JP2004316904A - Friction material for brake - Google Patents
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本発明は自動車等のブレーキ摩擦材に関し、より詳しくは、剪断強度の向上、摩擦係数の安定性、異音の低減性、品質安定性の向上を図ることが可能なブレーキ摩擦材に関するものである。 The present invention relates to a brake friction material for automobiles and the like, and more particularly, to a brake friction material capable of improving shear strength, stability of friction coefficient, reduction of abnormal noise, and improvement of quality stability. .
従来、自動車等のブレーキ摩擦材は、補強材として、スチール繊維などの金属繊維、セラミック繊維、アラミド繊維、チタン酸カリウム繊維または粉末（例えば、特許文献１〜４参照）、チタン酸ナトリウム多結晶繊維（例えば、特許文献５参照）などの天然または人造の繊維または粉末が使用され、この他、フェノール樹脂などの結合材、黒鉛、二硫化モリブデンなどの潤滑材、カシューダスト、セラミック粉、金属粉などの摩擦調整剤、硫酸バリウムなどの充填材、及び水酸化カルシウムなどのｐＨ調整材などを数種混合し、その後、常温にて圧縮成形（予備成形）し、次いで、予め接着剤を塗布した裏金とともに加熱圧縮成形し、さらに熱処理した後、溝加工や表面研磨を施すことにより製造されている。
このブレーキ摩擦材は、上記の様な材料を用いることで、剪断強度、摩擦特性、摩耗特性、鳴き性能等のブレーキ性能を満足するように調整している。
2. Description of the Related Art Conventionally, brake friction materials for automobiles and the like, as reinforcing materials, metal fibers such as steel fibers, ceramic fibers, aramid fibers, potassium titanate fibers or powders (for example, see Patent Documents 1 to 4), sodium titanate polycrystalline fibers (For example, see Patent Document 5), natural or artificial fibers or powders are used. In addition, binders such as phenolic resins, lubricants such as graphite and molybdenum disulfide, cashew dusts, ceramic powders, metal powders and the like A few kinds of friction modifiers, fillers such as barium sulfate, pH adjusters such as calcium hydroxide, etc. are mixed, and then compression molded (preformed) at room temperature, and then back metal coated with an adhesive beforehand It is manufactured by subjecting it to heat compression molding, further heat treatment, and then performing groove processing and surface polishing.
The brake friction material is adjusted to satisfy the brake performance such as shear strength, friction characteristics, wear characteristics, and squealing performance by using the above materials.
特に、上記の強化繊維の中では、チタン酸カリウム繊維が、ブレーキ摩擦材全体の強度、耐熱性を高め、耐摩耗性を向上させるだけでなく、ブレーキ摩擦材の摩擦係数を高めるものとして高く評価されている。
ところで、近年の自動車の性能の向上に伴い、ブレーキ摩擦材においても特性の向上が求められており、特に、摩擦特性や異音性能に対しては、さらなる特性の向上が求められている。
また、ブレーキ摩擦材に用いられているチタン酸カリウム繊維は、その直径が１μｍ以下の極めて細い針状結晶であることから、均一分散し難く、製造が難しいという問題点もあった。
By the way, with the improvement of the performance of automobiles in recent years, the characteristics of brake friction materials are also required to be improved. In particular, further improvements are required for the friction characteristics and abnormal noise performance.
Further, the potassium titanate fiber used for the brake friction material is an extremely fine needle-like crystal having a diameter of 1 μm or less, and therefore has a problem that it is difficult to uniformly disperse the crystal and difficult to manufacture.
本発明は上記事情に鑑みてなされたものであって、剪断強度、摩擦係数の安定性、異音の低減性、品質安定性に優れ、しかも、製造が容易なブレーキ摩擦材を提供することを目的とする。 The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a brake friction material that is excellent in shear strength, friction coefficient stability, noise reduction property, quality stability, and easy to manufacture. Aim.
上記課題を解決するために、本発明は次の様なブレーキ摩擦材を提供した。
すなわち、本発明のブレーキ摩擦材は、少なくとも強化繊維、結合材、潤滑材、摩擦調整材、及び充填材を含有してなるブレーキ摩擦材において、ブレーキ摩擦材を１００質量％としたとき、硬化剤の含有量が１２質量％以上のフェノール樹脂を３．５質量％以下かつ該フェノール樹脂を含むフェノール樹脂の全質量を８質量％以下、平均粒径が０．５〜１０μｍのチタン酸カリウムマグネシウム粉末を５〜２０質量％、金属繊維を１０〜２０質量％、含有してなることを特徴とする。
In order to solve the above problems, the present invention has provided the following brake friction material.
That is, in the brake friction material of the present invention, when the brake friction material is at least 100% by mass in a brake friction material containing at least a reinforcing fiber, a binder, a lubricant, a friction modifier, and a filler, a curing agent is used. Potassium magnesium titanate powder having a phenolic resin content of 12% by mass or more, 3.5% by mass or less, a total mass of the phenolic resin containing the phenolic resin of 8% by mass or less, and an average particle size of 0.5 to 10 μm. 5 to 20% by mass, and 10 to 20% by mass of metal fibers.
