JP2013163714A - Friction material - Google Patents
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- JP2013163714A JP2013163714A JP2012026368A JP2012026368A JP2013163714A JP 2013163714 A JP2013163714 A JP 2013163714A JP 2012026368 A JP2012026368 A JP 2012026368A JP 2012026368 A JP2012026368 A JP 2012026368A JP 2013163714 A JP2013163714 A JP 2013163714A
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- 239000002783 friction material Substances 0.000 title claims abstract description 73
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 52
- 239000002245 particle Substances 0.000 claims abstract description 38
- 239000000203 mixture Substances 0.000 claims abstract description 27
- 239000000835 fiber Substances 0.000 claims abstract description 23
- 238000000465 moulding Methods 0.000 claims abstract description 17
- 239000011230 binding agent Substances 0.000 claims abstract description 15
- 239000000463 material Substances 0.000 claims abstract description 15
- 239000012535 impurity Substances 0.000 claims abstract description 7
- 230000007704 transition Effects 0.000 claims abstract description 7
- 239000003607 modifier Substances 0.000 claims description 14
- 230000002159 abnormal effect Effects 0.000 abstract description 6
- 238000000034 method Methods 0.000 description 13
- 229920005989 resin Polymers 0.000 description 7
- 239000011347 resin Substances 0.000 description 7
- 229920001971 elastomer Polymers 0.000 description 5
- 239000000945 filler Substances 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 229920001187 thermosetting polymer Polymers 0.000 description 5
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 4
- 238000005299 abrasion Methods 0.000 description 4
- 239000000314 lubricant Substances 0.000 description 4
- 239000002994 raw material Substances 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 239000003082 abrasive agent Substances 0.000 description 3
- 238000001354 calcination Methods 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000012784 inorganic fiber Substances 0.000 description 3
- 239000011256 inorganic filler Substances 0.000 description 3
- 229910003475 inorganic filler Inorganic materials 0.000 description 3
- 239000010954 inorganic particle Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000002923 metal particle Substances 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 239000000806 elastomer Substances 0.000 description 2
- 239000008187 granular material Substances 0.000 description 2
- 239000012766 organic filler Substances 0.000 description 2
- 229920002972 Acrylic fiber Polymers 0.000 description 1
- 244000226021 Anacardium occidentale Species 0.000 description 1
- 229910001369 Brass Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 235000019492 Cashew oil Nutrition 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 241000357293 Leptobrama muelleri Species 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 229910001570 bauxite Inorganic materials 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- 239000000920 calcium hydroxide Substances 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 235000020226 cashew nut Nutrition 0.000 description 1
- 229940059459 cashew oil Drugs 0.000 description 1
- 239000010467 cashew oil Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- -1 etc. Polymers 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 229920002313 fluoropolymer Polymers 0.000 description 1
- 239000004811 fluoropolymer Substances 0.000 description 1
- 238000005469 granulation Methods 0.000 description 1
- 230000003179 granulation Effects 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910052976 metal sulfide Inorganic materials 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 239000011490 mineral wool Substances 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 238000007517 polishing process Methods 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 238000011417 postcuring Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 229920002545 silicone oil Polymers 0.000 description 1
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 1
- 229910001948 sodium oxide Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 238000003856 thermoforming Methods 0.000 description 1
- 239000010455 vermiculite Substances 0.000 description 1
- 229910052902 vermiculite Inorganic materials 0.000 description 1
- 235000019354 vermiculite Nutrition 0.000 description 1
- 239000004636 vulcanized rubber Substances 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 1
Abstract
Description
本発明は、自動車等のディスクブレーキパッド、ブレーキシューに使用される摩擦材に関する。 The present invention relates to a friction material used for a disc brake pad and a brake shoe of an automobile or the like.
