JP6799364B2 - Friction material composition, friction material and friction member - Google Patents
Friction material composition, friction material and friction member Download PDFInfo
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- JP6799364B2 JP6799364B2 JP2015015813A JP2015015813A JP6799364B2 JP 6799364 B2 JP6799364 B2 JP 6799364B2 JP 2015015813 A JP2015015813 A JP 2015015813A JP 2015015813 A JP2015015813 A JP 2015015813A JP 6799364 B2 JP6799364 B2 JP 6799364B2
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- 239000002783 friction material Substances 0.000 title claims description 140
- 239000000203 mixture Substances 0.000 title claims description 71
- 239000000835 fiber Substances 0.000 claims description 59
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 28
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 claims description 28
- 229910052802 copper Inorganic materials 0.000 claims description 28
- 239000010949 copper Substances 0.000 claims description 28
- 239000000463 material Substances 0.000 claims description 24
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 21
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 claims description 20
- 239000000920 calcium hydroxide Substances 0.000 claims description 20
- 229910001861 calcium hydroxide Inorganic materials 0.000 claims description 20
- 238000000465 moulding Methods 0.000 claims description 18
- 229910052725 zinc Inorganic materials 0.000 claims description 18
- 239000011701 zinc Substances 0.000 claims description 18
- 229910052751 metal Inorganic materials 0.000 claims description 17
- 239000002184 metal Substances 0.000 claims description 17
- 229910000831 Steel Inorganic materials 0.000 claims description 14
- 239000011256 inorganic filler Substances 0.000 claims description 14
- 229910003475 inorganic filler Inorganic materials 0.000 claims description 14
- 229910000029 sodium carbonate Inorganic materials 0.000 claims description 14
- 239000010959 steel Substances 0.000 claims description 14
- 229920006231 aramid fiber Polymers 0.000 claims description 13
- NJLLQSBAHIKGKF-UHFFFAOYSA-N dipotassium dioxido(oxo)titanium Chemical compound [K+].[K+].[O-][Ti]([O-])=O NJLLQSBAHIKGKF-UHFFFAOYSA-N 0.000 claims description 10
- 239000012766 organic filler Substances 0.000 claims description 10
- 239000011230 binding agent Substances 0.000 claims description 9
- 239000002245 particle Substances 0.000 claims description 5
- 239000000292 calcium oxide Substances 0.000 claims description 3
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 claims description 2
- AFNRRBXCCXDRPS-UHFFFAOYSA-N tin(ii) sulfide Chemical compound [Sn]=S AFNRRBXCCXDRPS-UHFFFAOYSA-N 0.000 claims description 2
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 57
- 239000005011 phenolic resin Substances 0.000 description 17
- 229920001568 phenolic resin Polymers 0.000 description 11
- 239000002585 base Substances 0.000 description 10
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 9
- 230000000694 effects Effects 0.000 description 9
- 230000003449 preventive effect Effects 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 7
- 239000000843 powder Substances 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 6
- 230000006866 deterioration Effects 0.000 description 6
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 6
- 239000012784 inorganic fiber Substances 0.000 description 5
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 4
- 239000010425 asbestos Substances 0.000 description 4
- 229910052895 riebeckite Inorganic materials 0.000 description 4
- 244000226021 Anacardium occidentale Species 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- 229910000881 Cu alloy Inorganic materials 0.000 description 3
- 239000004760 aramid Substances 0.000 description 3
- 235000020226 cashew nut Nutrition 0.000 description 3
- 229920001971 elastomer Polymers 0.000 description 3
- 230000007613 environmental effect Effects 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 239000010410 layer Substances 0.000 description 3
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 3
- 239000003607 modifier Substances 0.000 description 3
- 150000002989 phenols Chemical class 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 239000005060 rubber 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
- 229920000049 Carbon (fiber) Polymers 0.000 description 2
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229920000459 Nitrile rubber Polymers 0.000 description 2
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 239000012790 adhesive layer Substances 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
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 239000004917 carbon fiber Substances 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 238000011156 evaluation Methods 0.000 description 2
- 239000010419 fine particle Substances 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 239000000395 magnesium oxide Substances 0.000 description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- NUJOXMJBOLGQSY-UHFFFAOYSA-N manganese dioxide Chemical compound O=[Mn]=O NUJOXMJBOLGQSY-UHFFFAOYSA-N 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 239000010445 mica Substances 0.000 description 2
