JP2009132816A - Friction material - Google Patents

Friction material Download PDF

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JP2009132816A
JP2009132816A JP2007310555A JP2007310555A JP2009132816A JP 2009132816 A JP2009132816 A JP 2009132816A JP 2007310555 A JP2007310555 A JP 2007310555A JP 2007310555 A JP2007310555 A JP 2007310555A JP 2009132816 A JP2009132816 A JP 2009132816A
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friction material
friction
vol
cryolite
fading
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JP5200508B2 (en
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Hiroyuki Fujikawa
裕之 藤川
Hironari Kishimoto
裕也 岸本
Toshihiko Yuasa
俊彦 湯浅
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Advics Co Ltd
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Advics Co Ltd
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/02—Compositions of linings; Methods of manufacturing
    • F16D69/025—Compositions based on an organic binder
    • F16D69/026—Compositions based on an organic binder containing fibres
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/006—Materials; Production methods therefor containing fibres or particles
    • F16D2200/0069—Materials; Production methods therefor containing fibres or particles being characterised by their size

Abstract

<P>PROBLEM TO BE SOLVED: To provide a non-asbestos friction material that ensures a good coefficient of friction during fading and at the same time prevents a part of the friction material from peeling off and sticking to a partner material even if the application of pressure to the friction material is sustained during a stop after being subjected to fading in a high temperature range. <P>SOLUTION: The non-asbestos friction material comprises a fibrous base material, a binder, a lubricant and other fillers wherein calcium pyrophosphate as a filler is contained in an amount of 4-6 vol.% based on the total of the friction material and additionally cryolite is contained in an amount of 3-5 vol.% based on the total of the friction material. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

本発明は、車両のディスクロータやドラムに接触させて用いるブレーキパッドやブレーキライニング、およびクラッチフェーシング等の摩擦材に関する。   The present invention relates to a friction material such as a brake pad, a brake lining, and a clutch facing used in contact with a disk rotor or drum of a vehicle.

車両の燃料消費効率の向上にむけて、車両構成部品の軽量化が取り組まれている。軽量化の方策としては、部品使用素材の低密度化、既存部品の薄肉化及び小型化が挙げられる。ブレーキ構成部品関連では、ディスクロータ小型化対応摩擦材が求められている。   In order to improve the fuel consumption efficiency of vehicles, efforts have been made to reduce the weight of vehicle components. Measures for weight reduction include lowering the density of component-use materials and reducing the thickness and size of existing parts. In relation to brake components, there is a demand for friction materials that can be used to reduce the size of disk rotors.

フェード時の摩擦係数低下のメカニズムは、以下のように推定されている。つまり、制動時の摩擦熱により摩擦材の温度が上昇し、その温度によって摩擦材中の有機成分が分解してガスが発生する。この分解ガスは元の材料に対しての体積変化が大きく逃げ場も無いため、摩擦材とディスクロータとの間に介在する事で摩擦係数を低下させ、ブレーキの効きが急激に悪化するフェード現象が発生する。このフェード現象による摩擦係数低下対策として、従来より無機充填材として氷晶石（クリオライト）を添加してきた。ところが、この氷晶石を添加した材料系では、特にフェード相当の熱履歴を受けた状態で信号待ち等で、車両が停止した後もブレーキペダルを踏み込んだまま摩擦材が加圧された状態を維持すると、摩擦材がディスクロータの摺動面に貼り付きを起こすことが確認できた。この状態から再発進のために摩擦材の加圧状態を解除すると、摩擦材の表層部の一部が剥離してバキンという不快音を生じることがあった。また、摩擦材の一部が剥離してディスクロータの摺動面にはり付いたまま再度制動をかけると、表面粗度の極めて悪い（凹凸形状の大きい）貼り付き部が原因となって摩擦材が偏摩耗したり、ブレーキ振動の原因となるなどの問題が生じた。   The mechanism for reducing the coefficient of friction during fading is estimated as follows. That is, the temperature of the friction material rises due to frictional heat during braking, and the organic component in the friction material is decomposed by the temperature to generate gas. Since this cracked gas has a large volume change with respect to the original material and there is no escape space, the friction coefficient decreases by interposing between the friction material and the disk rotor, and the fade phenomenon that the effectiveness of the brake suddenly deteriorates is caused. appear. Conventionally, cryolite has been added as an inorganic filler as a countermeasure for reducing the friction coefficient due to the fade phenomenon. However, in the material system to which cryolite is added, the friction material is pressed while the brake pedal is depressed even after the vehicle stops, especially in the state of waiting for a signal while receiving a heat history equivalent to fading. When maintained, it was confirmed that the friction material stuck to the sliding surface of the disk rotor. When the pressurized state of the friction material is released for restarting from this state, a part of the surface layer portion of the friction material may be peeled off, resulting in an unpleasant noise. Also, if braking is applied again while part of the friction material is peeled off and stuck to the sliding surface of the disk rotor, the friction material is caused by a sticking part with extremely poor surface roughness (large unevenness). Have caused problems such as uneven wear and brake vibration.