従来、自動車の制動装置として、ディスクブレーキ、ドラムブレーキが使用されており、その摩擦部材として、鋼鉄等の金属製のベース部材に摩擦材が貼り付けられたディスクブレーキパッド、ブレーキシューが使用されている。 Conventionally, disc brakes and drum brakes are used as braking devices for automobiles, and disc brake pads and brake shoes in which a friction material is bonded to a metal base member such as steel are used as friction members. Yes.
摩擦材は、金属繊維、有機繊維、無機繊維等の繊維基材、熱硬化性樹脂等の結合材、有機充填材、無機充填材、無機研削材、潤滑剤および金属粒子等の摩擦調整材から成る摩擦材組成物を成型したものである。 Friction materials include fiber base materials such as metal fibers, organic fibers and inorganic fibers, binders such as thermosetting resins, organic fillers, inorganic fillers, inorganic abrasives, friction modifiers such as lubricants and metal particles. This friction material composition is molded.
摩擦材には、充分な制動力を得るために無機研削材として硬質の無機粒子が添加される場合がある。その中でもアルミナ粒子は適度な硬さを有しており、摩擦材に少量添加することで充分な制動力を得ることができることから広く使用されている。 In order to obtain a sufficient braking force, the friction material may be added with hard inorganic particles as an inorganic abrasive. Among them, alumina particles have an appropriate hardness and are widely used because a sufficient braking force can be obtained by adding a small amount to a friction material.
特許文献１には繊維成分と結合材と充填材とを含有してなる非石綿系摩擦材において、前記充填材として凝集アルミナを含有することを特徴とする摩擦材が記載されている。 Patent Document 1 describes a friction material characterized in that a non-asbestos-based friction material containing a fiber component, a binder, and a filler contains agglomerated alumina as the filler.
特許文献２には繊維材、潤滑材、摩擦調整材、及び充填材等に結合材を配合して得られるブレーキ摩擦材において、前記摩擦調整材の少なくとも一部に、結晶が凝集して平均粒径３０〜１００μｍの凝集体を形成するアルミナ粉を用いたブレーキ摩擦材が記載されている。 Patent Document 2 discloses a brake friction material obtained by blending a binder with a fiber material, a lubricant, a friction modifier, a filler, and the like. A brake friction material using alumina powder forming an aggregate having a diameter of 30 to 100 μm is described.
特許文献３には粒径１〜１０μｍで真球度が０．９５〜１の球状アルミナ粒子を３〜７体積％含む乗用車用ディスクパッド材が記載されている。 Patent Document 3 describes a disk pad material for a passenger car containing 3 to 7% by volume of spherical alumina particles having a particle diameter of 1 to 10 μm and a sphericity of 0.95 to 1.
特許文献４には、繊維基材、結合材、充填材、硬質無機粒子を主成分とする摩擦材組成物を成形、硬化してなる摩擦材において、該硬質無機粒子として一次結晶アルミナが二次凝集した凝集アルミナを湿式粉砕して作った粉砕凝集アルミナを含有する摩擦材が記載されている。 In Patent Document 4, in a friction material obtained by molding and curing a friction material composition mainly composed of a fiber base material, a binder, a filler, and hard inorganic particles, primary crystalline alumina is secondary as the hard inorganic particles. A friction material containing pulverized and aggregated alumina made by wet pulverization of aggregated and aggregated alumina is described.
しかし、充分な制動力を得るに足りる量のアルミナ粒子を摩擦材に添加すると、相手材であるローターの表面に線状痕が形成され、その結果、ローターと摩擦材が局所的に摺動し、摩擦材が異常摩耗する他、ブレーキ鳴きが発生しやすくなるという問題が生じる。 However, when an amount of alumina particles sufficient to obtain a sufficient braking force is added to the friction material, linear marks are formed on the surface of the rotor, which is the counterpart material, and as a result, the rotor and the friction material slide locally. In addition to abnormal wear of the friction material, problems arise that brake noise is likely to occur.
