724B2 (en) | 2001-09-07 | 2001-09-07 | Method for manufacturing friction member |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2011178570A (en) * | 2011-06-24 | 2011-09-15 | Nisshinbo Holdings Inc | Method for supporting a plurality of works |
| WO2012014535A1 (en) * | 2010-07-27 | 2012-02-02 | アイシン化工株式会社 | Dry friction material and method for manufacturing same |
| KR101895587B1 (en) * | 2018-01-31 | 2018-09-05 | 케이비오토시스 주식회사 | Brake pad manufacturing method and apparatus for stabilization of quality |
-
2001
- 2001-09-07 JP JP2001271568A patent/JP4458724B2/en not_active Expired - Fee Related
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2012014535A1 (en) * | 2010-07-27 | 2012-02-02 | アイシン化工株式会社 | Dry friction material and method for manufacturing same |
| JP5214061B2 (en) * | 2010-07-27 | 2013-06-19 | アイシン化工株式会社 | Dry friction material and manufacturing method thereof |
| US9587696B2 (en) | 2010-07-27 | 2017-03-07 | Aisin Kako Kabushiki Kaisha | Dry friction material and method for manufacturing the same |
| JP2011178570A (en) * | 2011-06-24 | 2011-09-15 | Nisshinbo Holdings Inc | Method for supporting a plurality of works |
| KR101895587B1 (en) * | 2018-01-31 | 2018-09-05 | 케이비오토시스 주식회사 | Brake pad manufacturing method and apparatus for stabilization of quality |
| WO2019151621A1 (en) * | 2018-01-31 | 2019-08-08 | 케이비오토시스 주식회사 | Method and apparatus for manufacturing brake pad for stabilization of quality |
| US11111976B2 (en) | 2018-01-31 | 2021-09-07 | Kb Autosys Co., Ltd | Method and apparatus for manufacturing brake pad for quality stabilization |
| US11940029B2 (en) | 2018-01-31 | 2024-03-26 | Kb Autosys Co., Ltd | Method and apparatus for manufacturing brake pad for quality stabilization |
Also Published As
| Publication number | Publication date |
|---|---|
| JP4458724B2 (en) | 2010-04-28 |
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