この摩擦材剥離機構を詳しく説明すると、制動時に摩擦材が高温となることで摩擦材表層部において氷晶石が溶融する。そのまま摩擦材の加圧状態が保持され摩擦材とディスクロータ等との密接状態が維持されると、摩擦材の降温に伴い溶融した氷晶石が固体化してディスクロータ等と固着する。この状態から再発進のために摩擦材の加圧状態が解除されると、ディスクロータ等の表面に固着した氷晶石によって、摩擦材の表層部がちぎれるように剥離し、ディスクロータ等の表面に摩擦材の一部が張り付いてしまうのである。そのため、摩擦材の表面粗度が悪化すると共に、ディスクロータにおける摩擦材貼り付き部も表面粗度が悪化し、制動不良の要因となる。   The friction material peeling mechanism will be described in detail. When the friction material becomes high temperature during braking, cryolite melts in the friction material surface layer. If the pressure state of the friction material is maintained as it is and the intimate state between the friction material and the disk rotor is maintained, the cryolite melted with the temperature decrease of the friction material is solidified and fixed to the disk rotor or the like. When the pressure of the friction material is released for restarting from this state, the surface layer of the friction material is peeled off by cryolite adhering to the surface of the disk rotor, etc. A part of the friction material sticks to the surface. Therefore, the surface roughness of the friction material is deteriorated, and the surface roughness of the friction material-attached portion of the disk rotor is also deteriorated, which causes a braking failure.

ここで、この種の摩擦材は、大きく分けて繊維基材と、広義の充填材と、これらを結合する結合剤（バインダー樹脂）とからなる。充填材は、その機能から摩擦調整材と呼ばれることもある。近年では、環境や人体に悪影響のある従来からの石綿（アスベスト）に代えて、繊維基材としてアラミド繊維等の有機繊維やスチール繊維等の無機繊維を使用した、いわゆるＮＡＯ（non Asbestos organic）材が使用されている。このような摩擦材として、例えば特許文献１ないし特許文献４がある。特許文献１の摩擦材は、繊維基材としてガラス繊維とアラミド繊維とを、結合剤としてフェノール樹脂をそれぞれ使用し、これに氷晶石を含む有機及び無機充填材を配合した有機成分主体の組成と成っている。特許文献１では、繊維基材にアスベストを使用しない無石綿摩擦材とすることで、摩擦係数やフェードの改良を図っている。特許文献２の摩擦材は、合成繊維を含む繊維基材を使用しながら充填材の１つとして氷晶石を使用し、有機成分主体の組成となっている。特許文献２では、繊維基材にアスベストを使用しない無石綿摩擦材としながら、繊維基材の配合量を低減することで、低摩耗率と高摩擦係数の実現を図っている。特許文献３の摩擦材は、繊維基材としてガラス繊維とパルプ化ポリパラフェニンレンテレフタルアミド繊維を使用しながら、５〜３０ｖｏｌ％の氷晶石粉末を配合している。特許文献３では、氷晶石の高配合によりフェードの抑制を図っている。特許文献４の摩擦材は、繊維基材と結合剤に加えて、研削材としての炭化ケイ素を１０〜３０重量％配合し、他に潤滑材として粗粒黒鉛、窒化ホウ素、氷晶石などを配合しており、その実使用温度を５００℃以上としている。特許文献４では、高温領域でも安定した高摩擦係数を有する炭化ケイ素を重点的に配合すると共に、適度な潤滑材を配合することで、５００℃以上の使用領域でも良好な摩擦係数及び耐摩耗性を有し、且つディスクロータなどの相手材への攻撃性（相手材の摩耗）の低減を図っている。   Here, this type of friction material is roughly composed of a fiber base material, a broadly defined filler, and a binder (binder resin) for binding them. The filler is sometimes called a friction modifier because of its function. In recent years, instead of conventional asbestos (asbestos), which has a negative impact on the environment and the human body, so-called NAO (non Asbestos organic) materials that use organic fibers such as aramid fibers and inorganic fibers such as steel fibers as the fiber base material Is used. As such a friction material, there exist patent document 1 thru | or patent document 4, for example. The friction material of Patent Document 1 uses a glass fiber and an aramid fiber as a fiber base material and a phenol resin as a binder, respectively, and is composed mainly of an organic component containing organic and inorganic fillers containing cryolite. It consists of. In patent document 1, the improvement of a friction coefficient and a fade is aimed at by making it the non-asbestos friction material which does not use asbestos for a fiber base material. The friction material of Patent Document 2 uses cryolite as one of the fillers while using a fiber base material containing synthetic fibers, and has a composition mainly composed of organic components. In Patent Document 2, a low wear rate and a high friction coefficient are achieved by reducing the blending amount of the fiber base material while using a non-asbestos friction material that does not use asbestos for the fiber base material. The friction material of patent document 3 mix | blends 5-30 vol% cryolite powder, using a glass fiber and a pulped polyparaphenylene terephthalamide fiber as a fiber base material. In Patent Document 3, fading is suppressed by high blending of cryolite. In addition to the fiber base material and the binder, the friction material of Patent Document 4 contains 10 to 30% by weight of silicon carbide as an abrasive, and in addition, coarse graphite, boron nitride, cryolite and the like as a lubricant. The actual use temperature is 500 ° C. or higher. In Patent Document 4, silicon carbide having a stable high friction coefficient even in a high temperature region is intensively blended, and an appropriate lubricant is blended, so that a good friction coefficient and wear resistance can be obtained even in a use region of 500 ° C. or higher. In addition, the aggression on the mating material such as a disk rotor (wear of the mating material) is reduced.