繊維基材と結合材と摩擦調整材とから成る摩擦材組成物を成型してなる摩擦材において、充分な制動力を有するとともに、摩擦材の異常摩耗が無く、且つ、ブレーキ鳴きの発生が少ない摩擦材を提供することを目的とする。 In a friction material formed by molding a friction material composition comprising a fiber base material, a binder, and a friction modifier, the friction material has sufficient braking force, there is no abnormal wear of the friction material, and there is little occurrence of brake squealing The object is to provide a friction material.
アルミナ粒子として、バイヤー法によりボーキサイトから水酸化アルミニウムを析出させ、ロータリーキルンで仮焼することにより製造された仮焼アルミナ粒子と、仮焼アルミナ粒子を電気炉で溶融し凝固させた塊を粉砕整粒した溶融アルミナ粒子が知られている。 As alumina particles, aluminum hydroxide is precipitated from bauxite by the Bayer method, and calcined alumina particles produced by calcining in a rotary kiln and lumps obtained by melting and solidifying calcined alumina particles in an electric furnace are pulverized and sized. Fused alumina particles are known.
通常、摩擦材の研削材として使用されているのは、化学的に安定で機械的強度が高いコランダム構造を有するα型の溶融アルミナ粒子、または、αアルミナの含有率が高い仮焼アルミナ粒子であるが、仮焼アルミナのうち仮焼の中間段階のもの、即ち、特定量のαアルミナと残部が遷移アルミナと不可避不純物から成る仮焼アルミナ粒子を使用すると、充分な制動力が得られるとともに、摩擦材の異常摩耗の原因となる相手材の摺動面の線状痕の形成が抑制され、且つ、ブレーキ鳴きの発生が少なくなることを知見し、本発明を完成させるに至った。 Usually, abrasive materials for friction materials are α-type fused alumina particles having a corundum structure that is chemically stable and high in mechanical strength, or calcined alumina particles having a high α-alumina content. However, among the calcined alumina, when using calcined alumina particles of intermediate stage of calcining, that is, calcined alumina particles whose specific amount of α alumina and the balance are transition alumina and unavoidable impurities, sufficient braking force is obtained, The inventors have found that the formation of linear traces on the sliding surface of the mating material that causes abnormal wear of the friction material is suppressed, and the occurrence of brake squealing is reduced, and the present invention has been completed.
本発明は、繊維基材と結合材と摩擦調整材とから成る摩擦材組成物を成型した摩擦材において、摩擦調整材として特定量のαアルミナと、残部が遷移アルミナと不可避不純物から成る仮焼アルミナ粒子を摩擦材組成物に特定量配合するものであって、以下の技術を基礎とするものである。 The present invention relates to a friction material obtained by molding a friction material composition comprising a fiber base material, a binder, and a friction modifier, and a calcined product comprising a specific amount of α-alumina as the friction modifier, the balance being transition alumina and inevitable impurities. A specific amount of alumina particles is blended in the friction material composition and is based on the following technique.
（１）繊維基材と結合材と摩擦調整材とから成る摩擦材組成物を成型してなる摩擦材において、摩擦調整材として、αアルミナを７０〜９５重量％含有し、残部として遷移アルミナと不可避不純物を含有する仮焼アルミナ粒子を摩擦材組成物全量に対し０．２〜５．０重量％含有する摩擦材。 (1) In a friction material formed by molding a friction material composition comprising a fiber base material, a binder, and a friction modifier, as a friction modifier, α-alumina is contained in an amount of 70 to 95% by weight, and the balance is transition alumina. A friction material containing calcined alumina particles containing inevitable impurities in an amount of 0.2 to 5.0% by weight based on the total amount of the friction material composition.
（２）仮焼アルミナ粒子は平均粒子径が３〜６０μｍである（１）の摩擦材。 (2) The friction material according to (1), wherein the calcined alumina particles have an average particle diameter of 3 to 60 μm.
