JP2006052845A - 摩擦調整材料のナノ粒子を有する多孔質摩擦材料 - Google Patents
摩擦調整材料のナノ粒子を有する多孔質摩擦材料 Download PDFInfo
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Abstract
【解決手段】多孔質基材、少なくとも1つのタイプの樹脂材料、及び少なくとも1つのタイプのナノ粒子サイズの摩擦調整粒子を含む摩擦材料を開示する。樹脂材料は、基材全体にわたって実質的に均一に分散し、予め定められた量のナノ粒子サイズの摩擦調整材料の不連続層は、基材表面に多孔質上面を形成する。
【選択図】なし
Description
本発明のさらなる目的は、改良された“耐シャダ”、耐“ホットスポット”性、高い耐熱性、高い摩擦安定性及び耐久性、並びに強度を有する摩擦材料を提供することにある。
基材中の摩擦調整粒子のナノ粒子は、得られた摩擦材料に改良された三次元構造を与える。
1態様においては、基材層は高度多孔質材料の例えば長繊維織物状材料を含み、他の態様においては、高度多孔質不織布材料を含む。特定の具体例においては、多孔質基材は、基材の総重量を基準として、約75〜約85%の範囲内の高い繊維含量を有し、特定の具体例においては、約80重量%である。基材は、基材の総重量を基準として、約15〜約25重量%の範囲内の充填材含量を有し、特定の具体例においては、約20重量%である。基材中の充填材がより少ないと、横方向浸透性をかなり向上させる。
摩擦調整材料層は、流体潤滑剤を基材中に保持し、摩擦材料の油保持容量を増大させる。本発明の摩擦材料は従って、油膜が表面に残存することを可能にする。これはまた、良好な摩擦係数特性及び良好なスリップ耐久性特性を与える。
基材内部にナノ粒子サイズの摩擦調整粒子を堆積させることは、基材の浸透性を大幅に低下させない多孔質表面層を生成する。基材の浸透性は、流体または潤滑剤が基材中に流れ、摩擦材料の表面で保持されたままにならないことを可能にする。
図1cは、粒子の相対的サイズを示す概略図であり、珪藻粒子の代表的な平均サイズとして10〜20マイクロメートルを示す。
Claims (26)
- 多孔質基材及び少なくとも1つのタイプの樹脂材料を含む第1の層、並びに前記多孔質基材の上面を少なくとも部分的に被覆する少なくとも1つのタイプのナノ粒子サイズの摩擦調整粒子を含む第2の層を含み、該第2の層は、前記基材を構成する個別の繊維及び充填材表面で平均厚さ約0〜200μmを有する、摩擦材料において、上層は、前記第1の層と実質的に同じかまたは超える浸透性を有する、摩擦材料。
- 前記多孔質基材を構成する個別の繊維及び充填材表面の前記ナノ粒子サイズの摩擦調整粒子の層は、厚さ約75〜約85μmを有する、請求項1に記載の摩擦材料。
- 前記上層は、前記多孔質基材よりも、半径方向に実質的に同じかまたは超える浸透性及び垂直方向に実質的に同じかまたは超える浸透性を有する、請求項1に記載の摩擦材料。
- 前記ナノ粒子サイズの摩擦調整粒子は、平均直径サイズ約10nm〜約150nmを有する、請求項1に記載の摩擦材料。
- 前記摩擦調整粒子のサイズは約1〜約20nmである、請求項1に記載の摩擦材料。
- 前記多孔質基材は平均空隙容量約65〜約85%を有する、請求項1に記載の摩擦材料。
- 前記ナノ粒子サイズの摩擦調整粒子はシリカ粒子を含む、請求項1に記載の摩擦材料。
- 前記ナノ粒子サイズの摩擦調整粒子はセライト粒子を含む、請求項7に記載の摩擦材料。
- 前記ナノ粒子サイズの摩擦調整粒子はケイソウ土を含む、請求項7に記載の摩擦材料。
- 前記ナノ粒子サイズの摩擦調整粒子は炭素粒子とシリカ粒子との混合物を含む、請求項1に記載の摩擦材料。
- セライトは不規則な形状を有する、請求項7に記載の摩擦材料。
- セライトの粒子は約2〜約20nmの範囲にわたるサイズを有する、請求項8に記載の摩擦材料。
- 前記ナノ粒子サイズの摩擦調整粒子は金属酸化物を含む、請求項1に記載の摩擦材料。
- 前記ナノ粒子サイズの摩擦調整粒子は窒化物を含む、請求項1に記載の摩擦材料。
- 前記ナノ粒子サイズの摩擦調整粒子は炭化物を含む、請求項1に記載の摩擦材料。
- 前記基材は繊維質基材を含む、請求項1に記載の摩擦材料。
- 前記基材は不織布繊維質材料である、請求項1に記載の摩擦材料。
- 前記基材は織物状繊維質材料である、請求項1に記載の摩擦材料。
- 前記繊維質基材は、約15〜約25%の綿、約40〜約50%のアラミド繊維、約10〜約20%の炭素繊維、約5〜約15%の炭素粒子、及び約5〜約15%のセライト、並びに所望により追加で約1〜約3%のラテックスを含む、請求項17に記載の摩擦材料。
