JP4836927B2 - Friction material manufacturing method - Google Patents
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- JP4836927B2 JP4836927B2 JP2007309811A JP2007309811A JP4836927B2 JP 4836927 B2 JP4836927 B2 JP 4836927B2 JP 2007309811 A JP2007309811 A JP 2007309811A JP 2007309811 A JP2007309811 A JP 2007309811A JP 4836927 B2 JP4836927 B2 JP 4836927B2
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- 239000002783 friction material Substances 0.000 title claims description 212
- 238000004519 manufacturing process Methods 0.000 title claims description 35
- 229920005989 resin Polymers 0.000 claims description 159
- 239000011347 resin Substances 0.000 claims description 159
- 238000001035 drying Methods 0.000 claims description 45
- 230000005540 biological transmission Effects 0.000 claims description 7
- 238000013007 heat curing Methods 0.000 claims description 2
- 238000009826 distribution Methods 0.000 description 61
- 238000000034 method Methods 0.000 description 21
- 239000000463 material Substances 0.000 description 12
- 239000002904 solvent Substances 0.000 description 10
- 238000010586 diagram Methods 0.000 description 8
- 230000007423 decrease Effects 0.000 description 7
- 238000012805 post-processing Methods 0.000 description 6
- 239000011230 binding agent Substances 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000005470 impregnation Methods 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 238000002474 experimental method Methods 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 238000001723 curing Methods 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000007799 cork Substances 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 239000010687 lubricating oil Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000003607 modifier Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
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- Mechanical Operated Clutches (AREA)
- Braking Arrangements (AREA)
Description
本発明は、自動車等の自動変速機やオートバイ等の変速機等に用いられる複数または単数の摩擦板を設けた摩擦材係合装置用の摩擦材の製造方法に関するものである。 The present invention relates to a method of manufacturing a friction material for a friction material engaging device provided with a plurality of or a single friction plate used in an automatic transmission such as an automobile or a transmission such as a motorcycle.
潤滑油中で使用される多板形クラッチ等の湿式摩擦係合装置において、湿式摩擦プレートの湿式摩擦材としては、燒結合金系、カーボン系、あるいはコルク系等の湿式摩擦材も知られているが、「ペーパー摩擦材」とも呼ばれるペーパー系湿式摩擦材が一般的に用いられている。 In wet friction engagement devices such as multi-plate clutches used in lubricating oil, wet friction materials such as saddle-bonded gold, carbon or cork are also known as wet friction materials for wet friction plates. However, a paper-type wet friction material also called “paper friction material” is generally used.
この湿式摩擦材は、パルプやアラミド繊維等の基材繊維と摩擦調整剤や体質充填材等の充填材とを抄造して得た抄紙体に、熱硬化性樹脂からなる樹脂結合剤を含浸し、加熱硬化して形成したものであり、軽量で安価であるだけでなく、材質が多孔質で比較的弾性にも富むため油吸収性が高く、しかも、耐熱性、耐摩耗性等にも比較的優れている等の特長を有している。 This wet friction material is made by impregnating a paper binder obtained by making a base fiber such as pulp or aramid fiber and a filler such as a friction modifier or a body filler with a resin binder made of a thermosetting resin. It is formed by heat-curing and is not only lightweight and inexpensive, but also has a high oil absorbency because it is porous and relatively elastic, and it is also compared with heat resistance, wear resistance, etc. It has features such as excellent performance.
ここで、摩擦材の摩擦表面付近の樹脂の存在は、摩擦材の耐熱性（特に、耐ヒートスポット性）を決定する要因の一つであり、摩擦表面付近の樹脂量が多いと摩擦材が硬くなり耐熱性が低下するため、摩擦表面付近の樹脂量は少ないことが望ましいと考えられている。 Here, the presence of resin near the friction surface of the friction material is one of the factors that determine the heat resistance (particularly heat spot resistance) of the friction material. It is considered desirable that the amount of resin near the friction surface is small because it becomes harder and heat resistance decreases.
しかし、摩擦表面付近の樹脂量を減らすため摩擦材中の樹脂量を減らせば摩擦材としての強度を維持することができなくなるため、必要最小限の樹脂を配合することにより、耐熱性と強度のバランスを確保している。 However, if the amount of resin in the friction material is reduced to reduce the amount of resin near the friction surface, the strength as a friction material cannot be maintained. Balance is secured.
しかし、近年摩擦材に要求されている超高耐熱性を達成するためには、どうしても摩擦表面の樹脂を除去する必要があり、その手段として表面研磨、高熱樹脂劣化処理（ヒートシア）等の後処理工程を追加することにより、耐熱性を向上させようとしている。 However, in order to achieve the ultra-high heat resistance required for friction materials in recent years, it is necessary to remove the resin on the friction surface. As a means for this, post-treatment such as surface polishing, high-heat resin degradation treatment (heat shear), etc. By adding a process, it is trying to improve heat resistance.
しかしながら、こういった後処理工程の追加はコストが高くなり、また表面研磨では摩擦面がボサボサになり引き摺りトルクの上昇が起こり、ヒートシアでは摩擦材内部まで高温になるため、強度低下等といった弊害の発生もあり、近年摩擦材に要求されている低コスト、超高耐熱性確保といった目標に対し達成が困難な状況となっている。 However, the addition of such post-processing steps is costly, and the friction surface becomes rough and rough in surface polishing, and drag torque increases. As a result, it has been difficult to achieve the low-cost and ultra-high heat resistance goals required for friction materials in recent years.
そこで、本発明は、強度低下を起こすことなく、低コストで超高耐熱性の摩擦材及びその製造方法を提供することを課題とするものである。 Therefore, an object of the present invention is to provide a low-cost, ultra-high heat-resistant friction material and a manufacturing method thereof without causing a decrease in strength.
請求項１の発明にかかる摩擦材の製造方法は、摩擦表面側から反摩擦面側までの厚み方向の樹脂量の分布が、樹脂の含浸により連続的に変化させて形成され、摩擦表面付近が前記厚み方向の最も高い樹脂量の部分よりも摩擦表面側が５％以上低く形成されてなる自動車の自動変速機やオートバイの変速機に用いられる複数または単数の摩擦板を設けた摩擦材係合装置用の摩擦材の製造方法において、２枚の摩擦材の摩擦表面同士を重ね合わせたまま乾燥した後、別々にしてまたは重ね合わせたまま高温で硬化させる工程を含むものである。
また、前記樹脂量の分布は、前記摩擦材全体の平均樹脂率よりも前記摩擦表面付近が約１％以上低い樹脂量となっているものである。したがって、前記摩擦表面付近の樹脂量が摩擦材内部もしくは反摩擦表面付近よりも低くなっているため、耐熱性、耐ヒートスポット性が格段に向上し、超高耐熱性の摩擦材となる。しかも、強度低下を起こすことなく、低コストで超高耐熱性の摩擦材とすることができる。
According to the first aspect of the present invention , there is provided a friction material manufacturing method, wherein the distribution of the resin amount in the thickness direction from the friction surface side to the anti-friction surface side is continuously changed by resin impregnation, and the vicinity of the friction surface is formed. Friction material engagement device provided with a plurality of or single friction plates used in an automatic transmission of an automobile or a transmission of a motorcycle, in which the friction surface side is formed to be 5% or more lower than the highest resin amount portion in the thickness direction. In the manufacturing method of the friction material for this, after the friction surfaces of the two friction materials are overlapped and dried, they are cured separately or at a high temperature while being overlapped.