本発明によれば、摩擦材組成物を成型した摩擦材において、充分な制動力を有するとともに、摩擦材の異常摩耗が無く、且つ、ブレーキ鳴きの発生が少ない摩擦材を提供できる。 ADVANTAGE OF THE INVENTION According to this invention, in the friction material which shape | molded the friction material composition, while having sufficient braking force, there is no abnormal wear of a friction material, and a friction material with little generation | occurrence | production of a brake squeal can be provided.
本発明においては、摩擦材組成物を成型してなる摩擦材において、αアルミナを７０〜９５重量％含有し、残部として遷移アルミナと不可避不純物を含有する仮焼アルミナ粒子を摩擦材組成物全量に対し０．２〜５．０重量％配合する。
仮焼アルミナ粒子の配合量が摩擦材組成物全量に対し０．２重量％未満であると、充分な制動力を得ることができず、仮焼アルミナ粒子の配合量が摩擦材組成物全量に対し５．０重量％を超えると、ブレーキ鳴きが発生しやすくなる。
In the present invention, in the friction material formed by molding the friction material composition, α-alumina is contained in an amount of 70 to 95% by weight, and the balance is calcined alumina particles containing transition alumina and inevitable impurities in the total amount of the friction material composition. In contrast, 0.2 to 5.0% by weight is blended.
If the amount of the calcined alumina particles is less than 0.2% by weight based on the total amount of the friction material composition, a sufficient braking force cannot be obtained, and the amount of the calcined alumina particles becomes the total amount of the friction material composition. On the other hand, if it exceeds 5.0% by weight, brake squealing is likely to occur.
なお、本発明において、遷移アルミナとはαアルミナ以外のγアルミナ、δアルミナ、θアルミナを意味し、不可避不純物とは仮焼アルミナの製造過程でごく微量残留する、摩擦材の性能に影響を与えない物質を意味するものであり、酸化ナトリウム、酸化鉄等が挙げられる。 In the present invention, transition alumina means γ-alumina other than α-alumina, δ-alumina, and θ-alumina, and unavoidable impurities affect the performance of the friction material, which remains in a very small amount during the production of calcined alumina. Which means no substances such as sodium oxide and iron oxide.
また、本発明の摩擦材組成物に配合する仮焼アルミナ粒子の平均粒子径は３〜６０μｍであることが好ましい。
仮焼アルミナ粒子の平均粒子径が３μｍ未満であると、制動力が低下しやすくなり、仮焼アルミナの平均粒子径が６０μｍを超えると、ブレーキ鳴きが発生しやすくなる。
なお、本発明においては、平均粒子径として、レーザー回折粒度分布法により測定した５０％粒径の数値を用いた。
Moreover, it is preferable that the average particle diameter of the calcination alumina particle | grains mix | blended with the friction material composition of this invention is 3-60 micrometers.
When the average particle diameter of the calcined alumina particles is less than 3 μm, the braking force tends to decrease, and when the average particle diameter of the calcined alumina exceeds 60 μm, brake squeal is likely to occur.
In the present invention, a numerical value of 50% particle diameter measured by the laser diffraction particle size distribution method was used as the average particle diameter.
また、本発明の摩擦材は、上記仮焼アルミナの他に、通常の摩擦材に使用される金属繊維、有機繊維、無機繊維等の繊維基材、熱硬化性樹脂等の結合材と、有機充填材、無機充填材、無機研削材、潤滑剤および金属粒子等の摩擦調整材とを含む摩擦材組成物から成る。 In addition to the calcined alumina, the friction material of the present invention includes metal substrates, organic fibers, inorganic fibers and other fiber base materials used in ordinary friction materials, binders such as thermosetting resins, and organic materials. The friction material composition includes a filler, an inorganic filler, an inorganic abrasive, a lubricant, and a friction modifier such as metal particles.