- 229910052618 mica group Inorganic materials 0.000 description 2
- 239000002557 mineral fiber Substances 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 229910052700 potassium Inorganic materials 0.000 description 2
- 239000011591 potassium Substances 0.000 description 2
- 229920003048 styrene butadiene rubber Polymers 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- 229920002972 Acrylic fiber Polymers 0.000 description 1
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 229920003043 Cellulose fiber Polymers 0.000 description 1
- MBMLMWLHJBBADN-UHFFFAOYSA-N Ferrous sulfide Chemical compound [Fe]=S MBMLMWLHJBBADN-UHFFFAOYSA-N 0.000 description 1
- 229920000271 Kevlar® Polymers 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 241000221535 Pucciniales Species 0.000 description 1
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 239000002174 Styrene-butadiene Substances 0.000 description 1
- 241001255854 Teras Species 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- 229920000561 Twaron Polymers 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- 239000005083 Zinc sulfide Substances 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 229920000800 acrylic rubber Polymers 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- -1 alkali metal salt Chemical class 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229940007424 antimony trisulfide Drugs 0.000 description 1
- NVWBARWTDVQPJD-UHFFFAOYSA-N antimony(3+);trisulfide Chemical compound [S-2].[S-2].[S-2].[Sb+3].[Sb+3] NVWBARWTDVQPJD-UHFFFAOYSA-N 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 238000000889 atomisation Methods 0.000 description 1
- 229920005549 butyl rubber Polymers 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- NNLOHLDVJGPUFR-UHFFFAOYSA-L calcium;3,4,5,6-tetrahydroxy-2-oxohexanoate Chemical compound [Ca+2].OCC(O)C(O)C(O)C(=O)C([O-])=O.OCC(O)C(O)C(O)C(=O)C([O-])=O NNLOHLDVJGPUFR-UHFFFAOYSA-L 0.000 description 1
- 239000004918 carbon fiber reinforced polymer Substances 0.000 description 1
- 229910000420 cerium oxide Inorganic materials 0.000 description 1
- 229920005556 chlorobutyl Polymers 0.000 description 1
- ZCDOYSPFYFSLEW-UHFFFAOYSA-N chromate(2-) Chemical compound [O-][Cr]([O-])(=O)=O ZCDOYSPFYFSLEW-UHFFFAOYSA-N 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 229910052570 clay Inorganic materials 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
- 239000010459 dolomite Substances 0.000 description 1
- 229910000514 dolomite Inorganic materials 0.000 description 1
- 239000011151 fibre-reinforced plastic Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000000383 hazardous chemical Substances 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- 229920003049 isoprene rubber Polymers 0.000 description 1
- 239000004761 kevlar Substances 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- HZZOEADXZLYIHG-UHFFFAOYSA-N magnesiomagnesium Chemical compound [Mg][Mg] HZZOEADXZLYIHG-UHFFFAOYSA-N 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 description 1
- 229910052982 molybdenum disulfide Inorganic materials 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
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- 239000010703 silicon Substances 0.000 description 1
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- 239000000377 silicon dioxide Substances 0.000 description 1
- 229920002379 silicone rubber Polymers 0.000 description 1
- 239000004945 silicone rubber Substances 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- GROMGGTZECPEKN-UHFFFAOYSA-N sodium metatitanate Chemical compound [Na+].[Na+].[O-][Ti](=O)O[Ti](=O)O[Ti]([O-])=O GROMGGTZECPEKN-UHFFFAOYSA-N 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
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- 239000000126 substance Substances 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
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- 238000010998 test method Methods 0.000 description 1
- 239000011135 tin Substances 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 239000004762 twaron Substances 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
- 210000002268 wool Anatomy 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
- 229940007718 zinc hydroxide Drugs 0.000 description 1
- 229910021511 zinc hydroxide Inorganic materials 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
- 235000014692 zinc oxide Nutrition 0.000 description 1
- 229910052984 zinc sulfide Inorganic materials 0.000 description 1
- DRDVZXDWVBGGMH-UHFFFAOYSA-N zinc;sulfide Chemical compound [S-2].[Zn+2] DRDVZXDWVBGGMH-UHFFFAOYSA-N 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
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- Braking Arrangements (AREA)
Description
本発明は、自動車等の制動に用いられるディスクブレーキパッド等の摩擦材に適した摩擦材組成物に関し、特にアスベストを含まないノンアスベスト摩擦材組成物に関する。また、該摩擦材組成物を用いた摩擦材および摩擦部材に関する。 The present invention relates to a friction material composition suitable for a friction material such as a disc brake pad used for braking an automobile or the like, and particularly to a non-asbestos friction material composition containing no asbestos. Further, the present invention relates to a friction material and a friction member using the friction material composition.