本発明の他のブレーキ摩擦材は、少なくとも強化繊維、結合材、潤滑材、摩擦調整材、及び充填材を含有してなるブレーキ摩擦材において、ブレーキ摩擦材を１００質量％としたとき、硬化剤の含有量が１２質量％以上のフェノール樹脂を３．５質量％以下かつ該フェノール樹脂を含むフェノール樹脂の全質量を８質量％以下、繊維径が５〜３０μｍのチタン酸カリウム繊維を５〜２０質量％、金属繊維を１０〜２０質量％、含有してなることを特徴とする。 Another brake friction material of the present invention is a hardening agent when the brake friction material is 100% by mass in a brake friction material containing at least a reinforcing fiber, a binder, a lubricant, a friction modifier, and a filler. Of phenolic resin having a content of 12% by mass or more and 3.5% by mass or less, the total mass of the phenolic resin containing the phenolic resin being 8% by mass or less, and a fiber diameter of 5 to 30 μm. % By mass, and 10 to 20% by mass of a metal fiber.
本発明の各ブレーキ摩擦材においては、前記金属繊維は、硬質金属繊維および／または軟質金属繊維であることが好ましい。 In each of the brake friction materials of the present invention, the metal fibers are preferably hard metal fibers and / or soft metal fibers.
本発明のブレーキ摩擦材によれば、硬化剤の含有量が１２質量％以上のフェノール樹脂を３．５質量％以下かつ該フェノール樹脂を含むフェノール樹脂の全質量を８質量％以下、金属繊維を１０〜２０質量％含有すると共に、平均粒径が０．５〜１０μｍのチタン酸カリウムマグネシウム粉末または繊維径が５〜３０μｍのチタン酸カリウム繊維を５〜２０質量％含有することとしたので、剪断強度を高めることができ、摩擦係数の変動を抑制して安定性に優れたものとすることができ、異音の防止を図ることができる。
また、従来の製造方法をそのまま適用することができるので、製造に格別困難性はなく、製造が容易である。
以上により、品質安定性に優れたブレーキ摩擦材を、低コストで提供することができる。
According to the brake friction material of the present invention, the content of the curing agent is not more than 3.5% by mass of the phenol resin having a content of 12% by mass or more, and the total mass of the phenol resin containing the phenol resin is not more than 8% by mass, and Since it contains 10 to 20% by mass and contains 5 to 20% by mass of potassium magnesium titanate powder having an average particle diameter of 0.5 to 10 μm or potassium titanate fiber having a fiber diameter of 5 to 30 μm, shearing is performed. The strength can be increased, the variation in the coefficient of friction can be suppressed, the stability can be improved, and abnormal noise can be prevented.
Further, since the conventional manufacturing method can be applied as it is, there is no particular difficulty in manufacturing, and the manufacturing is easy.
As described above, a brake friction material having excellent quality stability can be provided at low cost.
本発明のブレーキ摩擦材の各実施形態について説明する。
［第１の実施形態］
本実施形態のブレーキ摩擦材は、少なくとも強化繊維、結合材、潤滑材、摩擦調整材、及び充填材を含有したもので、ブレーキ摩擦材を１００質量％としたときに、硬化剤の含有量が１２質量％以上のフェノール樹脂を３．５質量％以下含有するとともに、このフェノール樹脂を含むフェノール樹脂の全質量を８質量％以下含有し、平均粒径が０．５〜１０μｍのチタン酸カリウムマグネシウム粉末を５〜２０質量％含有し、金属繊維を１０〜２０質量％含有している必要がある。
Each embodiment of the brake friction material of the present invention will be described.
[First Embodiment]
The brake friction material of the present embodiment contains at least a reinforcing fiber, a binder, a lubricant, a friction modifier, and a filler. When the brake friction material is 100% by mass, the content of the curing agent is reduced. Potassium magnesium titanate containing 12% by mass or more of 3.5% by mass or less of a phenolic resin, containing 8% by mass or less of the total mass of the phenolic resin containing the phenolic resin, and having an average particle size of 0.5 to 10 μm. It is necessary to contain 5 to 20% by mass of powder and 10 to 20% by mass of metal fiber.
このような構成とすることにより、硬化剤を含むフェノール樹脂と、硬化剤を含まないフェノール樹脂と、平均粒径が０．５〜１０μｍのチタン酸カリウムマグネシウム粉末と、金属繊維のそれぞれの含有量が最適化され、その結果、剪断強度が高まり、摩擦係数の変動が小さくなり安定性に優れ、異音の防止に優れたものとなる。 With such a configuration, a phenol resin containing a curing agent, a phenol resin containing no curing agent, potassium magnesium titanate powder having an average particle size of 0.5 to 10 μm, and the content of each of the metal fibers As a result, the shear strength is increased, the fluctuation of the coefficient of friction is reduced, the stability is excellent, and the noise is prevented.