繊維基材としては、スチール繊維、ステンレススチール繊維、銅繊維、真鍮繊維等の金属繊維、アラミド繊維、アクリル繊維等の有機繊維、カーボン繊維、セラミック繊維、ロックウール等の無機繊維が挙げられる。繊維基材の含有量は、充分な機械強度を確保するため、摩擦材組成物全量に対し５〜２０重量％とすることが好ましい。 Examples of the fiber base material include metal fibers such as steel fibers, stainless steel fibers, copper fibers and brass fibers, organic fibers such as aramid fibers and acrylic fibers, inorganic fibers such as carbon fibers, ceramic fibers and rock wool. The content of the fiber base material is preferably 5 to 20% by weight with respect to the total amount of the friction material composition in order to ensure sufficient mechanical strength.
結合材としては、フェノール樹脂、エポキシ樹脂等の熱硬化性樹脂、これらの熱硬化性樹脂をカシューオイル、シリコーンオイル、各種エラストマー等で変性した樹脂、これらの熱硬化性樹脂に各種エラストマー、フッ素ポリマー等を分散させた樹脂等が挙げられる。結合材の含有量は、充分な機械的強度、耐摩耗性を確保するため、摩擦材組成物全量に対し、４〜１５重量％とすることが好ましい。 Examples of the binder include thermosetting resins such as phenol resins and epoxy resins, resins obtained by modifying these thermosetting resins with cashew oil, silicone oil, various elastomers, etc., and various elastomers and fluoropolymers to these thermosetting resins. For example, a resin in which etc. are dispersed. In order to ensure sufficient mechanical strength and wear resistance, the content of the binder is preferably 4 to 15% by weight with respect to the total amount of the friction material composition.
摩擦調整材としては、カシューダスト、ゴムダスト（タイヤトレッドゴムの粉砕粉）、未加硫の各種ゴム粒子、加硫された各種ゴム粒子等の有機充填材、硫酸バリウム、炭酸カルシウム、水酸化カルシウム、バーミキュライト、マイカ等の無機充填材、酸化鉄、ケイ酸ジルコニウム、酸化マグネシウム等の無機研削材、黒鉛、コークス、金属硫化物等の潤滑剤、スズ粒子や亜鉛粒子等の金属粒子が挙げられる。摩擦調整材の含有量は、所望する摩擦特性に応じて、摩擦材組成物全量に対し６５〜９０重量％とすることが好ましい。 Examples of friction modifiers include cashew dust, rubber dust (pulverized tire tread rubber), unvulcanized rubber particles, organic fillers such as vulcanized rubber particles, barium sulfate, calcium carbonate, calcium hydroxide, Examples thereof include inorganic fillers such as vermiculite and mica, inorganic abrasives such as iron oxide, zirconium silicate and magnesium oxide, lubricants such as graphite, coke and metal sulfide, and metal particles such as tin particles and zinc particles. The content of the friction modifier is preferably 65 to 90% by weight based on the total amount of the friction material composition, depending on the desired friction characteristics.
これら、繊維基材、結合材、摩擦調整材は、所望する品質、機械的特性、摩擦摩耗特性に応じて適宜組み合わせて使用することができる。 These fiber base materials, binders, and friction modifiers can be used in appropriate combinations according to desired quality, mechanical properties, and friction and wear properties.
本発明の摩擦材は、所定量配合した上記の仮焼アルミナ、繊維基材、結合材、摩擦調整材を、混合機を用いて均一に混合する混合工程、得られた摩擦材原料混合物を熱成型型に投入し、加熱加圧して成型する加熱加圧成型工程、得られた成型品を加熱して結合材の硬化反応を完了させる熱処理工程、摩擦面を形成する研磨処理工程を経て製造される。 The friction material of the present invention comprises a mixing step of uniformly mixing the calcined alumina, the fiber base material, the binder, and the friction modifier mixed with a predetermined amount using a mixer, and the resulting friction material raw material mixture is heated. It is manufactured through a heat and pressure molding process in which it is put into a mold and heated and pressed to mold, a heat treatment process in which the obtained molded product is heated to complete the curing reaction of the binder, and a polishing process to form a friction surface. The
必要に応じて、加熱加圧成型工程の前に、摩擦材原料混合物を造粒する造粒工程、摩擦材原料混合物または造粒工程で得られた造粒物を予備成型型に投入し、予備成型物を成型する予備成型工程が実施され、加熱加圧成型工程の後に、塗装、塗装焼き付け工程、スコーチ工程が実施される。 If necessary, before the heat and pressure molding process, granulate the friction material raw material mixture, put the friction material raw material mixture or the granulated material obtained in the granulation process into a preforming mold, A pre-molding process for molding the molded product is performed, and after the heat and pressure molding process, painting, paint baking process, and scorch process are performed.