- 摩擦材料の上層は、前記不織布繊維質材料の繊維の表面及び前記繊維質基材中の充填材料の表面に堆積したシリカのナノ粒子サイズの摩擦調整粒子を含む、請求項19に記載の摩擦材料。
- 前記繊維質基材は平均細孔直径約5μmを有する、請求項17に記載の摩擦材料。
- 樹脂は、少なくとも1種のフェノール樹脂または少なくとも1種の変性フェノール樹脂を含む、請求項1に記載の摩擦材料。
- 前記樹脂は、少なくとも1種のフェノール樹脂と少なくとも1種のシリコーン樹脂との混合物を含み、該樹脂混合物中のシリコーン樹脂の量は、前記樹脂混合物の重量を基準として約5〜約80重量%の範囲にわたる、請求項1に記載の摩擦材料。
- 摩擦材料の製造方法であって、
少なくとも1種の樹脂材料及び少なくとも1つのタイプのナノ粒子サイズの摩擦調整粒子を含む飽和剤で多孔質基材を飽和させ、これによって、複数の摩擦調整粒子は、基材を構成する個別の繊維及び充填材の表面に層を形成し、ナノ粒子サイズの摩擦調整粒子の層は平均厚さ約0〜200μmを有し、上層は、ほぼ第1の層以上の浸透性を有することと、
飽和済み基材を、予め定められた温度で予め定められた時間硬化することと、
を含む方法。 - 摩擦材料の製造方法であって、
少なくとも1種の硬化可能な樹脂材料及び少なくとも1つのタイプのナノ粒子サイズの摩擦調整粒子を含む飽和剤材料を製造することと、
貫通して分散する複数の間隙を有する多孔質基材を製造することと、
前記多孔質基材を飽和剤材料で飽和させることと、を含み、これによって、前記基材を構成する個別の繊維表面に複数の前記ナノ粒子サイズの摩擦調整粒子を少なくとも部分的に堆積させ、前記樹脂材料を前記基材全体にわたって実質的に均一に分布させる、方法。 - 前記ナノ粒子サイズの摩擦調整粒子は、前記基材の少なくとも1つの面の表面に多孔質上層を形成する、請求項25に記載の方法。
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-
2004
- 2004-07-26 US US10/898,882 patent/US8603614B2/en not_active Expired - Fee Related
-
2005
- 2005-07-18 EP EP20050254474 patent/EP1621790A1/en not_active Ceased
- 2005-07-22 JP JP2005212382A patent/JP2006052845A/ja active Pending
- 2005-07-25 CN CNA2005100980513A patent/CN1740214A/zh active Pending
- 2005-07-26 KR KR1020050067751A patent/KR20060046780A/ko not_active Application Discontinuation
Cited By (5)
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JP2009500511A (ja) * | 2005-07-11 | 2009-01-08 | サルザー・フリクション・システムズ・(ユーエス)・インコーポレーテッド | 湿り気付与摩擦材料、システムおよび方法 |
JP2007255623A (ja) * | 2006-03-24 | 2007-10-04 | Ngk Insulators Ltd | 複合材ブレーキ |
JP2016530366A (ja) * | 2013-07-29 | 2016-09-29 | ボーグワーナー インコーポレーテッド | 摩擦材料 |
JP2020143286A (ja) * | 2013-07-29 | 2020-09-10 | ボーグワーナー インコーポレーテッド | 摩擦材料 |
US10989263B2 (en) | 2016-11-15 | 2021-04-27 | Borgwarner Inc. | Friction material |
Also Published As
Publication number | Publication date |
---|---|
CN1740214A (zh) | 2006-03-01 |
KR20060046780A (ko) | 2006-05-17 |
US8603614B2 (en) | 2013-12-10 |
EP1621790A1 (en) | 2006-02-01 |
US20060019080A1 (en) | 2006-01-26 |
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