上記の金属繊維としては、硬質金属繊維および／または軟質金属繊維が好ましい。
上記の硬質金属繊維としては、例えば、スチール繊維が好適に用いられ、また、軟質金属繊維としては、例えば、銅繊維が好適に用いられる。
この金属繊維に、その他の繊維として、アラミド繊維等の有機繊維および／またはロックウール等の無機繊維を含んでもよい。
結合材としては、上記のフェノール樹脂の他、フェノール・ｐ−キシリレングリコールジメチルエーテル重縮合物、変性フェノール・ホルムアルデヒド重縮合物等が好適に用いられる。
潤滑材としては、黒鉛、コークス、三硫化アンチモン、二硫化モリブデン等が好適に用いられる。
As the above metal fibers, hard metal fibers and / or soft metal fibers are preferable.
As the hard metal fibers, for example, steel fibers are preferably used, and as the soft metal fibers, for example, copper fibers are preferably used.
The metal fibers may contain, as other fibers, organic fibers such as aramid fibers and / or inorganic fibers such as rock wool.
As the binder, in addition to the phenol resin described above, phenol / p-xylylene glycol dimethyl ether polycondensate, modified phenol / formaldehyde polycondensate, and the like are suitably used.
As the lubricant, graphite, coke, antimony trisulfide, molybdenum disulfide and the like are preferably used.
摩擦調整材としては、有機系摩擦調整材および／または無機系摩擦調整材が好適に用いられる。有機系摩擦調整材としては、カシューダスト、ゴム粉等が、無機系摩擦調整材としては、珪酸ジルコニウム、アルミナ、酸化鉄、錫等の粉末が好適に用いられる。
充填材としては、硫酸バリウム等、ｐＨ調整材としては水酸化カルシウム等が用いられる。
As the friction modifier, an organic friction modifier and / or an inorganic friction modifier is preferably used. As the organic friction modifier, cashew dust, rubber powder and the like are preferably used, and as the inorganic friction modifier, powders of zirconium silicate, alumina, iron oxide, tin and the like are suitably used.
Barium sulfate or the like is used as the filler, and calcium hydroxide or the like is used as the pH adjuster.
摩擦材においては、気孔率と呼ばれる空孔が高温時の分解生成物（ガスや液状の重合物）の逃げ道となり摩擦係数の低下防止を図るとともに、摩擦材の剛性をさげ減衰性を向上させることで異音の発生を防止している。通常の摩擦材においては、気孔率だ１５〜２０％になるように、材料の配合、成形条件を管理している。 In friction materials, pores called porosity serve as escape paths for decomposition products (gas and liquid polymer) at high temperatures, prevent the reduction of the friction coefficient, and reduce the rigidity of the friction material to improve damping. Is used to prevent the generation of abnormal noise. In a normal friction material, the composition of the materials and the molding conditions are controlled so that the porosity is 15 to 20%.
硬化剤の含有量を多くしたフェノール樹脂で摩擦材を構成した場合、加熱圧縮成型時の高圧下で硬化が進むため、成形後金型取り出し後の摩擦材の厚みの戻りが少なく、気孔率が低下してしまうという不具合が生じる。
また、硬化剤の含有量が少ないフェノール樹脂で摩擦材を構成した場合、成形時間が短いと、摩擦材中央部の硬化が不十分で割れや膨れという不具合が生じ、また、充分な成形時間を取った場合には気孔率が低下するという不具合が生じる。
また、フェノール樹脂の量が多い場合、他の材料の隙間に樹脂が充填され気孔率が低下し、フェノール樹脂の量が少なすぎると、気孔率は高く保持できるものの、強度が低下する不具合が生じる。
When the friction material is composed of a phenolic resin with a high content of a curing agent, curing proceeds under high pressure during heat compression molding. There is a problem that it is lowered.
In addition, when the friction material is composed of a phenol resin having a low content of a hardening agent, if the molding time is short, a problem of cracking or swelling due to insufficient curing of the friction material center portion occurs, and sufficient molding time is required. When taken, there is a problem that the porosity decreases.
In addition, when the amount of the phenol resin is large, the resin is filled into the gaps of other materials and the porosity decreases, and when the amount of the phenol resin is too small, the porosity can be maintained high, but the strength is reduced. .
そこで、この不具合を解消するために、加熱圧縮成型時には、割れ、膨れ等の不具合が生じないような形状を保持できる程度のフェノール樹脂の硬化を行い、後工程の熱処理にて未硬化の樹脂を硬化させることで、気孔率の向上と強度の確保の両立が図られる。
加熱圧縮成型時の形状保持には、樹脂中の硬化剤の含有量が１２％以上のフェノール樹脂が必要であり、この硬化剤を含むフェノール樹脂の含有量としては、３．５％以下とすることで気孔率の低下を防止することができる。
また、かつフェノール樹脂の総配合量を８質量％以下とした理由は、樹脂量が多いと他の材料の隙間に樹脂が充填され、気孔率が低下するが、８％を超えると摩擦係数の低下、異音の発生等の不具合が生じるためである。
Therefore, in order to solve this problem, at the time of heat compression molding, the phenol resin is cured to the extent that it can maintain a shape that does not cause cracks, swelling, etc., and the uncured resin is removed by heat treatment in the subsequent process. By curing, both improvement of porosity and securing of strength are achieved.