ディスクブレーキパッドを製造する場合には、加熱加圧成型工程において、予め洗浄、表面処理、接着剤を塗布した鋼鉄等の金属製のバックプレートと前記摩擦材原料混合物または造粒物および予備成型物を重ねた状態で成型が施される。 In the case of manufacturing a disc brake pad, in the heating and pressing molding process, a metal back plate such as steel, which has been previously washed, surface-treated, and coated with an adhesive, and the friction material raw material mixture or granulated product and preformed product. Molding is performed in a state of overlapping.
以下、実施例及び比較例を示し、本発明を具体的に説明するが、本発明は下記の実施例に制限されるものではない。 EXAMPLES Hereinafter, although an Example and a comparative example are shown and this invention is demonstrated concretely, this invention is not restrict | limited to the following Example.
［実施例１〜７・比較例１〜４の摩擦材の製造方法］
表１に示す組成の摩擦材組成物をレディゲミキサーにて５分間混合し、成型金型内で３０ＭＰaにて１分加圧して予備成型をした。
[Methods for producing friction materials of Examples 1 to 7 and Comparative Examples 1 to 4]
The friction material composition having the composition shown in Table 1 was mixed for 5 minutes with a Redige mixer, and pre-molded by pressurizing at 30 MPa in a molding die for 1 minute.
この予備成型物を、予め洗浄、表面処理、接着剤を塗布した鋼鉄製のバックプレート上に重ね、熱成型型内で成型温度１５０℃、成型圧力３０ＭＰaの条件下で６分間成型した後、２００℃で４時間熱処理（後硬化）を行い、研磨して乗用車用ディスクブレーキパッドを作製した（実施例１〜７、比較例１〜４）。これらのディスクブレーキパッドの平均摩擦係数、摩擦材摩耗量、ブレーキ鳴きについて下記の条件で評価を行った。評価結果を表１に示す。 This preform is placed on a steel back plate that has been previously cleaned, surface-treated, and coated with an adhesive, and molded in a thermoforming mold at a molding temperature of 150 ° C. and a molding pressure of 30 MPa for 6 minutes. Heat treatment (post-curing) was carried out at 4 ° C. for 4 hours, followed by polishing to produce passenger car disc brake pads (Examples 1 to 7, Comparative Examples 1 to 4). The average friction coefficient, friction material wear amount, and brake squeal of these disc brake pads were evaluated under the following conditions. The evaluation results are shown in Table 1.
＜平均摩擦係数＞
ＪＡＳＯ Ｃ４０６（一般性能）に規定される第２効力試験の、初速度５０ｋｍ／ｈから液圧４ＭＰａにて制動した試験を５回行い、そのときの平均値を求めた。
◎： ０．４２以上 ０．４６未満
○： ０．３８以上 ０．４２未満
△： ０．３４以上 ０．３８未満
×： ０．３４未満
<Average friction coefficient>
The second potency test specified in JASO C406 (general performance) was tested five times with braking at an initial speed of 50 km / h and a hydraulic pressure of 4 MPa, and the average value at that time was determined.