The distribution of the resin amount is such that the resin amount in the vicinity of the friction surface is lower by about 1% or more than the average resin ratio of the entire friction material. Therefore, since the amount of resin near the friction surface is lower than that inside the friction material or near the anti-friction surface, the heat resistance and heat spot resistance are remarkably improved, and the friction material has an ultra-high heat resistance. In addition, the friction material can be manufactured at a low cost and with a very high heat resistance without causing a decrease in strength.
この場合には、突き合わされた摩擦表面からは乾燥は起こらず、外側になった反摩擦表面から溶剤が乾燥していくため、摩擦材中の樹脂も引きずられて移動し、厚み方向の樹脂量の分布が反摩擦表面付近において最も高く、摩擦表面付近において最も低くなる。したがって、上述の如く優れた性質を備えた超高耐熱性の摩擦材となる。しかも、本製造方法は従来からある乾燥工程において好ましい樹脂量の分布を形成するもので、工程を追加する必要がないので低コストで実施することができる。 In this case, drying does not occur from the abutted friction surfaces, and the solvent dries from the outer anti-friction surface, so that the resin in the friction material also drags and moves, and the amount of resin in the thickness direction Distribution is highest near the anti-friction surface and lowest near the friction surface. Therefore, it becomes an ultra-high heat-resistant friction material having excellent properties as described above. In addition, the present production method forms a preferable distribution of the resin amount in the conventional drying process, and can be carried out at a low cost because it is not necessary to add a process.
以上説明したように、請求項１の発明にかかる摩擦材の製造方法は、２枚の摩擦材の摩擦表面同士を重ね合わせたまま乾燥した後、別々にしてまたは重ね合わせたまま高温で硬化させる工程を含むものである。したがって、突き合わされた摩擦表面からは乾燥は起こらず、外側になった反摩擦表面から溶剤が乾燥していくため、摩擦材中の樹脂も引きずられて移動し、厚み方向の樹脂量の分布が反摩擦表面付近において最も高く、摩擦表面付近において最も低くなり、超高耐熱性の摩擦材となる。しかも、本製造方法は従来からある乾燥工程において好ましい樹脂量の分布を形成するもので、工程を追加する必要がないので低コストで実施することができる。
そして、摩擦表面付近の樹脂量が厚み方向の中で最も高い部分の５％以上低くしたものであり、前記樹脂量の分布は、前記摩擦材全体の平均樹脂率よりも前記摩擦表面付近が約１％以上低い樹脂量となっているものであるから耐熱性、耐ヒートスポット性が格段に向上し、超高耐熱性の摩擦材となる。しかも、摩擦材の厚み方向の樹脂量の分布は摩擦材の乾燥工程で決定することができるから、後処理工程を行う必要がない。
更に、前記摩擦材の樹脂量の分布を連続的に変化させたものは、耐熱性、耐ヒートスポット性が格段に向上し超高耐熱性の摩擦材となる。しかも、摩擦材の厚み方向の樹脂量の分布は摩擦材の乾燥工程で決定でき、後処理工程を行う必要がない。殊に、前記摩擦材の樹脂量の分布が連続的に変化するから、特定の部分に機械的ストレスが集中して加わることがない。
更にまた、樹脂の含浸によって形成したものであるから、樹脂を含浸させてから摩擦材の乾燥工程において摩擦表面の温度を低くし、反摩擦表面の温度を高くすることができ、摩擦材中の樹脂は、高温部へ移動して乾燥していく溶剤に引きずられて低温部から高温部へ移動する性質を有するため、厚み方向の樹脂量の分布が反摩擦表面付近において最も高く、摩擦表面付近において最も低くできる。
As described above, the friction material manufacturing method according to the first aspect of the present invention is a method in which the friction surfaces of the two friction materials are dried while being overlapped and then cured at a high temperature separately or overlapped. It includes a process. Therefore, drying does not occur from the abutting friction surfaces, and the solvent dries from the anti-friction surface on the outside, so that the resin in the friction material is also dragged and moved, and the distribution of the resin amount in the thickness direction is It is the highest near the anti-friction surface and the lowest near the friction surface, resulting in an ultra-high heat resistant friction material. In addition, the present production method forms a preferable distribution of the resin amount in the conventional drying process, and can be carried out at a low cost because it is not necessary to add a process.
The amount of resin near the friction surface is lower by 5% or more than the highest portion in the thickness direction, and the distribution of the resin amount is about about the friction surface near the average resin ratio of the entire friction material. Since the resin amount is 1% or more lower, the heat resistance and heat spot resistance are remarkably improved, and the friction material has ultra high heat resistance. In addition, since the distribution of the resin amount in the thickness direction of the friction material can be determined in the friction material drying step, there is no need to perform a post-processing step.
Further, a material in which the distribution of the resin amount of the friction material is continuously changed, the heat resistance and heat spot resistance are remarkably improved, and the friction material has an ultra high heat resistance. Moreover, the distribution of the resin amount in the thickness direction of the friction material can be determined in the friction material drying step, and there is no need to perform a post-processing step. In particular, since the distribution of the resin amount of the friction material changes continuously, mechanical stress is not concentrated on a specific portion.
Furthermore, since it is formed by impregnation of the resin, the temperature of the friction surface can be lowered and the temperature of the anti-friction surface can be increased in the friction material drying process after impregnation of the resin. Since the resin has the property of moving from the low temperature part to the high temperature part by being dragged by the solvent that moves to the high temperature part and dries, the distribution of the resin amount in the thickness direction is the highest near the anti-friction surface, and near the friction surface Can be the lowest.
以下、本発明の実施の形態について、図１乃至図４を参照して説明する。 Hereinafter, embodiments of the present invention will be described with reference to FIGS. 1 to 4.
図１は本発明の実施の形態にかかる摩擦材及びその変形例のライニング部の厚み方向の樹脂量の分布を示す図である。図２は本発明の実施の形態にかかる摩擦材の耐ヒートスポット性を従来材と比較して示す図である。図３は本発明の実施の形態にかかる摩擦材のμ−Ｖ正勾配性を従来材と比較して示す図である。図４は本発明の実施の形態にかかる摩擦材の初期特性を従来材と比較して示す図である。 FIG. 1 is a diagram showing a resin amount distribution in the thickness direction of a lining portion of a friction material according to an embodiment of the present invention and a modified example thereof. FIG. 2 is a diagram showing the heat spot resistance of the friction material according to the embodiment of the present invention in comparison with the conventional material. FIG. 3 is a diagram showing the μ-V positive gradient property of the friction material according to the embodiment of the present invention in comparison with the conventional material. FIG. 4 is a diagram showing the initial characteristics of the friction material according to the embodiment of the present invention in comparison with the conventional material.