In order to maintain the shape at the time of heat compression molding, a phenol resin having a curing agent content of 12% or more in the resin is required. The content of the phenol resin containing the curing agent is 3.5% or less. This can prevent a decrease in porosity.
In addition, the reason why the total amount of the phenolic resin is set to 8% by mass or less is that if the amount of the resin is large, the resin is filled in the gap between other materials and the porosity is reduced. This is because problems such as reduction and generation of abnormal noise occur.
チタン酸カリウムマグネシウム粉末の平均粒径を０．５〜１０μｍとした理由は、同じ配合量でも粒径が小さくなると表面積が大きくなることから、平均粒径が０．５μｍ未満の粉末では表面積が大きくなるために、材料同士を結合するフェノール樹脂が多く必要となり、摩擦材全体のフェノール樹脂量が多くなるため、高温時の分解生成物が多量に発生し、摩擦係数の低下といった不具合が発生し易いからであり、また、平均粒径が１０μｍを超えると、上記と反対に表面積が小さくなり、結合材のフェノール樹脂がチタン酸カリウムマグネシウム粉末以外の材料の間に充填され、気孔率の低下による摩擦係数の低下、異音の発生といった不具合が生じるからである。 The reason for setting the average particle size of the potassium magnesium titanate powder to 0.5 to 10 μm is that, even with the same blending amount, the surface area increases when the particle size decreases, so that the surface area increases when the average particle size is less than 0.5 μm. Therefore, a large amount of phenolic resin is required to bond the materials together, and the amount of phenolic resin in the entire friction material is increased. When the average particle size exceeds 10 μm, the surface area is reduced, contrary to the above, the phenol resin of the binder is filled between materials other than the potassium magnesium titanate powder, and the friction due to the decrease in the porosity is reduced. This is because problems such as a decrease in coefficient and generation of abnormal noise occur.
このチタン酸カリウムマグネシウム粉末の含有量を５〜２０質量％とした理由は、含有量が５質量％未満であると、異音が発生するという不具合があり、また、含有量が２０質量％を超えると、強度が低下するという不具合があるからである。
また、この金属繊維の含有量を１０〜２０質量％とした理由は、含有量が１０質量％未満であると、強度が低下し、また、含有量が２０質量％を超えると、異音が発生するからである。
The reason for setting the content of the potassium magnesium titanate powder to 5 to 20% by mass is that if the content is less than 5% by mass, there is a problem that abnormal noise is generated. If it exceeds, there is a problem that the strength is reduced.
The reason for setting the content of the metal fiber to 10 to 20% by mass is that when the content is less than 10% by mass, the strength is reduced, and when the content exceeds 20% by mass, abnormal noise is generated. Because it occurs.
［第２の実施形態］
本実施形態のブレーキ摩擦材は、少なくとも強化繊維、結合材、潤滑材、摩擦調整材、及び充填材を含有したもので、ブレーキ摩擦材を１００質量％としたときに、硬化剤の含有量が１２質量％以上のフェノール樹脂を３．５質量％以下含有するとともに、このフェノール樹脂を含むフェノール樹脂の全質量を８質量％以下含有し、繊維径が５〜３０μｍのチタン酸カリウム繊維を５〜２０質量％含有し、金属繊維を１０〜２０質量％含有している必要がある。
[Second embodiment]
The brake friction material of the present embodiment contains at least a reinforcing fiber, a binder, a lubricant, a friction modifier, and a filler. When the brake friction material is 100% by mass, the content of the curing agent is reduced. It contains not more than 12% by mass of phenolic resin of 3.5% by mass or less, and contains not more than 8% by mass of the total mass of the phenolic resin containing this phenolic resin and has a fiber diameter of 5 to 30 μm. 20% by mass and 10 to 20% by mass of metal fibers.
このような構成とすることにより、硬化剤を含むフェノール樹脂と、硬化剤を含まないフェノール樹脂と、繊維径が５〜３０μｍのチタン酸カリウム繊維と、金属繊維のそれぞれの含有量が最適化され、その結果、剪断強度が高まり、摩擦係数の変動が小さくなり安定性に優れ、異音の防止に優れたものとなる。 With such a configuration, the content of each of the phenol resin containing a curing agent, the phenol resin containing no curing agent, the potassium titanate fiber having a fiber diameter of 5 to 30 μm, and the metal fiber is optimized. As a result, the shear strength is increased, the fluctuation in the coefficient of friction is reduced, the stability is excellent, and the noise is prevented.
上記の金属繊維としては、硬質金属繊維および／または軟質金属繊維が好ましい。
上記の硬質金属繊維としては、例えば、スチール繊維が好適に用いられ、また、軟質金属繊維としては、例えば、銅繊維が好適に用いられる。
この金属繊維に、アラミド繊維等の有機繊維および／またはロックウール等の無機繊維を含んでもよい。
As the above metal fibers, hard metal fibers and / or soft metal fibers are preferable.
As the hard metal fibers, for example, steel fibers are preferably used, and as the soft metal fibers, for example, copper fibers are preferably used.
The metal fibers may include organic fibers such as aramid fibers and / or inorganic fibers such as rock wool.