特開昭６２−１１７３２号公報Japanese Patent Laid-Open No. Sho 62-11732 特公昭６２−４６５８９号公報Japanese Patent Publication No.62-46589 特開昭６２−１１７８９号公報JP 62-11789 A 特許第３８５５１２５号公報Japanese Patent No. 3855125

特許文献１や特許文献２の摩擦材は、フェード現象の大きな発生原因たる有機成分主体の組成であり、かつ研削材が乏しいので、高温域でのフェード現象による摩擦係数の低下に対応し難く、かつ摩擦材の貼り付きが発生する危険性が高い。特許文献３の摩擦材は氷晶石を高配合しているので、フェード時の摩擦係数確保の観点からは有意な効果が期待できる。しかし、氷晶石を高配合していることで、氷晶石の溶着による貼り付きの危険性が増大する。特許文献４の摩擦材は、研削材として炭化ケイ素を１０〜３０重量％配合しているので、高温域での潤滑性は確保されている。しかし、このような配合では、例えば２００℃以下のような一般使用温度域での相手攻撃性が悪化するので、ディスクロータ等の相手材の摩耗寿命が低下してしまう。   The friction material of Patent Document 1 and Patent Document 2 is a composition mainly composed of organic components that causes a large fade phenomenon, and since the abrasive is scarce, it is difficult to cope with a decrease in the friction coefficient due to the fade phenomenon in a high temperature range. In addition, there is a high risk of friction material sticking. Since the friction material of Patent Literature 3 contains high cryolite, a significant effect can be expected from the viewpoint of securing the friction coefficient during fading. However, the high blending of cryolite increases the risk of sticking due to cryolite welding. Since the friction material of patent document 4 mix | blends 10-30 weight% of silicon carbide as an abrasive, the lubricity in a high temperature range is ensured. However, in such a composition, since the opponent aggressiveness in a general use temperature range such as 200 ° C. or less is deteriorated, the wear life of the counterpart material such as a disk rotor is reduced.

そこで本発明は、フェード時の摩擦係数を有意に確保しながら、高温域でのフェード後に加圧停止状態が維持されても、摩擦材の一部が剥離して相手材へ貼り付くことのない無石綿摩擦材を提供することを目的とする。   Therefore, the present invention ensures that the coefficient of friction at the time of fading is significantly ensured, and even if the pressure stop state is maintained after fading in a high temperature range, a part of the friction material does not peel off and stick to the counterpart material. An object is to provide an asbestos friction material.

本発明は繊維基材と、結合剤と、潤滑材と、その他の充填材とからなるアスベスト不使用の無石綿摩擦材であって、前記充填材としてピロリン酸カルシウムを含有していることを特徴とする。充填材とは、繊維基材、結合剤、潤滑材以外の配合物全般を意味し、研削材なども含む概念である。   The present invention is an asbestos-free asbestos-free friction material comprising a fiber base material, a binder, a lubricant, and other fillers, characterized in that it contains calcium pyrophosphate as the filler. To do. The filler means a general composition other than a fiber base material, a binder, and a lubricant, and is a concept including an abrasive.

また、前記充填材として氷晶石を含有している。前記ピロリン酸カルシウムの配合割合は、摩擦材全体に対して４〜６ｖｏｌ％（体積％）とし、前記氷晶石の配合割合は摩擦材全体に対して３〜５ｖｏｌ％（体積％）とすることが好ましい。   Moreover, cryolite is contained as the filler. The blending ratio of the calcium pyrophosphate is 4 to 6 vol% (volume%) with respect to the entire friction material, and the blending ratio of the cryolite is 3 to 5 vol% (volume%) with respect to the entire friction material. preferable.

本発明によれば、無石綿摩擦材なので、環境や人体へ悪影響を及ぼすことがない。そのうえで、ピロリン酸カルシウムと氷晶石とを適度に配合しているので、フェード時の摩擦係数を有意に確保しながら、高温域でのフェード後に加圧停止状態が維持されても、摩擦材の一部が剥離して相手材へ貼り付くことを有効に防ぐことができる。   According to the present invention, since it is an asbestos friction material, it does not adversely affect the environment and the human body. In addition, since calcium pyrophosphate and cryolite are mixed appropriately, even if the pressure stop state is maintained after fading in the high temperature range while significantly ensuring the coefficient of friction during fading, It is possible to effectively prevent the part from peeling off and sticking to the counterpart material.

本発明の摩擦材は、アスベストではない繊維基材、結合剤、潤滑材、その他の充填材とを有する無石綿摩擦材（ＮＡＯ材）である。全体として無機成分を主体とし、充填材として氷晶石とピロリン酸カルシウム（Ｃａ２Ｐ２Ｏ７）を含有している。本発明の摩擦材は、自動車や電車などの車両や航空機などのディスクロータやドラムに接触させて用いるブレーキパッドやブレーキライニング、およびクラッチフェーシング用の摩擦材として適用できる。 The friction material of the present invention is an asbestos friction material (NAO material) having a fiber base material that is not asbestos, a binder, a lubricant, and other fillers. As a whole, it mainly contains inorganic components, and contains cryolite and calcium pyrophosphate (Ca 2 P 2 O 7 ) as fillers. The friction material of the present invention can be applied as a friction material for brake pads and brake linings used in contact with disk rotors and drums of vehicles such as automobiles and trains and airplanes, and clutch facing.