本実施の形態の摩擦材の原材料となる摩擦材は樹脂含浸タイプの摩擦材であって、本実施の形態の摩擦材は、様々な方法で製造することができる。 The friction material used as the raw material of the friction material of the present embodiment is a resin-impregnated friction material, and the friction material of the present embodiment can be manufactured by various methods.
例えば、摩擦材の乾燥工程において摩擦表面の温度を低くし、反摩擦表面の温度を高くする。摩擦材中の樹脂は、高温部へ移動して乾燥していく溶剤に引きずられて低温部から高温部へ移動する性質を有するため、厚み方向の樹脂量の分布が反摩擦表面付近において最も高く、摩擦表面付近において最も低くなる。 For example, in the friction material drying process, the temperature of the friction surface is lowered and the temperature of the anti-friction surface is raised. Since the resin in the friction material has the property of moving from the low temperature part to the high temperature part by being dragged by the solvent that moves to the high temperature part and dries, the distribution of the resin amount in the thickness direction is the highest near the anti-friction surface. It becomes the lowest near the friction surface.
また、２枚の摩擦材の摩擦表面同士を重ね合わせたまま２４時間以上自然乾燥した後、別々にしてまたは重ね合わせたまま高温で硬化させることによっても製造することができる。この場合も、突き合わされた摩擦表面からは乾燥は起こらず、外側になった反摩擦表面から溶剤が乾燥していくため、厚み方向の樹脂量の分布が反摩擦表面付近において最も高く、摩擦表面付近において最も低くなる。 Further, it can also be produced by naturally drying for 24 hours or more with the friction surfaces of the two friction materials being overlapped, and then curing them at a high temperature separately or with being overlapped. Also in this case, drying does not occur from the abutted friction surface, and the solvent is dried from the anti-friction surface on the outer side, so the resin amount distribution in the thickness direction is the highest near the anti-friction surface, and the friction surface The lowest in the vicinity.
このようにして製造された摩擦材中の厚み方向の樹脂量の分布を示すのが、図１のＡａ及びＡｂである。図１に示されるように、Ａａ及びＡｂの摩擦材においては、厚み方向の樹脂量の分布が反摩擦表面付近において最も高く、内部に行くにしたがって低くなり、摩擦表面付近において最も低くなっている。かかる樹脂量の分布を有する摩擦材は、次に述べる耐ヒートスポット性を始めとして摩擦材として優れた特性を示す。 Aa and Ab in FIG. 1 show the distribution of the resin amount in the thickness direction in the friction material thus manufactured. As shown in FIG. 1, in the friction material of Aa and Ab, the distribution of the resin amount in the thickness direction is the highest near the anti-friction surface, becomes lower toward the inside, and becomes the lowest near the friction surface. . The friction material having such a resin amount distribution exhibits excellent characteristics as a friction material including heat spot resistance described below.
また、変形例としてＢのように樹脂量の分布が摩擦表面付近において最も低くなってはいないが反摩擦面付近等の他の部分よりは低くなっている摩擦材、さらに、Ａａ及びＡｂのように滑らかな分布ではないが、Ｃ、Ｄのような摩擦表面付近において低い樹脂量の分布を示す摩擦材においても、同様に優れた耐ヒートスポット性が示される。 Further, as a modification, a friction material in which the distribution of the resin amount is not the lowest in the vicinity of the friction surface as in B, but is lower than other portions such as in the vicinity of the anti-friction surface, and further, as in Aa and Ab Even in a friction material that shows a low resin content distribution near the friction surface such as C and D, the heat spot resistance is also excellent.
次に、これらの摩擦材の中から、２枚の摩擦材の摩擦表面同士を重ね合わせたまま２４時間以上自然乾燥した後、樹脂を２００℃×１時間で完全硬化し、接着剤を塗布した芯金に貼り付けて製造した摩擦材について、従来の摩擦材と比較して、耐ヒートスポット性試験を実施した。耐ヒートスポット性試験とは、摩擦材を鉄材に圧着して回転させ、鉄材表面に最初に焼け焦げ（ヒートスポット）が生じるまでに何回転かかるかを測定することによって、摩擦材の耐熱性を評価する試験である。 Next, from these friction materials, after naturally drying for 24 hours or more with the friction surfaces of the two friction materials overlapped, the resin was completely cured at 200 ° C. × 1 hour, and an adhesive was applied. A heat spot resistance test was performed on the friction material manufactured by pasting to a cored bar, compared with a conventional friction material. The heat spot resistance test evaluates the heat resistance of a friction material by measuring how many rotations it takes before the first scorch (heat spot) occurs on the iron material surface by pressing the friction material against the iron material and rotating it. It is a test to do.
試験機としてはＳＡＥ＃２テスターを用い、回転数７８００ｒｐｍ、慣性量０．０８６ｋｇ・ｍ2 、面圧７８５ｋＰａ、油量１８０ｍｌ／ｍｉｎの条件下で評価した。結果を図２に示す。従来の摩擦材に対して、本実施の形態の摩擦材は１５倍近くまで耐ヒートスポット性が向上していることが分かる。 A SAE # 2 tester was used as a tester, and evaluation was performed under conditions of a rotational speed of 7800 rpm, an inertial amount of 0.086 kg · m2, a surface pressure of 785 kPa, and an oil amount of 180 ml / min. The results are shown in FIG. It can be seen that the heat spot resistance of the friction material of the present embodiment is improved up to about 15 times that of the conventional friction material.
次に、μ−Ｖ正勾配性について、従来の摩擦材と比較して試験した。結果を図３に示す。従来の摩擦材にはμ−Ｖ正勾配性が認められないのに対して、本実施の形態の摩擦材には顕著なμ−Ｖ正勾配性が認められる。このように、本実施の形態の摩擦材は摩擦表面付近の樹脂量が少ないため、係合特性、μ−Ｖ正勾配性等、実車フィーリングが向上する。 Next, it tested about (mu) -V positive gradient property compared with the conventional friction material. The results are shown in FIG. The μ-V positive gradient property is not recognized in the conventional friction material, whereas the remarkable μ-V positive gradient property is recognized in the friction material of the present embodiment. Thus, since the friction material of the present embodiment has a small amount of resin near the friction surface, the actual vehicle feeling such as engagement characteristics and μ-V positive gradient is improved.