結合材としては、上記のフェノール樹脂の他、フェノール・ｐ−キシリレングリコールジメチルエーテル重縮合物、変性フェノール・ホルムアルデヒド重縮合物等が好適に用いられる。
潤滑材としては、黒鉛、コークス、三硫化アンチモン、二硫化モリブデン等が好適に用いられる。
As the binder, in addition to the phenol resin described above, phenol / p-xylylene glycol dimethyl ether polycondensate, modified phenol / formaldehyde polycondensate, and the like are suitably used.
As the lubricant, graphite, coke, antimony trisulfide, molybdenum disulfide and the like are preferably used.
摩擦調整材としては、有機系摩擦調整材および／または無機系摩擦調整材が好適に用いられる。有機系摩擦調整材としては、カシューダスト、ゴム粉等が、無機系摩擦調整材としては、珪酸ジルコニウム、アルミナ、酸化鉄、錫等の粉末が好適に用いられる。
充填材としては、硫酸バリウム等、ｐＨ調整材としては水酸化カルシウム等が用いられる。
As the friction modifier, an organic friction modifier and / or an inorganic friction modifier is preferably used. As the organic friction modifier, cashew dust, rubber powder and the like are preferably used, and as the inorganic friction modifier, powders of zirconium silicate, alumina, iron oxide, tin and the like are suitably used.
Barium sulfate or the like is used as the filler, and calcium hydroxide or the like is used as the pH adjuster.
ここで、フェノール樹脂中の硬化剤の含有量を１２質量％以上、硬化剤を含むフェノール樹脂の含有量を３．５質量％以下、硬化剤含有フェノール樹脂を含む全フェノール樹脂の含有量を８質量％以下、及び金属繊維の含有量を１０〜２０質量％と、それぞれ限定した理由は、上記の第１の実施形態と全く同様である。 Here, the content of the curing agent in the phenol resin is 12% by mass or more, the content of the phenol resin containing the curing agent is 3.5% by mass or less, and the content of all the phenol resins including the curing agent-containing phenol resin is 8%. The reasons for limiting the content of the metal fiber to 10% by mass or less and the content of the metal fiber to 10 to 20% by mass are exactly the same as in the first embodiment.
チタン酸カリウム繊維の繊維径を５〜３０μｍとした理由は、繊維径が５μｍ未満であると、均一分散がし難いからであり、また、繊維径が３０μｍを超えると、気孔率が低下し、異音が発生するからである。
このチタン酸カリウム繊維の含有量を５〜２０質量％とした理由は、含有量が５質量％未満であると、異音が発生する不具合があり、また、含有量が２０質量％を超えると、強度が低下するという不具合があるからである。
The reason why the fiber diameter of the potassium titanate fiber is 5 to 30 μm is that if the fiber diameter is less than 5 μm, uniform dispersion is difficult, and if the fiber diameter exceeds 30 μm, the porosity decreases, This is because abnormal noise is generated.
The reason for setting the content of the potassium titanate fiber to 5 to 20% by mass is that if the content is less than 5% by mass, there is a problem that abnormal noise occurs, and if the content exceeds 20% by mass. This is because there is a problem that the strength is reduced.
以下、実施例及び比較例により本発明を具体的に説明するが、本発明はこれらの実施例によって限定されるものではない。 Hereinafter, the present invention will be described specifically with reference to Examples and Comparative Examples, but the present invention is not limited to these Examples.
１．チタン酸カリウムマグネシウム粉末を用いた例
実施例１〜４のブレーキパッド（ブレーキ摩擦材）を作製した。
まず、溶剤を用いて裏金を充分に洗浄した後、この裏金の表面に接着剤を塗布し乾燥した。
一方、硬化剤を１２質量％含有するフェノール樹脂、硬化剤を１０質量％含有するフェノール樹脂、平均粒径が０．５〜１０μｍのチタン酸カリウムマグネシウム粉末、スチール繊維、銅繊維、アラミド繊維、ロックウール等の無機繊維、黒鉛、コークス等の潤滑材、カシューダスト、ゴム粉等の有機系摩擦調整材、珪酸ジルコニウム粉末、アルミナ粉末、酸化鉄粉末、錫粉末等の無機系摩擦調整材、充填材として硫酸バリウム、ｐＨ調整材として水酸化カルシウムを、表１に示す様に所定量秤量し、混合した。
1. Example using potassium magnesium titanate powder Brake pads (brake friction materials) of Examples 1 to 4 were produced.
First, after the back metal was sufficiently washed with a solvent, an adhesive was applied to the surface of the back metal and dried.
On the other hand, a phenol resin containing 12% by mass of a curing agent, a phenol resin containing 10% by mass of a curing agent, potassium magnesium titanate powder having an average particle size of 0.5 to 10 μm, steel fiber, copper fiber, aramid fiber, rock Inorganic fibers such as wool and the like, lubricants such as graphite and coke, organic friction modifiers such as cashew dust and rubber powder, inorganic friction modifiers such as zirconium silicate powder, alumina powder, iron oxide powder and tin powder, fillers And barium sulfate as a pH adjuster were weighed and mixed in predetermined amounts as shown in Table 1.