［繊維基材］
繊維基材は、従来からＮＡＯ材として使用されているものであれば特に限定されず、各種無機繊維や有機繊維を使用できる。無機繊維としては、スチール繊維や銅繊維等の金属繊維のほか、チタン酸カリウム繊維等のセラミックス繊維や炭素繊維，ガラス繊維などがある。有機繊維としては、アラミド繊維，ポリエステル繊維，カオウール繊維等の合成樹脂繊維やパルプ等の天然繊維などがある。中でも、無機繊維としてはスチール繊維が、有機繊維としてはアラミド繊維が好ましい。また、基材を補佐的に構成する充填材として、青銅、黄銅、銅などの金属粉末を適宜添加することもできる。これらの繊維基材や金属粉末は、１種のみを単独で使用してもよく、２種以上を混合して使用してもよいが、無機繊維と有機繊維とを併用することが好ましい。無機繊維は耐熱性や耐摩耗性が良好であり、金属繊維であれば放熱性も良好である。有機繊維は充填材などの保持力が良好であり各成分の均一分散性が向上する。無機繊維と有機繊維とを併用することで、これらの特性を同時に得られる。繊維基材の配合量としては、摩擦材全体に対して５〜３０ｖｏｌ％（体積％）程度とすればよい。繊維基材が５ｖｏｌ％未満であると、摩擦材の機械的強度が低下する。繊維基材が３０ｖｏｌ％を超えると、耐摩耗性が低下すると共に、他の充填物等の配合割合が減少して摩擦係数等の各種性能も悪化する。好ましくは１０〜２５ｖｏｌ％、より好ましくは１０〜１５ｖｏｌ％である。なお、無機繊維と有機繊維とを併用する場合は、有機繊維の配合割合に対して無機繊維の配合割合を多くしておくことが好ましい。有機繊維の配合割合の方が多くなると高温域において分解ガスの発生量が増え、フェード時の摩擦係数が低下し易くなる。好ましくは、無機繊維の配合割合に対して、有機繊維の配合割合を半分以下にする。 [Fiber base]
A fiber base material will not be specifically limited if it is conventionally used as a NAO material, Various inorganic fiber and organic fiber can be used. Inorganic fibers include metal fibers such as steel fibers and copper fibers, ceramic fibers such as potassium titanate fibers, carbon fibers, and glass fibers. Examples of the organic fibers include synthetic resin fibers such as aramid fibers, polyester fibers, and kao wool fibers, and natural fibers such as pulp. Among these, steel fibers are preferable as the inorganic fibers, and aramid fibers are preferable as the organic fibers. Moreover, metal powders, such as bronze, brass, copper, can also be added suitably as a filler which comprises a base material auxiliary. These fiber base materials and metal powders may be used alone or in combination of two or more, but it is preferable to use inorganic fibers and organic fibers in combination. Inorganic fibers have good heat resistance and wear resistance, and metal fibers have good heat dissipation. Organic fibers have good holding power for fillers and the like, and improve the uniform dispersibility of each component. By using the inorganic fiber and the organic fiber in combination, these characteristics can be obtained at the same time. What is necessary is just to set it as about 5-30 vol% (volume%) with respect to the whole friction material as a compounding quantity of a fiber base material. When the fiber base material is less than 5 vol%, the mechanical strength of the friction material is lowered. When the fiber substrate exceeds 30 vol%, the wear resistance is lowered, and the blending ratio of other fillers is reduced, and various performances such as a friction coefficient are deteriorated. Preferably it is 10-25 vol%, More preferably, it is 10-15 vol%. In addition, when using together an inorganic fiber and an organic fiber, it is preferable to increase the mixture ratio of an inorganic fiber with respect to the mixture ratio of an organic fiber. If the blending ratio of the organic fiber is increased, the generation amount of the decomposition gas is increased at a high temperature range, and the friction coefficient at the time of fading is easily lowered. Preferably, the blending ratio of the organic fiber is made half or less with respect to the blending ratio of the inorganic fiber.

