JP2007084725A - Method for adhering friction material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for adhering a friction material which is friendly to the environment, as it is free from generation of waste water because the whole of its adhesion process is carried out in a dry process, and which achieves a stable quality after adhesion, by the flow of a powdery adhesive having been applied and the formation of a film caused by preheating of a pressure plate using superheated steam. <P>SOLUTION: The method for adhering a friction material, wherein the friction material is adhered to the pressure plate of a friction member, comprises the steps of degreasing the surface of the pressure plate and simultaneously producing an oxide film under the superheated steam, applying the powdery adhesive, and adhering the friction material laminated on the adhesive by heat and pressure. The steps of degreasing the surface of the pressure plate by the superheated steam and of producing an oxide film are carried out at 250-800°C in an atmosphere of superheated steam for a time of 15-60 minutes, and the step of applying is preferably performed at the surface temperature of the pressure plate being the range of 120-170°C. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for adhering a friction material that does not generate waste water because it is an all-adhesion process, is environmentally friendly, and has a stable adhesion quality. More specifically, the present invention relates to a powder adhesive by preheating in the adhesion process. By forming a film of an adhesive layer by flowing the material, the adhesive strength between the pressure plate (metal plate) of the metal plate and the porous material, for example, the friction member (brake pad) and the friction material (porous plate) is stabilized. The present invention relates to a method for bonding a friction material.

In the adhesion of the friction material and the pressure plate, in Patent Document 1, a phosphoric acid film is applied to the pressure plate as an environmentally friendly adhesion method, and then a powdery thermosetting resin is attached by electrostatic coating and heated. Pre-curing is described.
JP 2000-88021 A

However, since the phosphate treatment is performed in a wet manner, the concentrated liquid and the waste liquid from the water washing and hot water washing accompanying this treatment are discharged, which is not environmentally preferable.
Moreover, since it passes through the process of pre-processing, the accompanying water washing, hot water washing, drying, adhesive application | coating, and the heating after application | coating, there exists a subject that an installation space becomes large and processing time is long.

  The present invention has been made in view of such conventional problems, and since the bonding process is all performed in a dry manner, it is environmentally friendly because no wastewater is generated, and it is applied by preheating the pressure plate with superheated steam. It is an object of the present invention to provide a method for adhering a friction material in which the adhesion quality is stabilized by the flow of the powdered adhesive and the formation of a film.

In order to achieve the above object, the present invention comprises the following constitution.
(1) In the method for bonding a friction material, the friction material is bonded to the pressure plate of the friction member.
Degreasing the pressure plate surface with superheated steam and generating an oxide film;
Applying a powdery adhesive to the coated surface of the pressure plate;
A method of bonding the friction material, comprising the steps of: stacking the friction materials and bonding them by heating and pressing.
(2) The step of degreasing the pressure plate surface with the superheated steam and generating an oxide film is performed in a superheated steam atmosphere at a temperature of 250 to 800 ° C. for a time of 15 to 60 minutes. 1) The friction material bonding method according to 1).
(3) The method for adhering a friction material according to (1), wherein the step of applying the powdery adhesive is performed in a range where the surface temperature of the pressure plate is 120 to 170 ° C.
(4) The method for adhering a friction material according to (1), wherein a powder of a thermosetting resin adhesive is used as the powder adhesive.

  That is, in the bonding method of the present invention, in principle, the pressure plate processing method is composed of two steps of heating with superheated steam and application of powdered adhesive, and the powder applied using preheating of superheated steam The point is to liquefy and flow the adhesive to form an adhesive layer.

According to the present invention, since all of the bonding process is a dry process, no waste water is generated, so that the environment-friendly line is obtained. As a result, both the installation space and the processing time are reduced to 1/2 to 1/3 as compared with the adhesion method for performing the conventional phosphating process performed in a wet process.
Furthermore, because the adhesive plate liquefies and flows immediately after application due to preheating of the pressure plate, and forms a film, there is no dropout or scattering of the powdery adhesive during application and after application until heating the adhesive. Adhesive quality can be secured.

Embodiments of the present invention will be described below.
The following embodiment is applied to manufacture of a friction member (brake pad) used for a vehicle brake, and a porous material (porous friction material layer) is bonded to the surface of a metal plate which is a pressure plate. Is.