◎: 0.42 or more, but less than 0.46 ○: 0.38 or more, but less than 0.42 Δ: 0.34 or more, but less than 0.38 ×: less than 0.34
＜摩擦材摩耗量＞
ＪＡＳＯ Ｃ４２７ 「摩耗試験」に準拠し、制動初速度５０ｋｍ／ｈ、制動減速度０．３Ｇ、制動回数適宜、制動前ブレーキ温度１００℃、２００℃の条件で、摩擦材の摩耗量（ｍｍ）を測定し、制動回数１０００回あたりの摩耗量に換算後、下記基準にて評価した。
◎：摩擦材の摩耗量（ｍｍ）＜０．１５
○：０．１５≦ディスクパッドの摩耗量（ｍｍ）＜０．２０
△：０．２０≦ディスクパッドの摩耗量（ｍｍ）＜０．２５
×：摩擦材の摩耗量（ｍｍ）≧０．２５
<Abrasion amount of friction material>
In accordance with JASO C427 “Abrasion Test”, the initial braking speed is 50 km / h, the braking deceleration is 0.3 G, the number of times of braking is as appropriate. After measuring and converting to the amount of wear per 1000 brakings, the following criteria were evaluated.
A: Abrasion amount of friction material (mm) <0.15
A: 0.15 ≦ disc pad wear (mm) <0.20
Δ: 0.20 ≦ disc pad wear (mm) <0.25
X: Abrasion amount of friction material (mm) ≧ 0.25
＜ブレーキ鳴き＞
ＪＡＳＯ Ｃ４０４準拠。実車試験により、鳴き発生率を下記基準に基づき評価した。
◎：１．０％未満
○：１．０％以上１．５％未満
△：１．５％以上２．０％未満
×：２．０％以上
<Brake squeal>
Conforms to JASO C404. Based on actual vehicle tests, the occurrence rate of squeal was evaluated based on the following criteria.
A: Less than 1.0% B: 1.0% or more and less than 1.5% Δ: 1.5% or more and less than 2.0% ×: 2.0% or more
本発明により、充分な制動力を有するとともに、摩擦材の異常摩耗が無く、且つ、ブレーキ鳴きの発生が少ない摩擦材を得ることができ、自動車の制動装置である、ディスクブレーキまたはドラムブレーキに使用される摩擦材として、実用的効果がきわめて高いものである。
According to the present invention, it is possible to obtain a friction material having a sufficient braking force, having no abnormal wear of the friction material and generating less brake squeal, and used for a disc brake or a drum brake which is a braking device of an automobile. As a friction material, the practical effect is extremely high.
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|---|---|---|---|---|
| FR1532113A (en) * | 1967-07-24 | 1968-07-05 | Abex Corp | Friction element |
| JPS63303809A (en) * | 1987-01-29 | 1988-12-12 | Sumitomo Chem Co Ltd | Production of alumina powder having narrow particle size distribution |
| JP2004346179A (en) * | 2003-05-22 | 2004-12-09 | Hitachi Chem Co Ltd | Friction material composition and friction material using the same |
| JP2008163178A (en) * | 2006-12-28 | 2008-07-17 | Advics:Kk | Friction material for brake |
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR1532113A (en) * | 1967-07-24 | 1968-07-05 | Abex Corp | Friction element |
| JPS63303809A (en) * | 1987-01-29 | 1988-12-12 | Sumitomo Chem Co Ltd | Production of alumina powder having narrow particle size distribution |
| JP2004346179A (en) * | 2003-05-22 | 2004-12-09 | Hitachi Chem Co Ltd | Friction material composition and friction material using the same |
| JP2008163178A (en) * | 2006-12-28 | 2008-07-17 | Advics:Kk | Friction material for brake |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP3217033A1 (en) | 2016-03-07 | 2017-09-13 | Akebono Brake Industry Co., Ltd. | Friction material |
| JP2017160296A (en) * | 2016-03-07 | 2017-09-14 | 曙ブレーキ工業株式会社 | Friction material |
| US10233989B2 (en) | 2016-03-07 | 2019-03-19 | Akebono Brake Industry Co., Ltd. | Friction material |
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