［結合剤］
結合剤は、繊維基材と充填材とを結着させるものであって、従来からＮＡＯ材の結合剤として使用されている各種熱硬化性の合成樹脂やゴムが使用できる。熱硬化性樹脂としては、例えばフェノール樹脂，イミド樹脂，ゴム変性フェノール樹脂，メラミン樹脂，エポキシ樹脂などが挙げられる。ゴムとしては、ＮＢＲ，ニトリルゴム，アクリルゴムなどを挙げられる。中でも、耐熱性が良好なフェノール樹脂が好適である。これらの結合剤は、１種を単独で使用することもできるし、２種以上を組み合せて使用することもできる。結合剤の配合量は、摩擦材全体に対して５〜３０ｖｏｌ％程度とすればよい。結合剤の主な機能は、摩擦材の機械的強度を維持することにある。したがって、結合剤の配合量が５ｖｏｌ％未満であると、摩擦材の強度が低くなって耐摩耗性が低下する。一方、結合剤の配合量が３０ｖｏｌ％を超えると、高温時に分解がすすんでフェード時の摩擦係数が低下し易くなる。好ましくは１０〜２５ｖｏｌ％、より好ましくは１５〜２０ｖｏｌ％である。 [Binder]
The binder binds the fiber base and the filler, and various thermosetting synthetic resins and rubbers conventionally used as a binder for NAO materials can be used. Examples of the thermosetting resin include phenol resin, imide resin, rubber-modified phenol resin, melamine resin, and epoxy resin. Examples of rubber include NBR, nitrile rubber, and acrylic rubber. Among them, a phenol resin having good heat resistance is preferable. These binders can also be used individually by 1 type, and can also be used in combination of 2 or more type. What is necessary is just to let the compounding quantity of a binder be about 5-30 vol% with respect to the whole friction material. The main function of the binder is to maintain the mechanical strength of the friction material. Therefore, when the compounding amount of the binder is less than 5 vol%, the strength of the friction material is lowered and the wear resistance is lowered. On the other hand, when the compounding amount of the binder exceeds 30 vol%, decomposition proceeds at a high temperature, and the friction coefficient at the time of fading tends to decrease. Preferably it is 10-25 vol%, More preferably, it is 15-20 vol%.

［潤滑材］
潤滑材は、摩擦材がディスクロータ等の相手材と摺接することで両者が摩耗することを低減する機能を有する。潤滑材としては、例えば、二硫化モリブデン、三硫化アンチモン、硫化スズ、二硫化亜鉛、硫化鉄、硫化鉛等の金属硫化物や、粒状黒鉛（グラファイト）、窒化ホウ素などを適宜使用できる。これら潤滑材は、１種のみを単独で使用してもよく、２種以上を混合して使用してもよい。粒状黒鉛の配合により、概ね１００℃未満の低温域から１００〜２００℃程度の一般使用温度域において良好な潤滑性（耐摩耗性、及び相手攻撃性）を担保できる。黒鉛は、一般的に平均粒子径（メジアン径）が４０〜１００μｍ程度の粒状黒鉛が使用されるが、平均粒子径が１０００μｍ以上の粗粒黒鉛を使用することもできる。平均粒子径が大きくなる程、耐熱温度も上昇する傾向がある。金属硫化物は融点が高く、高温域でも良好な潤滑性を発揮する。つまり、摩擦材が高温となることでこれらが軟化若しくは溶融し、摩擦材と相手材との間で保護膜を形成する。したがって、広い温度域において良好な潤滑性を担保するためには、粒状黒鉛と金属硫化物とを併用することが好ましい。 [Lubricant]
The lubricant has a function of reducing wear of the friction material due to sliding contact with a mating material such as a disk rotor. As the lubricant, for example, metal sulfides such as molybdenum disulfide, antimony trisulfide, tin sulfide, zinc disulfide, iron sulfide, lead sulfide, granular graphite (graphite), boron nitride, and the like can be used as appropriate. These lubricants may be used alone or in combination of two or more. By blending the granular graphite, good lubricity (abrasion resistance and opponent attack) can be ensured in a general use temperature range of approximately 100 to 200 ° C. from a low temperature range of approximately less than 100 ° C. As the graphite, granular graphite having an average particle diameter (median diameter) of about 40 to 100 μm is generally used, but coarse graphite having an average particle diameter of 1000 μm or more can also be used. As the average particle size increases, the heat resistant temperature tends to increase. Metal sulfides have a high melting point and exhibit good lubricity even at high temperatures. That is, when the friction material becomes high temperature, they are softened or melted, and a protective film is formed between the friction material and the counterpart material. Therefore, in order to ensure good lubricity in a wide temperature range, it is preferable to use granular graphite and metal sulfide in combination.

潤滑材全体の配合量は、摩擦材全体に対して３〜３０ｖｏｌ％程度とすればよい。潤滑材の配合量が３ｖｏｌ％未満であると、摩擦材の耐摩耗性が低下すると共に、相手材への攻撃性が増大する。潤滑材の配合量が３０ｖｏｌ％を超えると、良好な摩擦係数を得られないばかりか摩擦材強度が著しく低下し、摺動負荷に耐えられなくなる。好ましくは１０〜３０ｖｏｌ％、より好ましくは１５〜２５ｖｏｌ％である。   What is necessary is just to let the compounding quantity of the whole lubricant be about 3-30 vol% with respect to the whole friction material. When the blending amount of the lubricant is less than 3 vol%, the wear resistance of the friction material is lowered, and the attacking property to the counterpart material is increased. When the blending amount of the lubricant exceeds 30 vol%, not only a good friction coefficient can be obtained, but also the friction material strength is remarkably lowered and the sliding load cannot be endured. Preferably it is 10-30 vol%, More preferably, it is 15-25 vol%.