  First, the pressure plate surface is degreased with superheated steam and an oxide film is formed. The treatment with superheated steam generally has a temperature range of 250 to 800 ° C. and a time period of 15 to 60 minutes. However, the removal of a normal mineral-based rust inhibitor and the same rust prevention effect as an iron phosphate coating are possible. If expected, a treatment at 250 ° C. for 15 minutes is sufficient.

  After performing the superheated steam treatment, when the surface temperature of the pressure plate is in the range of 120 to 170 ° C., a powdery adhesive is attached to the pressure plate by electrostatic powder coating, and the pressure plate of the pressure plate is heated by the superheated steam. Using preheating, the applied powdered adhesive is liquefied and fluidized to form a film as an adhesive layer, then thermoformed and heated with a preformed product, and a friction member (brake) that is pressed against the friction material Pad).

A thermosetting resin can be suitably used as the powder adhesive, and as a suitable adhesive, straight phenol resin, thermoplastic modified phenol resin, epoxy resin, polybenzoxazine resin adhesive, and other various thermosetting resins. Is mentioned.
The thickness of the adhesive layer (film) is 10 to 100 μm after the flow, and more preferably 20 to 20 in consideration of ensuring a sufficient anchor effect with the friction material and protruding the adhesive from between the pressure plate and the friction material. 50 μm.

  Hereinafter, the present invention will be described in more detail and specifically with reference to examples, but the present invention is not limited to these examples.

Example 1
The pressure plate was subjected to a superheated steam treatment at a temperature of 250 ° C. for 15 minutes to perform degreasing and temporary rust-proof oxide film generation. After the superheated steam treatment, when the pressure plate surface temperature is in the range of 120 to 170 ° C., a powdery adhesive made of epoxy / phenolic thermosetting resin is applied by corona charging type powder electrostatic coating. An adhesive film having a thickness of 30 μm was formed, and thereafter, a friction member (brake pad) was obtained by thermoforming and heating the preform.

Comparative Example 1
As a comparative example, a chemical conversion treatment is performed on the pressure plate, and after degreasing and iron phosphate coating production, a powdered adhesive is electrostatically applied in the same manner as in Example 1 above, and heated and fluidized at 130 ° C. for 15 minutes. After forming an adhesive film having a thickness of 30 μm, a preforming product was similarly thermoformed and heated to produce a friction member (brake pad).

The blending ratio (part by mass) of the raw material of the friction material preform used in Example 1 and Comparative Example 1 is as shown below.
Phenolic resin 15
Aramid pulp 10
Inorganic fiber 15
Zirconium silicate 3
Organic dust 7
Barium sulfate 45
Flake graphite 5
The processing steps of Example 1 and Comparative Example 1 are shown in FIG.
Table 1 shows the evaluation results of the adhesion performance of the friction members (brake pads) manufactured according to Example 1 and Comparative Example 1 described above.

  From the shear test result of the friction member (brake pad) shown in Table 1, Example 1 has an adhesive strength equivalent to that in the case where an iron phosphate coating is formed by performing wet phosphate treatment as in the past. It was confirmed that the processing can be performed in about 1/3 of the conventional time, which is advantageous in terms of manufacturing cost.

  According to the method for adhering the friction material of the present invention, since all the processes are dry processes, no waste water is generated and the environment-friendly line is obtained, and the facility space and the processing time are 1/2 to 1/3 of the conventional ones. In addition, since the powdered adhesive does not fall off or scatter during the process from application to application and after application, a friction member (brake pad) with stable adhesion quality can be obtained, so passenger cars, industrial machinery, railways Wide applications can be expected for vehicles and the like.

It is a flowchart which shows the main manufacturing process of the friction material of Example 1 and Comparative Example 1 of this invention.

Claims (4)

In the method of bonding the friction material, the friction material is bonded to the pressure plate of the friction member.
Degreasing the pressure plate surface with superheated steam and generating an oxide film;
Applying a powdery adhesive to the coated surface of the pressure plate;
A method of bonding the friction material, comprising the steps of: stacking the friction materials and bonding them by heating and pressing.   2. The step of degreasing the pressure plate surface with the superheated steam and generating the oxide film is performed in a temperature range of 250 to 800 ° C. for 15 to 60 minutes in a superheated steam atmosphere. Friction material adhesion method.   2. The method for adhering a friction material according to claim 1, wherein the step of applying the powdery adhesive is performed in a range where the surface temperature of the pressure plate is 120 to 170 [deg.] C.   2. The friction material bonding method according to claim 1, wherein a powder of a thermosetting resin adhesive is used as the powder adhesive.

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