さらに、初期特性について、従来の摩擦材と比較して試験した。結果を図４に示す。従来の摩擦材に比べて本実施の形態の摩擦材は初期特性が格段に向上していることが分かる。このように、本実施の形態の摩擦材は摩擦表面の樹脂量が少ないため、初期特性が向上する。これによって、ＡＴ（オートマチック・トランスミッション）の性能が初期から安定する。 Furthermore, initial characteristics were tested in comparison with conventional friction materials. The results are shown in FIG. It can be seen that the initial characteristics of the friction material of the present embodiment are significantly improved compared to the conventional friction material. Thus, since the friction material of this embodiment has a small amount of resin on the friction surface, the initial characteristics are improved. This stabilizes the performance of the AT (automatic transmission) from the beginning.
このように、本実施の形態の摩擦材は、摩擦材のライニング部の厚み方向の樹脂量の分布が摩擦表面付近において前記厚み方向の最も高い樹脂量の部分よりも低いものである。例えば、樹脂含浸タイプの摩擦材であって、樹脂成分を有する摩擦材の摩擦表面の温度を低くし、反摩擦表面の温度を高くする乾燥によって、摩擦材のライニング部の厚み方向の樹脂量の分布が摩擦表面付近において前記厚み方向の最も高い樹脂量の部分よりも低くしたものである。即ち、摩擦表面付近の樹脂量が摩擦材内部もしくは反摩擦表面付近よりも低くなっているから、耐熱性、耐ヒートスポット性が格段に向上し超高耐熱性の摩擦材となる。 As described above, in the friction material of the present embodiment, the distribution of the resin amount in the thickness direction of the lining portion of the friction material is lower in the vicinity of the friction surface than the portion with the highest resin amount in the thickness direction. For example, it is a resin-impregnated type friction material, and the temperature of the friction material of the friction material lining is increased by drying to lower the temperature of the friction surface of the friction material having a resin component and to increase the temperature of the anti-friction surface. The distribution is lower than the portion with the highest resin amount in the thickness direction near the friction surface. That is, since the amount of resin in the vicinity of the friction surface is lower than that in the friction material or near the anti-friction surface, the heat resistance and heat spot resistance are remarkably improved, resulting in an ultra-high heat resistance friction material.
しかも、摩擦材の厚み方向の樹脂量の分布は摩擦材の乾燥工程で決まり、後処理工程を行う必要がないので強度低下を起こすことなく、低コストで超高耐熱性の摩擦材を提供することができる。また、摩擦表面付近の樹脂量が少ないため、係合特性、μ−Ｖ正勾配性等、実車フィーリングが向上する。さらに、摩擦表面の樹脂量が少ないため初期特性が向上し、これによってＡＴの性能が初期から安定するという効果が得られる。 In addition, the distribution of the amount of resin in the thickness direction of the friction material is determined by the drying process of the friction material, and it is not necessary to perform a post-treatment process, so that an ultra-high heat resistance friction material is provided at low cost without causing a decrease in strength. be able to. In addition, since the amount of resin near the friction surface is small, the actual vehicle feeling such as engagement characteristics and μ-V positive gradient is improved. Furthermore, since the amount of the resin on the friction surface is small, the initial characteristics are improved, and this provides the effect that the AT performance is stabilized from the beginning.
ここで、「摩擦表面付近」とは、摩擦材全体の厚さに対して摩擦表面から約１０％の深さまでの範囲内をいう。また、「樹脂率」という用語を「単位体積当りの樹脂の量」を意味するものとして定義すると、本実施の形態の摩擦材は、摩擦材全体の平均樹脂率よりも摩擦表面から摩擦材全体の厚さに対して約１０％の深さまでの範囲内の平均樹脂率の方が低いものということもできる。これは、摩擦表面から摩擦材全体の厚さに対して約５％の深さまでの範囲内の平均樹脂率の方が低いものと定義しても同じであり、発明者らの実験では、平均樹脂率は摩擦表面から摩擦材全体の厚さに対して約４０％程度の深さまでは、平均樹脂率の方が低いことを確認した。しかし、図１の特性から見れば、約４０％を超える程度の深さまでは、平均樹脂率の方が低いことが推定できる。 Here, “near the friction surface” means within a range from the friction surface to a depth of about 10% with respect to the thickness of the entire friction material. Further, when the term “resin ratio” is defined as meaning “amount of resin per unit volume”, the friction material of the present embodiment is more effective than the average resin ratio of the entire friction material. It can also be said that the average resin ratio in the range up to a depth of about 10% with respect to the thickness is lower. This is the same even if it is defined that the average resin ratio in the range from the friction surface to the depth of about 5% with respect to the thickness of the entire friction material is lower. It was confirmed that the average resin ratio was lower at a depth of about 40% from the friction surface to the thickness of the entire friction material. However, from the characteristics shown in FIG. 1, it can be estimated that the average resin ratio is lower at a depth exceeding about 40%.
また、本実施の形態の摩擦材のうち、図１のＡａ、Ａｂ、Ｃ、Ｄで示される摩擦材は、前記厚み方向の樹脂量の分布が前記摩擦表面付近において最も低いものである。そして、摩擦材のライニング部の厚み方向の樹脂量の分布が、摩擦表面付近において、平均樹脂率に対して約±３％以上（絶対値が大きいという意味）の高い樹脂量の部分と低い樹脂量の部分が存在することによる前述の効果であると推定される。ここで、特に必要なのは、平均樹脂率に対して摩擦表面付近が約−３％よりも低い樹脂量となっていることによる効果であると推定される。 Further, among the friction materials of the present embodiment, the friction materials indicated by Aa, Ab, C, and D in FIG. 1 have the lowest resin amount distribution in the thickness direction near the friction surface. And the distribution of the resin amount in the thickness direction of the lining portion of the friction material has a high resin amount portion and a low resin in the vicinity of the friction surface that are about ± 3% or more (meaning that the absolute value is large) with respect to the average resin ratio. It is presumed that the above-mentioned effect is due to the presence of the quantity part. Here, it is presumed that what is particularly required is an effect due to the resin amount in the vicinity of the friction surface being lower than about −3% with respect to the average resin ratio.
更に、発明者らの実験結果に基づくと、摩擦表面付近の平均樹脂率が０〜５０％であって、摩擦材全体の平均樹脂率よりも低い摩擦材と特定することもできる。この場合にも、同様の効果が得られるものと考えられる。 Furthermore, based on the results of experiments conducted by the inventors, it can be specified that the average resin ratio in the vicinity of the friction surface is 0 to 50% and is lower than the average resin ratio of the entire friction material. In this case, it is considered that the same effect can be obtained.