［充填材］
充填材は、主に潤滑材や繊維基材による各種性能を効果的に発揮できるよう調整するために配合されるものである。例えば、氷晶石のほか、カシューダスト，レジンダスト，ラバーダスト等の有機ダスト、珪酸カルシウム，ドロマイト，硫酸カルシウム，炭酸カルシウム，水酸化カルシウム等のＣａＯ化合物、チタン酸アルカリ金属塩，チタン酸アルカリ金属・第２属元素塩等のチタン酸化物、酸化鉄、雲母（マイカ）、カオリン、タルク、ゾノトライト、バーミキュライトなどを挙げられる。これら充填材は、１種のみを単独で使用してもよく、２種以上を混合して使用してもよい。 [Filler]
The filler is blended in order to adjust so that various performances mainly by the lubricant and the fiber base material can be effectively exhibited. For example, in addition to cryolite, organic dust such as cashew dust, resin dust, rubber dust, CaO compounds such as calcium silicate, dolomite, calcium sulfate, calcium carbonate, calcium hydroxide, alkali metal titanate, alkali metal titanate -Titanium oxides such as Group 2 element salts, iron oxides, mica (mica), kaolin, talc, zonotlite, vermiculite, etc. These fillers may be used alone or in combination of two or more.

さらに、充填材の１つとして研削材（アブレシブ材）がある。研削材は、主としてディスクロータ等の相手材表面の付着物（摩擦材成分や相手材の酸化膜）を除去する機能を有する。これにより、潤滑材の機能が良好に発揮される。研削材としては、アルミナ，酸化ジルコニウム，珪酸ジルコニウム，酸化マグネシウムなどを挙げることができる。これら研削材も、１種のみを単独で使用してもよく、２種以上を混合して使用してもよい。但し、相手材表面自体を傷つけないように、相手材の材料に応じて相手材の硬度（モース硬度）よりも硬度の低いものを選択することが好ましい。相手材表面を傷つけることなく相手材表面に移着した付着物を除去することができれば、良好な摩擦係数を得ることができると共に、摩擦材自身の摩耗量も少なくすることができる。   Furthermore, there is an abrasive (abrasive material) as one of the fillers. The abrasive mainly has a function of removing deposits (friction material components and an oxide film of the counterpart material) on the surface of the counterpart material such as a disk rotor. Thereby, the function of a lubricant is exhibited satisfactorily. Examples of the abrasive include alumina, zirconium oxide, zirconium silicate, magnesium oxide and the like. These abrasives may also be used alone or in combination of two or more. However, it is preferable to select a material whose hardness is lower than the hardness (Mohs' hardness) of the counterpart material according to the material of the counterpart material so as not to damage the counterpart material surface itself. If the deposits transferred to the surface of the counterpart material can be removed without damaging the surface of the counterpart material, a good coefficient of friction can be obtained and the wear amount of the friction material itself can be reduced.

そして、本発明で最も大きな特徴として、ピロリン酸カルシウム（Ｃａ２Ｐ２Ｏ７）を配合している。ピロリン酸カルシウムを配合していることで、氷晶石が溶着し得るような高温域におけるフェード時でも、摩擦材に圧力を作用させ相手材と密着させた状態を保持した後に摩擦材への加圧を除去しても、摩擦材の表層部が剥離して相手材の表面に貼り付くことがなくなる。この理由は必ずしも明らかではないが、ピロリン酸カルシウムによって氷晶石の溶融が阻害されるか、溶融した氷晶石がピロリン酸カルシウムと反応して相手材への溶着力が低減するからと考えられる。 And as a biggest feature in the present invention, calcium pyrophosphate (Ca 2 P 2 O 7 ) is blended. By adding calcium pyrophosphate, pressure is applied to the friction material after maintaining the state in which the friction material is pressured and kept in close contact with the mating material even when fading in a high temperature range where cryolite can be deposited. Even if it removes, the surface layer part of a friction material does not peel and stick to the surface of a counterpart material. The reason for this is not necessarily clear, but it is thought that the melting of cryolite is inhibited by calcium pyrophosphate, or the molten cryolite reacts with calcium pyrophosphate to reduce the welding power to the counterpart material.

『氷晶石の配合割合は、摩擦材全体に対して３〜５ｖｏｌ％とする。上述のように、氷晶石は本発明で必須成分のピロリン酸カルシウムとの相関作用により優れた特性を有するものであり、ピロリン酸カルシウムの配合量との関係から、上記範囲を逸脱すると摩擦係数が低下したり高温域でのフェード後に摩擦材が相手材に貼り付くことを回避できなくなる。具体的には、氷晶石の配合割合が３ｖｏｌ％未満であると、フェード時の摩擦係数が低下する。一方、氷晶石の配合割合が５ｖｏｌ％を超えると、ピロリン酸カルシウムの影響が小さくなるので、摩擦材の貼り付き防止機能が損なわれる。（段落００１６から移動）』ピロリン酸カルシウムの配合割合は、氷晶石の配合割合との相関関係から、摩擦材全体に対して４〜６ｖｏｌ％とする。ピロリン酸カルシウムの配合割合が４ｖｏｌ％未満であると、摩擦材の貼り付きが発生する。一方、ピロリン酸カルシウムの配合割合が６ｖｏｌ％を超えていると、摩擦材の貼り付きは防止できるがフェード時の摩擦係数が低減する。これら氷晶石及びピロリン酸カルシウムを含む各種充填材は、上記繊維基材、潤滑材、結合剤の配合割合に応じて、求められる摩擦係数、耐摩耗性、耐熱性、相手攻撃性等の各種性能を考慮しながら適宜調整すればよいが、目安としては概ね３０〜７０ｖｏｌ％の範囲で上記繊維基材等の各配合物を含めて全体で１００ｖｏｌ％となるようにすればよい。好ましくは４０〜６５ｖｏｌ％であり、より好ましくは５０〜６０ｖｏｌ％である。   “The blending ratio of cryolite is 3 to 5 vol% with respect to the entire friction material. As described above, cryolite has excellent characteristics due to the correlation with the essential component calcium pyrophosphate in the present invention. From the relationship with the amount of calcium pyrophosphate, the coefficient of friction decreases when it deviates from the above range. It becomes impossible to avoid the friction material sticking to the counterpart material after fading or fading in a high temperature range. Specifically, when the blending ratio of cryolite is less than 3 vol%, the friction coefficient at the time of fading decreases. On the other hand, when the blending ratio of cryolite exceeds 5 vol%, the effect of calcium pyrophosphate is reduced, so that the function of preventing the sticking of the friction material is impaired. (Move from paragraph 0016)] The blending ratio of calcium pyrophosphate is 4 to 6 vol% with respect to the entire friction material from the correlation with the blending ratio of cryolite. If the blending ratio of calcium pyrophosphate is less than 4 vol%, sticking of the friction material occurs. On the other hand, when the blending ratio of calcium pyrophosphate exceeds 6 vol%, sticking of the friction material can be prevented, but the friction coefficient during fading is reduced. The various fillers containing cryolite and calcium pyrophosphate have various performances such as coefficient of friction, wear resistance, heat resistance, opponent attack, etc. required depending on the mixing ratio of the fiber base material, lubricant, and binder. However, as a guideline, it may be adjusted to 100 vol% in total, including each compound such as the fiber base material, in the range of approximately 30 to 70 vol%. Preferably it is 40-65 vol%, More preferably, it is 50-60 vol%.