その後、この混合物を所定の金型を用いて、５０ＭＰａの圧力かつ常温（２５℃）にて冷間圧縮成形した。
次いで、この冷間圧縮成形品と上記の接着剤を塗布した裏金を、１５０℃に加熱した金型内にセットし、この温度にて４０ＭＰａの圧力で２５０〜３００秒加熱圧縮成形した。
次いで、この成型品を２２０℃にて６時間熱処理し、さらに、研磨加工、溝加工を施し、実施例１〜４のブレーキパッドとした。
Thereafter, the mixture was subjected to cold compression molding using a predetermined mold at a pressure of 50 MPa and a normal temperature (25 ° C.).
Next, the cold compression-molded product and the back metal coated with the above-mentioned adhesive were set in a mold heated to 150 ° C., and heated and compression-molded at this temperature at a pressure of 40 MPa for 250 to 300 seconds.
Next, this molded product was heat-treated at 220 ° C. for 6 hours, and further polished and grooved to obtain brake pads of Examples 1 to 4.
一方、硬化剤を１２質量％含有するフェノール樹脂の量が本発明より多いものを比較例１として、フェノール樹脂の全質量が本発明より多いものを比較例２として、チタン酸カリウムマグネシウム粉末の量が本発明より少ないものを比較例３として、チタン酸カリウムマグネシウム粉末の量が本発明より多いものを比較例４として、金属繊維の量が本発明より少ないものを比較例５として、金属繊維の量が本発明より多いものを比較例６として、上記実施例１〜４と全く同様にして比較例１〜６のブレーキパッド（ブレーキ摩擦材）を作製した。 On the other hand, the amount of potassium magnesium titanate powder was set as Comparative Example 1 in which the amount of the phenol resin containing 12% by mass of the curing agent was larger than the present invention, and Comparative Example 2 in which the total amount of the phenol resin was larger than the present invention. Is less than the present invention as Comparative Example 3; the amount of potassium magnesium titanate powder is greater than the present invention as Comparative Example 4; the amount of metal fiber is less than the present invention as Comparative Example 5; Brake pads (brake friction materials) of Comparative Examples 1 to 6 were produced in exactly the same manner as in Examples 1 to 4 except that the amount was larger than that of the present invention as Comparative Example 6.
このようにして作製された実施例１〜４及び比較例１〜６のブレーキパッドについて、剪断強度、摩擦特性及び実車による鳴き・異音発生頻度を測定した。
剪断強度は、日本工業規格ＪＩＳ Ｄ ４４２２「自動車用ブレーキシューアッセンブリ及びディスクブレーキパッドの接着強度試験方法」に基づき測定した。
摩擦特性は、自動車技術会規格ＪＡＳＯ Ｃ ４０６「乗用車−ブレーキ装置−ダイナモメータ試験方法」に基づき測定した。
With respect to the brake pads of Examples 1 to 4 and Comparative Examples 1 to 6 thus manufactured, the shear strength, the friction characteristics, and the frequency of squealing / abnormal noise generated by an actual vehicle were measured.
The shear strength was measured based on Japanese Industrial Standards JIS D 4422 "Test Method for Adhesive Strength of Automotive Brake Shoe Assembly and Disc Brake Pad".
The friction characteristics were measured based on the Japan Society of Automotive Engineers Standard JASO C 406 “Passenger car-brake device-dynamometer test method”.
鳴き・異音発生頻度は、ブレーキパッドの温度を所定温度範囲とし、ディスクブレーキキャリパへの供給液圧を所定範囲としたときの、それぞれの組み合わせで所定回数、ダイナモメータにより制動試験を行い、このときに発生する音の大きさのレベルが一定値以上となったときの回数を計数して、その割合を算出した。
これらの測定結果を表２に示す。
The frequency of squealing / abnormal noise was determined by performing a braking test with a dynamometer a predetermined number of times for each combination when the temperature of the brake pad was set to a predetermined temperature range and the supply pressure to the disc brake caliper was set to a predetermined range. The number of times when the loudness level of the occasionally generated sound became a certain value or more was counted, and the ratio was calculated.
Table 2 shows the measurement results.
表２によれば、実施例１〜４は、比較例１〜６に比べて剪断強度が高く、摩擦係数の変動が小さく安定性に優れ、異音の防止に優れていることを確認することができた。また、実施例１〜４は、従来の製造方法をそのまま適用することができるので、製造に格別困難性はなく、製造が容易であることが確認された。
以上により、品質安定性に優れたブレーキパッドを、低コストで提供することが可能になった。
According to Table 2, it is confirmed that Examples 1 to 4 have higher shear strength than Comparative Examples 1 to 6, have a small variation in the coefficient of friction, have excellent stability, and are excellent in preventing abnormal noise. Was completed. Further, in Examples 1 to 4, the conventional manufacturing method can be applied as it is, and therefore, it was confirmed that the manufacturing was not particularly difficult and the manufacturing was easy.
As described above, it has become possible to provide a brake pad having excellent quality stability at low cost.