特に、摩擦材のライニング部の厚み方向の樹脂量の分布が摩擦表面付近において最も低くなっているから、極めて耐熱性、耐ヒートスポット性が高く超高耐熱性の摩擦材となる。しかも、摩擦材の厚み方向の樹脂量の分布は摩擦材の乾燥工程で決まり、後処理工程を行う必要がないので、低コストで済み、かつ、強度低下を起こすことがない。更に、強度アップを目的に摩擦材の樹脂の配合量を増やしたとしても、摩擦表面付近の樹脂量は従来のものよりも少ない状態となるため、耐熱性を損なうことなく強度を上げることが可能となる。 In particular, since the distribution of the resin amount in the thickness direction of the lining portion of the friction material is the lowest in the vicinity of the friction surface, the friction material has extremely high heat resistance and heat spot resistance and is extremely high heat resistance. In addition, the distribution of the resin amount in the thickness direction of the friction material is determined by the drying step of the friction material, and it is not necessary to perform a post-processing step. Therefore, the cost is low and the strength is not reduced. Furthermore, even if the resin content of the friction material is increased for the purpose of increasing the strength, the amount of resin near the friction surface will be less than that of the conventional one, so the strength can be increased without sacrificing heat resistance. It becomes.
また、本実施の形態の摩擦材の製造方法は、摩擦材の乾燥工程において摩擦表面の温度を低くし、反摩擦表面の温度を高くする工程を含むものであるから、これによって、摩擦材中の樹脂は高温部へ移動して乾燥していく溶剤に引きずられて低温部から高温部へ移動する性質を有するため、厚み方向の樹脂量の分布が摩擦表面付近において最も低くなる。したがって、上述の如く優れた性質を備えた超高耐熱性の摩擦材となる。しかも、本製造方法は従来からある乾燥工程において好ましい樹脂量の分布を形成するもので、工程を追加する必要がないので低コストで実施することができる。 Further, the friction material manufacturing method of the present embodiment includes a step of lowering the temperature of the friction surface and increasing the temperature of the anti-friction surface in the drying step of the friction material. Has the property of moving from the low temperature part to the high temperature part by being dragged by the solvent that moves to the high temperature part and dries, so that the distribution of the resin amount in the thickness direction is the lowest in the vicinity of the friction surface. Therefore, it becomes an ultra-high heat-resistant friction material having excellent properties as described above. In addition, the present production method forms a preferable distribution of the resin amount in the conventional drying process, and can be carried out at a low cost because it is not necessary to add a process.
特に、本実施の形態においては、２枚の摩擦材の摩擦表面同士を重ね合わせたまま２４時間以上自然乾燥する方法で摩擦表面付近の樹脂量を少なくして製造した摩擦材について特性試験を実施したが、摩擦材の乾燥工程において摩擦表面の温度を低くし、反摩擦表面の温度を高くする方法で摩擦表面付近の樹脂量を少なくして製造した摩擦材においても、同様な特性の向上がみられる。 In particular, in this embodiment, a characteristic test is performed on a friction material manufactured by reducing the amount of resin near the friction surface by a method of natural drying for 24 hours or more while the friction surfaces of two friction materials are overlapped. However, friction materials manufactured by reducing the amount of resin near the friction surface by lowering the temperature of the friction surface in the drying process of the friction material and increasing the temperature of the anti-friction surface can improve the same characteristics. Be looked at.
そして、摩擦表面付近の樹脂量を少なくする方法は、これら２つの方法に限らず、他にも減圧，加圧，遠心分離，スプレー，リッピング，ローラー等の片面塗布等、種々の方法によることができる。また、本実施の形態においては樹脂含浸タイプの摩擦材を例に挙げて説明したが、本発明の摩擦材は樹脂含浸タイプに限られず、樹脂積層タイプを始めとして樹脂を成分として含むものであればどのような摩擦材にも適用される。 The method for reducing the amount of resin in the vicinity of the friction surface is not limited to these two methods, but may be other various methods such as pressure reduction, pressurization, centrifugal separation, spraying, ripping, single-sided application such as a roller. it can. Further, in this embodiment, the resin-impregnated friction material has been described as an example. However, the friction material of the present invention is not limited to the resin-impregnated type, and may contain a resin as a component including a resin laminate type. It applies to any friction material.
殊に、粉体樹脂の場合には、摩擦材を成形する際に均一に分布させるように混練し、摩擦材の乾燥工程において摩擦表面の温度を低くし、反摩擦表面の温度を高くする工程によっても同様に製造することができる。また、均一分布状態の摩擦材の乾燥工程において、一方の面に粉体樹脂を撒いてもよいし、一方の面に粉体樹脂を含浸させるように付着させてもよい。 In particular, in the case of a powder resin, a process in which the friction material is kneaded so as to be uniformly distributed during molding, and the temperature of the friction surface is lowered and the temperature of the anti-friction surface is increased in the drying process of the friction material. Can also be manufactured in the same manner. Further, in the step of drying the friction material in a uniformly distributed state, the powder resin may be applied on one surface, or may be adhered so that the powder resin is impregnated on one surface.
摩擦材のその他の部分の構成、形状、数量、材質、大きさ、接続関係等、また摩擦材の製造方法のその他の工程についても、本実施の形態に限定されるものではない。 The configuration, shape, quantity, material, size, connection relationship, etc. of other parts of the friction material, and other steps of the method for manufacturing the friction material are not limited to the present embodiment.
通常、上記実施の形態の摩擦材の製造方法は、摩擦材の乾燥工程において、片方の表面の温度を低くし、及び／またはもう他方の表面の温度を高くする工程を入れることにより、摩擦材中の樹脂は高温部へ移動して乾燥していく有機溶剤に引きずられて低温部から高温部へ移動する性質を有するから、厚み方向の樹脂量の分布が一方の表面付近において最も低くなる。したがって、上述の如く優れた性質を備えた超高耐熱性の摩擦材となる。しかも、本製造方法は従来からある乾燥工程において好ましい樹脂量の分布を形成するもので、工程を追加する必要がないので低コストで実施することができる。 Usually, the manufacturing method of the friction material of the above-described embodiment includes the step of lowering the temperature of one surface and / or increasing the temperature of the other surface in the drying step of the friction material. Since the resin inside has the property of moving from the low temperature part to the high temperature part by being dragged by the organic solvent that moves to the high temperature part and is dried, the distribution of the resin amount in the thickness direction becomes the lowest in the vicinity of one surface. Therefore, it becomes an ultra-high heat-resistant friction material having excellent properties as described above. In addition, the present production method forms a preferable distribution of the resin amount in the conventional drying process, and can be carried out at a low cost because it is not necessary to add a process.
また、上記実施の形態の摩擦材の製造方法は、２枚の摩擦材の摩擦表面同士を重ね合わせたまま乾燥した後、別々にしてまたは重ね合わせたまま高温で硬化させる工程を含むものである。この場合は、突き合わされた摩擦表面からは乾燥が起こらず、外側になった反摩擦表面から溶剤が乾燥していくため、摩擦材中の樹脂も引きずられて移動し、厚み方向の樹脂量の分布が反摩擦表面付近において最も高く、摩擦表面付近において最も低くなる。したがって、上述の如く優れた性質を備えた超高耐熱性の摩擦材となる。しかも、本製造方法は従来からある乾燥工程において好ましい樹脂量の分布を形成するもので、工程を追加する必要がないので低コストで実施することができる。 Moreover, the manufacturing method of the friction material of the said embodiment includes the process of making it harden | cure at high temperature separately or after overlapping, after drying the friction surfaces of two friction materials. In this case, drying does not occur from the abutting friction surfaces, and the solvent dries from the anti-friction surface that is on the outside, so that the resin in the friction material also drags and moves, and the amount of resin in the thickness direction The distribution is highest near the anti-friction surface and lowest near the friction surface. Therefore, it becomes an ultra-high heat-resistant friction material having excellent properties as described above. In addition, the present production method forms a preferable distribution of the resin amount in the conventional drying process, and can be carried out at a low cost because it is not necessary to add a process.