このように、本発明の摩擦材は繊維基材、潤滑材、充填材、結合剤を含有するが、摩擦材全体の組成としては、無機成分を主体とするように調整することが好ましい。無機成分が主体となっていれば、有機物由来の分解ガス発生量が低減し、フェード時の摩擦係数低下を低減できる。摩擦材全体に対する有機成分の配合量は、少なくとも５０ｖｏｌ％未満とし、４０ｖｏｌ％以下が好ましく、３０ｖｏｌ％以下がより好ましい。   Thus, although the friction material of this invention contains a fiber base material, a lubricant, a filler, and a binder, it is preferable to adjust so that a composition of the whole friction material may mainly contain an inorganic component. If the inorganic component is the main component, the generation amount of decomposition gas derived from organic substances can be reduced, and the reduction in friction coefficient during fading can be reduced. The blending amount of the organic component with respect to the entire friction material is at least less than 50 vol%, preferably 40 vol% or less, and more preferably 30 vol% or less.

［製造方法］
摩擦材は、例えば周知のモールド法などによって製造できる。具体的には、繊維基材、潤滑材などの各配合物をミキサー等で十分に混合し、加圧型中に入れて常温で予備成形する。次いで、予備成形体をホットプレスし、その後熱処理することで得られる。予備成形やホットプレス時の圧力は１０〜１００ＭＰａ程度とすればよい。ホットプレス温度は１３０〜２００℃程度である。また、熱処理は、１５０〜４００℃程度で２〜４８時間程度である。ミキサーとしては、アイリッヒミキサー，ユニバーサルミキサー，レーディゲミキサーなどを利用することができる。 [Production method]
The friction material can be manufactured by, for example, a known molding method. Specifically, each compound such as a fiber base material and a lubricant is sufficiently mixed with a mixer or the like, placed in a pressure mold, and preformed at room temperature. Next, the preform is obtained by hot pressing, followed by heat treatment. The pressure at the time of preforming or hot pressing may be about 10 to 100 MPa. Hot press temperature is about 130-200 degreeC. The heat treatment is performed at about 150 to 400 ° C. for about 2 to 48 hours. As the mixer, an Eirich mixer, a universal mixer, a Ladige mixer, or the like can be used.

（実施例）
表１〜６の組成表に示されるように、ピロリン酸カルシウム及び氷晶石の配合割合のみを段階的に変化させた摩擦材１〜４２を製造し、これらにおけるフェード時の摩擦係数（μ）と相手材への貼り付きの有無を評価した。なお、表１〜６中の数字はｖｏｌ％である。また、各摩擦材における結果を比較対比し易いよう纏めたものを表７に示す。 (Example)
As shown in the composition tables of Tables 1 to 6, friction materials 1 to 42 in which only the blending ratio of calcium pyrophosphate and cryolite was changed in stages were manufactured, and the friction coefficient (μ) at the time of fading in these The presence or absence of sticking to the counterpart material was evaluated. In addition, the number in Tables 1-6 is vol%. Table 7 shows a summary of the results for each friction material so that they can be easily compared.