２．チタン酸カリウム繊維を用いた例
実施例１１〜１４のブレーキパッド（ブレーキ摩擦材）を作製した。
まず、溶剤を用いて裏金を充分に洗浄した後、この裏金の表面に接着剤を塗布し乾燥した。
一方、硬化剤を１２質量％含有するフェノール樹脂、硬化剤を１０質量％含有するフェノール樹脂、繊維径が５〜３０μｍのチタン酸カリウム繊維、スチール繊維、銅繊維、アラミド繊維、ロックウール等の無機繊維、黒鉛、コークス等の潤滑材、カシューダスト、ゴム粉等の有機系摩擦調整材、珪酸ジルコニウム粉末、アルミナ粉末、酸化鉄粉末、錫粉末等の無機系摩擦調整材、充填材として硫酸バリウム、ｐＨ調整材として水酸化カルシウムを、表３に示す様に所定量秤量し、混合した。
2. Example using potassium titanate fiber The brake pads (brake friction materials) of Examples 11 to 14 were produced.
First, after the back metal was sufficiently washed with a solvent, an adhesive was applied to the surface of the back metal and dried.
On the other hand, a phenol resin containing 12% by mass of a curing agent, a phenol resin containing 10% by mass of a curing agent, and inorganic materials such as potassium titanate fiber having a fiber diameter of 5 to 30 μm, steel fiber, copper fiber, aramid fiber, and rock wool. Lubricants such as fibers, graphite and coke; organic friction modifiers such as cashew dust and rubber powder; inorganic friction modifiers such as zirconium silicate powder, alumina powder, iron oxide powder, and tin powder; barium sulfate as a filler; A predetermined amount of calcium hydroxide was weighed and mixed as a pH adjuster as shown in Table 3.
その後、この混合物を所定の金型を用いて、５０ＭＰａの圧力かつ常温（２５℃）にて冷間圧縮成形した。
次いで、この冷間圧縮成形品と上記の接着剤を塗布した裏金を、１５０℃に加熱した金型内にセットし、この温度にて４０ＭＰａの圧力で２５０〜３００秒加熱圧縮成形した。
次いで、この成型品を２２０℃にて６時間熱処理し、さらに、研磨加工、溝加工を施し、実施例１１〜１４のブレーキパッドとした。
Thereafter, the mixture was subjected to cold compression molding using a predetermined mold at a pressure of 50 MPa and a normal temperature (25 ° C.).
Next, the cold compression-molded product and the back metal coated with the above-mentioned adhesive were set in a mold heated to 150 ° C., and heated and compression-molded at this temperature at a pressure of 40 MPa for 250 to 300 seconds.
Next, this molded product was heat-treated at 220 ° C. for 6 hours, and further subjected to polishing and groove processing to obtain brake pads of Examples 11 to 14.
一方、硬化剤を１２質量％含有するフェノール樹脂の量が本発明より多いものを比較例１１として、フェノール樹脂の全質量が本発明より多いものを比較例１２として、チタン酸カリウム繊維の量が本発明より少ないものを比較例１３として、チタン酸カリウム繊維の量が本発明より多いものを比較例１４として、金属繊維の量が本発明より少ないものを比較例１５として、金属繊維の量が本発明より多いものを比較例１６として、繊維径が４０〜６０μｍのチタン酸カリウム繊維を用いたものを比較例１７として、上記実施例１１〜１４と全く同様にして比較例１１〜１７のブレーキパッドを作製した。 On the other hand, when the amount of the phenolic resin containing 12% by mass of the curing agent is larger than that of the present invention as Comparative Example 11, and when the total amount of the phenolic resin is larger than the present invention as Comparative Example 12, the amount of the potassium titanate fiber is reduced. The amount of the metal fiber was smaller than that of the present invention as Comparative Example 14; the amount of the metal fiber was smaller than the present invention as Comparative Example 15; The brakes of Comparative Examples 11 to 17 were manufactured in exactly the same manner as in Examples 11 to 14 described above as Comparative Example 16 in which the number was larger than that of the present invention and Comparative Example 17 was formed using potassium titanate fibers having a fiber diameter of 40 to 60 μm. Pads were made.
このようにして作製された実施例１１〜１４及び比較例１１〜１７のブレーキパッドについて、上記の実施例１〜４及び比較例１〜６と全く同様の方法により剪断強度、摩擦特性及び実車による鳴き・異音発生頻度を測定した。
これらの測定結果を表４に示す。
With respect to the brake pads of Examples 11 to 14 and Comparative Examples 11 to 17 thus produced, the shear strength, friction characteristics, and the actual vehicle were measured in exactly the same manner as in Examples 1 to 4 and Comparative Examples 1 to 6 described above. The frequency of squeaking and abnormal noise was measured.
Table 4 shows the measurement results.
表４によれば、実施例１１〜１４は、比較例１１〜１７に比べて剪断強度が高く、摩擦係数の変動が小さく安定性に優れ、異音の防止に優れていることを確認することができた。また、実施例１１〜１４は、従来の製造方法をそのまま適用することができるので、製造に格別困難性はなく、製造が容易であることが確認された。
以上により、品質安定性に優れたブレーキパッドを、低コストで提供することが可能になった。
According to Table 4, it is confirmed that Examples 11 to 14 have higher shear strength than Comparative Examples 11 to 17, have a small variation in the coefficient of friction, have excellent stability, and are excellent in preventing abnormal noise. Was completed. Further, in Examples 11 to 14, since the conventional manufacturing method can be applied as it is, it was confirmed that the manufacturing was not particularly difficult and the manufacturing was easy.