そして、上記摩擦材の製造方法は、２枚以上の樹脂量を異にする摩擦材を重ね合わせて、一体化するもので、特に、２枚以上の樹脂量を異にする摩擦材を形成し、少なくとも、それらの１以上の樹脂量を異にする摩擦材の乾燥完了前の適当に乾燥した状態で重ね合わせて、バインダを介在させて接着し、一体化することにより、厚み方向の樹脂量の分布が反摩擦表面付近において最も高く、摩擦表面付近において最も低く構成することができ、所望の超高耐熱性の摩擦材となる。即ち、摩擦材の摩擦表面側から反摩擦面側までの厚み方向の樹脂量の分布が摩擦表面付近で、前記厚み方向の最も高い樹脂量の部分よりも低くなるように、摩擦表面付近の摩擦材の樹脂量を少なくして乾燥させ、それを乾燥前の摩擦材の上に載せて、一体化することができる。また、複数枚の摩擦材を重ね合わせ、そこに樹脂を含浸させても、複数枚の摩擦材の面相互間で不連続な摩擦材を形成することができる。 The method for manufacturing the friction material is one in which two or more friction materials having different resin amounts are overlapped and integrated. In particular, two or more friction materials having different resin amounts are formed. The amount of resin in the thickness direction is obtained by superimposing them in an appropriately dried state before completion of drying of the friction materials having different amounts of one or more of these resins, bonding them with a binder, and integrating them. Is the highest in the vicinity of the anti-friction surface and the lowest in the vicinity of the friction surface, and a desired ultra-high heat-resistant friction material is obtained. That is, the friction near the friction surface is such that the distribution of the resin amount in the thickness direction from the friction surface side to the anti-friction surface side of the friction material is lower near the friction surface than the portion with the highest resin amount in the thickness direction. It is possible to dry by reducing the amount of resin of the material, and place it on the friction material before drying to integrate. Further, even if a plurality of friction materials are overlapped and impregnated with resin, discontinuous friction materials can be formed between the surfaces of the plurality of friction materials.
上記のように、この発明にかかる摩擦材は、摩擦材のライニング部の厚み方向、即ち、摩擦表面側から反摩擦面側までの厚み方向の樹脂量の分布が摩擦表面付近において、前記厚み方向の最も高い樹脂量の部分よりも低いものであり、その実施の形態としては、摩擦材の厚み方向の樹脂量の分布は摩擦材の乾燥工程で、適度に乾燥した摩擦表面と反摩擦面の表裏をバインダで接合することにより、摩擦表面側から反摩擦面側までの厚み方向の樹脂量の分布が摩擦表面付近において、前記厚み方向の最も高い樹脂量の部分よりも低く形成することができる。後処理工程を行う必要がないので強度低下を起こすことなく、低コストで超高耐熱性の摩擦材を得ることができる。 As described above, in the friction material according to the present invention, the thickness direction of the lining portion of the friction material, that is, the distribution of the resin amount in the thickness direction from the friction surface side to the anti-friction surface side is in the vicinity of the friction surface. In the embodiment, the distribution of the resin amount in the thickness direction of the friction material is such that the friction surface and the anti-friction surface are appropriately dried in the friction material drying process. By bonding the front and back with a binder, the distribution of the resin amount in the thickness direction from the friction surface side to the anti-friction surface side can be formed lower in the vicinity of the friction surface than the portion with the highest resin amount in the thickness direction. . Since it is not necessary to perform a post-processing step, an ultra-high heat-resistant friction material can be obtained at low cost without causing a decrease in strength.
このように、摩擦材の摩擦表面側から反摩擦面側までの厚み方向の樹脂量の分布が、摩擦表面付近で前記厚み方向の最も高い樹脂量の部分よりも低く形成されているから、耐熱性、耐ヒートスポット性が格段に向上し超高耐熱性の摩擦材となる。しかも、摩擦材の厚み方向の樹脂量の分布は摩擦材の乾燥工程で決まり、後処理工程を行う必要がないので強度低下を起こすことなく、低コストで超高耐熱性とすることができる。 Thus, since the distribution of the resin amount in the thickness direction from the friction surface side to the anti-friction surface side of the friction material is formed lower than the portion with the highest resin amount in the thickness direction near the friction surface, And heat spot resistance are greatly improved, resulting in an ultra-high heat-resistant friction material. In addition, the distribution of the amount of resin in the thickness direction of the friction material is determined by the drying step of the friction material, and it is not necessary to perform a post-processing step.
上記実施の形態の摩擦材の樹脂は、図１のＡａの実施例では、摩擦表面側と反摩擦面側とで摩擦表面側が２０％以上低くしたものであるから、摩擦表面付近の樹脂量が反摩擦表面付近よりも低くなっており、耐熱性、耐ヒートスポット性が格段に向上し、超高耐熱性の摩擦材となる。しかし、発明者等の実験によれば、摩擦表面側と反摩擦面側とで摩擦表面側が５％以上低くしたものでも、耐熱性、耐ヒートスポット性が向上し、超高耐熱性としての特性の向上が確認され、結果、摩擦材の摩擦表面側から反摩擦面側までの厚み方向の樹脂量の分布は、摩擦表面付近が厚み方向の最も高い樹脂量の部分よりも低く形成されていればよいことが判明した。 In the embodiment of Aa in FIG. 1, the friction material resin of the above embodiment is such that the friction surface side is lower by 20% or more on the friction surface side and the anti-friction surface side. It is lower than the vicinity of the anti-friction surface, and the heat resistance and heat spot resistance are remarkably improved, resulting in an ultra-high heat resistance friction material. However, according to experiments by the inventors, even when the friction surface side and the friction surface side are reduced by 5% or more, the heat resistance and heat spot resistance are improved, and the characteristics as ultra high heat resistance As a result, the distribution of the resin amount in the thickness direction from the friction surface side to the anti-friction surface side of the friction material should be lower in the vicinity of the friction surface than the portion with the highest resin amount in the thickness direction. It turned out to be good.