各摩擦材は次のようにして製造した。各種配合物をアイリッヒミキサーによって５分間乾式にて混合することで原料混合物を得た。この原料混合物を成形温度１６０℃、成形圧力２０ＭＰａ、成形時間１０分の条件において加熱加圧し成形した。最後に、この成形物を２３０℃、３時間の条件において硬化させ、１３０ｍｍ×４８ｍｍ×１２ｍｍの摩擦材を得た。なお、各表中金属硫化物としては、二硫化モリブデン，三硫化アンチモン，硫化スズを混合使用した。有機ダストとしてはカシューダスト及びラバーダストを混合使用した。無機添加物としては、黄銅，青銅，銅を混合使用した。研削材としては、アルミナ，酸化ジルコニウム，珪酸ジルコニウムを混合使用した。   Each friction material was manufactured as follows. Various blends were mixed in a dry process for 5 minutes by an Eirich mixer to obtain a raw material mixture. This raw material mixture was heated and pressed under the conditions of a molding temperature of 160 ° C., a molding pressure of 20 MPa, and a molding time of 10 minutes. Finally, this molded product was cured at 230 ° C. for 3 hours to obtain a friction material of 130 mm × 48 mm × 12 mm. In each table, molybdenum disulfide, antimony trisulfide, and tin sulfide were mixed and used as the metal sulfide. As organic dust, cashew dust and rubber dust were mixed and used. As the inorganic additive, brass, bronze, and copper were mixed and used. As the abrasive, alumina, zirconium oxide and zirconium silicate were mixed and used.

各評価方法は次の通りである。
＜フェード（摩擦係数）試験＞
ＪＡＳＯ Ｃ４０６の摺り合わせと、第１フェードのみの組み合わせで実施した。
摺り合わせ：２００回
フェード１０回目：温度ＭＡＸ６５０℃
減速度９ｍ／ｓ２、インターバル無し
判定基準：○；摩擦係数０．３μ以上 ×；摩擦係数０．３μ未満
＜貼り付き＞
フェード試験の１０回目において、停止時に摩擦材へ圧力９ＭＰａを作用させたまま３分間保持した。その後圧力を解除してロータを再始動させ、ロータへの貼り付きの有無を目視にて確認した。
判定基準：○；貼り付き無し ×；貼り付き有り Each evaluation method is as follows.
<Fade (coefficient of friction) test>
It was carried out by combining JASO C406 and only the first fade.
Sliding: 200 times Fade 10th time: Temperature MAX650 ° C
Deceleration 9 m / s 2 , no interval Judgment criteria: ◯; Friction coefficient 0.3 μ or more ×; Friction coefficient less than 0.3 μ
In the 10th fade test, the friction material was held at a pressure of 9 MPa for 3 minutes when stopped. Thereafter, the pressure was released and the rotor was restarted, and the presence or absence of sticking to the rotor was visually confirmed.
Judgment criteria: ○: No sticking ×: With sticking

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Figure 2009132816

表７に纏めた結果より、氷晶石が３ｖｏｌ％未満ではフェード時の摩擦係数が低い。逆に、氷晶石が６ｖｏｌ％以上であっても、ピロリン酸カルシウムの配合量が多いとフェード時の摩擦係数が低く成る傾向にあることがわかった（摩擦材３５、４２）。また、氷晶石の配合量が増加するにつれて、貼り付きが発生し易い傾向にあることもわかる。一方、ピロリン酸カルシウムの配合量を増やすにつれて、有意に貼り付きを防止できる傾向にあることがわかる。しかし、ピロリン酸カルシウムの配合量が７ｖｏｌ％以上では、フェード時の摩擦係数が低下してしまうことがわかった。ピロリン酸カルシウムの配合量が４〜６ｖｏｌ％であり、かつ氷晶石の配合量が３〜５ｖｏｌ％であれば、フェード時の摩擦係数が良好でありながら摩擦材の張り付きも発生しないことがわかった。つまり、この条件を満たす、摩擦材１８〜２０、２５〜２７、３２〜３４が、本発明に係る実施例となる。
From the results summarized in Table 7, the coefficient of friction during fading is low when cryolite is less than 3 vol%. On the contrary, it was found that even if the cryolite is 6 vol% or more, the friction coefficient at the time of fading tends to be low when the amount of calcium pyrophosphate is large (friction materials 35 and 42). It can also be seen that sticking tends to occur as the amount of cryolite increases. On the other hand, it turns out that it exists in the tendency which can prevent sticking significantly as the compounding quantity of calcium pyrophosphate is increased. However, it was found that when the blending amount of calcium pyrophosphate is 7 vol% or more, the friction coefficient at the time of fading decreases. It was found that when the blending amount of calcium pyrophosphate is 4 to 6 vol% and the blending amount of cryolite is 3 to 5 vol%, the friction coefficient at the time of fading is good, but the sticking of the friction material does not occur. . That is, the friction materials 18 to 20, 25 to 27, and 32 to 34 that satisfy this condition are examples according to the present invention.

Claims (3)

繊維基材と、結合剤と、潤滑材と、その他の充填材とからなる無石綿摩擦材において、
前記充填材としてピロリン酸カルシウムを含有することを特徴とする無石綿摩擦材 In asbestos friction material consisting of fiber base material, binder, lubricant, and other fillers,
Asbestos-free friction material containing calcium pyrophosphate as the filler さらに前記充填材として、氷晶石を含有する請求項１に記載の摩擦材。   The friction material according to claim 1, further comprising cryolite as the filler. 前記ピロリン酸カルシウムを４〜６ｖｏｌ％含有し、
前記氷晶石を３〜５ｖｏｌ％含有する、請求項２に記載の摩擦材。

Containing 4 to 6 vol% of the calcium pyrophosphate,
The friction material according to claim 2, containing 3 to 5 vol% of cryolite.

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