As described above, it has become possible to provide a brake pad having excellent quality stability at low cost.
本発明は、フェノール樹脂及び金属繊維に加えて、平均粒径が０．５〜１０μｍのチタン酸カリウムマグネシウム粉末または繊維径が５〜３０μｍのチタン酸カリウム繊維を５〜２０質量％含有したことにより、剪断強度、摩擦係数の安定性、異音の低減性、品質安定性を改善したものであるから、自動車はもちろんのこと、ブレーキ機構を有する動力機械等へも適用可能であり、その工業的意義は極めて大である。 The present invention provides a powder of potassium magnesium titanate having an average particle diameter of 0.5 to 10 μm or a potassium titanate fiber having a fiber diameter of 5 to 30 μm in addition to the phenol resin and the metal fiber by 5 to 20% by mass. It has improved shear strength, friction coefficient stability, noise reduction, and quality stability, so it can be applied not only to automobiles but also to power machinery with a brake mechanism. The significance is enormous.
Claims (3)
ブレーキ摩擦材を１００質量％としたとき、
硬化剤の含有量が１２質量％以上のフェノール樹脂を３．５質量％以下かつ該フェノール樹脂を含むフェノール樹脂全質量を８質量％以下、
平均粒径が０．５〜１０μｍのチタン酸カリウムマグネシウム粉末を５〜２０質量％、
金属繊維を１０〜２０質量％、
含有してなることを特徴とするブレーキ摩擦材。 At least a reinforcing fiber, a binder, a lubricant, a friction modifier, and a brake friction material containing a filler,
When the brake friction material is 100% by mass,
The content of the curing agent is not more than 3.5% by mass of the phenol resin having 12% by mass or more, and the total mass of the phenol resin containing the phenol resin is not more than 8% by mass,
5 to 20% by mass of potassium magnesium titanate powder having an average particle size of 0.5 to 10 μm,
10 to 20% by mass of metal fiber,
A brake friction material characterized by containing.
ブレーキ摩擦材を１００質量％としたとき、
硬化剤の含有量が１２質量％以上のフェノール樹脂を３．５質量％以下かつ該フェノール樹脂を含むフェノール樹脂全質量を８質量％以下、
繊維径が５〜３０μｍのチタン酸カリウム繊維を５〜２０質量％、
金属繊維を１０〜２０質量％、
含有してなることを特徴とするブレーキ摩擦材。 At least a reinforcing fiber, a binder, a lubricant, a friction modifier, and a brake friction material containing a filler,
When the brake friction material is 100% by mass,
The content of the curing agent is not more than 3.5% by mass of the phenol resin having 12% by mass or more, and the total mass of the phenol resin containing the phenol resin is not more than 8% by mass,
5-20% by mass of potassium titanate fiber having a fiber diameter of 5-30 μm,
10 to 20% by mass of metal fiber,
A brake friction material characterized by containing.
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Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2007277418A (en) * | 2006-04-07 | 2007-10-25 | Advics:Kk | Friction material |
| KR101058376B1 (en) | 2010-07-12 | 2011-08-22 | 동해케미칼공업주식회사 | A method for preparing rod-type titanic acid salts and rod-type titanic acid salts prepared by the same |
| KR101058379B1 (en) | 2010-07-12 | 2011-08-22 | 동해케미칼공업주식회사 | A method for preparing flake-type titanic acid whiskers and flake-type titanic acid whiskers prepared by the same |
| JP2012233064A (en) * | 2011-04-28 | 2012-11-29 | Hitachi Automotive Systems Ltd | Brake friction material |
| KR20140053254A (en) * | 2011-08-18 | 2014-05-07 | 페더럴-모걸 코오포레이숀 | Friction material for brakes |
| JP2014167076A (en) * | 2013-02-28 | 2014-09-11 | Akebono Brake Ind Co Ltd | Friction material |
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Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2007277418A (en) * | 2006-04-07 | 2007-10-25 | Advics:Kk | Friction material |
| KR101058376B1 (en) | 2010-07-12 | 2011-08-22 | 동해케미칼공업주식회사 | A method for preparing rod-type titanic acid salts and rod-type titanic acid salts prepared by the same |
| KR101058379B1 (en) | 2010-07-12 | 2011-08-22 | 동해케미칼공업주식회사 | A method for preparing flake-type titanic acid whiskers and flake-type titanic acid whiskers prepared by the same |
| JP2012233064A (en) * | 2011-04-28 | 2012-11-29 | Hitachi Automotive Systems Ltd | Brake friction material |
| KR20140053254A (en) * | 2011-08-18 | 2014-05-07 | 페더럴-모걸 코오포레이숀 | Friction material for brakes |
| KR102116768B1 (en) | 2011-08-18 | 2020-06-01 | 페더럴-모걸 엘엘씨 | Friction material for brakes |
| JP2014167076A (en) * | 2013-02-28 | 2014-09-11 | Akebono Brake Ind Co Ltd | Friction material |
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