殊に、上記実施の形態の摩擦材は、摩擦表面側と摩擦材内部とで摩擦表面側が略５％以上低くしたものであり、摩擦表面付近の樹脂量が摩擦材内部よりも低くなっているため、摩擦表面付近の樹脂量が反摩擦表面付近よりも低くなっている実施例と同様、耐熱性、耐ヒートスポット性が格段に向上し超高耐熱性の摩擦材となる。しかも、摩擦材の厚み方向の樹脂量の分布は摩擦材の乾燥工程で決まり、後処理工程を行う必要がないので強度低下を起こすことなく、低コストで超高耐熱性の摩擦材を提供することができる。 In particular, the friction material of the above-described embodiment is such that the friction surface side is approximately 5% or more lower between the friction surface side and the friction material side, and the amount of resin in the vicinity of the friction surface is lower than that inside the friction material. Therefore, the heat resistance and heat spot resistance are remarkably improved and the friction material has an extremely high heat resistance, as in the embodiment in which the amount of resin near the friction surface is lower than that near the anti-friction surface. In addition, the distribution of the amount of resin in the thickness direction of the friction material is determined by the drying process of the friction material, and it is not necessary to perform a post-treatment process, so that an ultra-high heat resistance friction material is provided at low cost without causing a decrease in strength. be able to.
特に、上記実施の形態では、図１に示すように、摩擦材の樹脂量の分布を連続的に変化させたものであるから、特定の部分に機械的ストレスが集中して加わることが回避できる。 In particular, in the above embodiment, as shown in FIG. 1, since the distribution of the resin amount of the friction material is continuously changed, it is possible to avoid the concentration of mechanical stress on a specific portion. .
また、上記実施の形態では、図１に示すように、摩擦材の樹脂量の分布を連続的に変化させたものであるが、摩擦材の製造工程において、樹脂量を異にする２枚または３枚以上の摩擦材を形成し、少なくとも、それらの１以上の樹脂量を異にする摩擦材の乾燥完了前の適度に乾燥した状態でバインダを用いて接合により重ね合わせ、複数の樹脂量を異にする摩擦材を一体化することによっても製造することができる。 Moreover, in the said embodiment, as shown in FIG. 1, although distribution of the resin amount of a friction material was changed continuously, in the manufacturing process of a friction material, two sheets which differ in the resin amount or Three or more friction materials are formed, and at least the friction materials having different amounts of one or more of them are overlapped by bonding using a binder in a properly dried state before completion of drying, and a plurality of resin amounts are added. It can also be manufactured by integrating different friction materials.
この場合には、摩擦材の樹脂量の分布を不連続的に変化させたものとなるが、複数の樹脂量を異にする摩擦材における樹脂の含有率を任意に設定でき、耐熱性、耐ヒートスポット性が格段に向上し、超高耐熱性の摩擦材となる。しかも、摩擦材の厚み方向の樹脂量の分布は重ね合わせによって決定でき、任意の低コストで超高耐熱性の摩擦材を得ることができる。 In this case, the resin amount distribution of the friction material is discontinuously changed. However, the resin content in the friction material with different resin amounts can be arbitrarily set, and the heat resistance, The heat spot property is remarkably improved, and it becomes a friction material with ultra high heat resistance. Moreover, the distribution of the resin amount in the thickness direction of the friction material can be determined by superposition, and an ultra-high heat resistance friction material can be obtained at any low cost.
そして、上記実施の形態の摩擦材は、樹脂の含浸によって形成したものであり、樹脂を含浸させてから摩擦材の乾燥工程において摩擦表面の温度を低くし、反摩擦表面の温度を高くすることによって、摩擦材中の樹脂は、高温部へ移動して乾燥していく溶剤に引きずられて低温部から高温部へ移動する性質を有するため、厚み方向の樹脂量の分布が反摩擦表面付近において最も高く、摩擦表面付近において最も低くなる。故に、廉価に製造が容易となる。 The friction material of the above embodiment is formed by impregnation with resin, and after impregnating the resin, the temperature of the friction surface is lowered and the temperature of the anti-friction surface is increased in the drying step of the friction material. Because the resin in the friction material has the property of moving from the low temperature part to the high temperature part by being dragged by the solvent that moves to the high temperature part and dries, the distribution of the resin amount in the thickness direction is near the anti-friction surface. Highest and lowest near the friction surface. Therefore, manufacture becomes easy at low cost.
上記実施の形態の摩擦材の樹脂量の分布は、発明者等の実験により、平均樹脂率よりも摩擦表面付近が約１％以上低い樹脂量となっているものでは、摩擦表面付近の樹脂量が摩擦材内部もしくは反摩擦表面付近よりも低くなり、耐熱性、耐ヒートスポット性が格段に向上し、超高耐熱性の摩擦材となる。しかも、強度低下を起こすことなく、低コストで超高耐熱性の摩擦材とすることができる。 The distribution of the resin amount of the friction material of the above embodiment is that the resin amount near the friction surface is about 1% or more lower than the average resin rate by the inventors' experiments. Becomes lower than the inside of the friction material or near the anti-friction surface, and the heat resistance and heat spot resistance are remarkably improved, and the friction material has ultra high heat resistance. In addition, the friction material can be manufactured at a low cost and with a very high heat resistance without causing a decrease in strength.
ところで、本発明の実施の形態にかかる摩擦材の製造方法は、摩擦材の乾燥工程において、一方の表面の温度を低くし、及び／またはもう一方の表面の温度を高くする工程を含むことによって製造可能である。これによって、摩擦材中の樹脂は高温部へ移動して乾燥していく溶剤に引きずられて低温部から高温部へ移動する性質を有するため、厚み方向の樹脂量の分布が一方の表面付近において最も低くなる。したがって、上述の如く優れた性質を備えた超高耐熱性の摩擦材となる。しかも、本製造方法は従来からある乾燥工程において好ましい樹脂量の分布を形成するもので、工程を追加する必要がないので低コストで実施することができる。 By the way, the manufacturing method of the friction material according to the embodiment of the present invention includes the step of lowering the temperature of one surface and / or increasing the temperature of the other surface in the drying step of the friction material. It can be manufactured. As a result, since the resin in the friction material has the property of moving from the low temperature part to the high temperature part by being dragged by the solvent that moves to the high temperature part and dries, the distribution of the resin amount in the thickness direction is near one surface. The lowest. Therefore, it becomes an ultra-high heat-resistant friction material having excellent properties as described above. In addition, the present production method forms a preferable distribution of the resin amount in the conventional drying process, and can be carried out at a low cost because it is not necessary to add a process.
また、本発明の実施の形態にかかる摩擦材の製造方法は、その製造工程において、２枚の摩擦材または２枚以上の摩擦材の摩擦表面同士を重ね合わせたまま乾燥した後、別々にしてまたは重ね合わせたまま高温で硬化させる工程を含むものである。この場合、突き合わされた摩擦表面からは乾燥は起こらず、外側になった反摩擦表面から溶剤が乾燥していくため、摩擦材中の樹脂も引きずられて移動し、厚み方向の樹脂量の分布が反摩擦表面付近において最も高く、摩擦表面付近において最も低くなる。したがって、上述の如く優れた性質を備えた超高耐熱性の摩擦材となる。しかも、本製造方法は従来からある乾燥工程において好ましい樹脂量の分布を形成するもので、工程を追加する必要がないので低コストで実施することができる。 In addition, in the manufacturing method of the friction material according to the embodiment of the present invention, in the manufacturing process, after the friction surfaces of two friction materials or two or more friction materials are overlapped and dried, separately. Alternatively, it includes a step of curing at a high temperature while being superposed. In this case, drying does not occur from the abutted friction surfaces, and the solvent dries from the outer anti-friction surface, so that the resin in the friction material is also dragged and moved, and the resin amount distribution in the thickness direction Is highest near the anti-friction surface and lowest near the friction surface. Therefore, it becomes an ultra-high heat-resistant friction material having excellent properties as described above. In addition, the present production method forms a preferable distribution of the resin amount in the conventional drying process, and can be carried out at a low cost because it is not necessary to add a process.
そして、本発明の実施の形態にかかる摩擦材の製造方法は、摩擦材に樹脂を含浸させる工程において、前記摩擦材の一方の面に樹脂を追加含浸させ、摩擦材の乾燥工程において、前記摩擦材の樹脂を追加含浸させた側を外側として、その厚み方向に遠心力を付与しながら、所定の温度条件で乾燥させる工程を含むものであるから、前記摩擦材の樹脂を追加含浸させた側の摩擦表面側から反摩擦面側までの厚み方向の樹脂量の分布を、摩擦表面付近が前記厚み方向の最も高い樹脂量の部分よりも低く形成することができる。 Then, in the method of manufacturing the friction material according to the embodiment of the present invention, in the step of impregnating the friction material with the resin, one surface of the friction material is additionally impregnated with the resin. Since it includes a step of drying at a predetermined temperature condition while applying centrifugal force in the thickness direction with the side additionally impregnated with the resin of the material, the friction on the side additionally impregnated with the resin of the friction material The distribution of the resin amount in the thickness direction from the surface side to the anti-friction surface side can be formed lower in the vicinity of the friction surface than the portion with the highest resin amount in the thickness direction.
図５は本発明の実施の形態にかかる摩擦材の製造を示す説明図である。 FIG. 5 is an explanatory view showing the production of the friction material according to the embodiment of the present invention.
本発明の実施の形態にかかる摩擦材の製造方法は、摩擦材１０の乾燥工程において、摩擦材１０に樹脂を含浸させた状態で、回転ドラム５０に補助具５１に配置させた摩擦材１０を係合手段５２によって使用して取付け、回転ドラム５０の回転によって、摩擦材１０の厚み方向に遠心力を付与しながら、所定の温度条件で乾燥させる工程を含むものであるから、温度条件及び遠心力によって、摩擦材１０の摩擦表面側から反摩擦面側までの厚み方向の樹脂量の分布を、摩擦表面付近が前記厚み方向の最も高い樹脂量の部分よりも任意に低く形成することができる。または、摩擦材１０の乾燥工程において、摩擦材１０の粘性の大きい樹脂を外側として、その厚み方向に遠心力を付与しながら、所定の温度条件で乾燥させる工程を含むものであるから、摩擦材１０の表裏に粘性状態、温度条件及び遠心力によって、摩擦材１０の摩擦表面側から反摩擦面側までの厚み方向の樹脂量の分布を、摩擦表面付近が厚み方向の最も高い樹脂量の部分よりも任意に低く形成することができる。
In the method of manufacturing the friction material according to the embodiment of the present invention, in the drying process of the
上記各実施の形態では、二次元的な操作を前提に説明したが、図５に示すように、三次元的処理を行うことができる。 In each of the above-described embodiments, description has been made on the assumption of a two-dimensional operation, but three-dimensional processing can be performed as shown in FIG.
図６は本発明の実施の形態にかかる摩擦材の製造を示す説明図である。 FIG. 6 is an explanatory view showing the production of the friction material according to the embodiment of the present invention.
即ち、所定の温度条件で乾燥させる際に、所定の回転数で回転する回転台６０の中心に摩擦材１０を置き、摩擦材１０を回転させ、その遠心力によって、摩擦材１０の周囲の樹脂量の分布を高くしたものである。したがって、上記各実施の形態に加えて、摩擦材１０の周囲の樹脂量の分布を高くしたものであるから、負荷に対応した偶力が大きくなる方向の機械的強度を得ることができ、安定した強度となる。
That is, when drying under a predetermined temperature condition, the
即ち、摩擦材１０を最大長の直径で切断したとき、その断面の幅方向と厚み方向の樹脂量の分布は、二次元的に変化することになる。例えば、図６の実施の形態では、この二次元的な樹脂量の分布変化は、摩擦材１０の外周側がその中心側に比較して樹脂量の分布が高く形成されていることになる。また、摩擦材１０の厚みと、その遠心力、温度、樹脂粘度によって、任意の樹脂量の分布変化を得ることができる。
That is, when the
Claims (1)
２枚の摩擦材の摩擦表面同士を重ね合わせたまま乾燥した後、別々にしてまたは重ね合わせたまま加熱硬化させる工程を含むことを特徴とする摩擦材の製造方法。 The resin amount of the impregnated resin is continuously changed in the thickness direction from the friction surface side to the anti-friction surface side by impregnating the resin and drying, and the resin amount in the vicinity of the friction surface is The resin amount is 5% or more lower than the highest resin amount in the thickness direction, and the resin amount in the vicinity of the friction surface is 1% or more lower than the average resin ratio of the entire friction material. In a method of manufacturing a friction material for a friction material engaging device provided with a plurality of or a single friction plate used in an automatic transmission of an automobile or a transmission of a motorcycle,
A method for producing a friction material, comprising: a step of drying the two friction materials while overlapping the friction surfaces, and then heat-curing the friction surfaces separately or while overlapping.
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| JP3831430B2 (en) * | 1995-05-23 | 2006-10-11 | Ｎｓｋワーナー株式会社 | Method for producing wet friction material |
| JPH0989016A (en) * | 1995-09-21 | 1997-03-31 | Sumitomo Electric Ind Ltd | Disk brake pad |
| JPH11322960A (en) * | 1998-03-16 | 1999-11-26 | Akebono Brake Res & Dev Center Ltd | Friction material |
| JP2001026657A (en) * | 1999-07-16 | 2001-01-30 | Toyota Motor Corp | Wet-type friction material and preparation thereof |
| JP2002080824A (en) * | 2000-09-05 | 2002-03-22 | Toyota Motor Corp | Friction material |
| JP4171961B2 (en) * | 2001-01-29 | 2008-10-29 | 株式会社 サーモセッタ | Resin clutch facing and manufacturing method thereof |
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2007
- 2007-11-30 JP JP2007309811A patent/JP4836927B2/en not_active Expired - Lifetime
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