自動車等には、その制動のためにディスクブレーキパッド、ブレーキライニング等の摩擦材が使用されている。摩擦材は、ディスクローター、ブレーキドラム等の対面材と摩擦することにより、制動の役割を果たしている。そのため、摩擦材には、良好な摩擦係数、耐摩耗性（摩擦材の寿命が長いこと）、強度、音振性（ブレーキ鳴きや異音が発生しにくいこと）等が要求される。摩擦係数は車速、減速度やブレーキ温度によらず安定であることが要求される。また、摩擦界面で発生した錆によって摩擦材が摩擦対面材と固着し、発車時の異音発生や摩擦材の表面剥離（錆剥離）などの問題が生じる場合がある。錆固着性能を改善するために、犠牲陽極として作用する亜鉛やｐＨを上げるアルカリ金属塩を添加するなどの摩擦材組成が提案されている。（特許文献１〜２） Friction materials such as disc brake pads and brake linings are used for braking in automobiles and the like. The friction material plays a role of braking by rubbing against a facing material such as a disc rotor and a brake drum. Therefore, the friction material is required to have a good friction coefficient, wear resistance (the life of the friction material is long), strength, sound vibration property (less likely to generate brake squeal or abnormal noise), and the like. The coefficient of friction is required to be stable regardless of vehicle speed, deceleration and braking temperature. In addition, the rust generated at the friction interface may cause the friction material to adhere to the friction facing material, causing problems such as generation of abnormal noise at the time of departure and surface peeling (rust peeling) of the friction material. In order to improve the rust fixing performance, a friction material composition such as adding zinc acting as a sacrificial anode or an alkali metal salt for raising pH has been proposed. (Patent Documents 1 and 2)
摩擦材には、結合材、繊維基材、無機充填材および有機充填材等を含む摩擦材組成物が用いられ、前記特性を発現させるために、一般的に、各成分を１種または２種以上を組合せた摩擦材組成物が用いられる。中でも銅は繊維や粉末の形態で摩擦材に配合され、高温での制動条件下での摩擦係数の保持（耐フェード性）や高温での耐摩耗性改善、摩擦材の強度向上に有効な成分である。しかし、銅を含有する摩擦材は、制動時に生成する摩耗粉に銅を含み、河川、湖や海洋汚染等の原因となる可能性が示唆されているため、使用を制限する動きが高まっている。 As the friction material, a friction material composition containing a binder, a fiber base material, an inorganic filler, an organic filler and the like is used, and in order to exhibit the above-mentioned characteristics, generally one or two kinds of each component are used. A friction material composition combining the above is used. Among them, copper is compounded in the friction material in the form of fiber or powder, and is an effective component for maintaining the friction coefficient (fade resistance) under braking conditions at high temperature, improving wear resistance at high temperature, and improving the strength of the friction material. Is. However, copper-containing friction materials contain copper in the abrasion powder generated during braking, and it has been suggested that it may cause pollution of rivers, lakes, oceans, etc., so there is a growing movement to limit its use. ..
このような銅の使用量を制限する動きの中、特許文献３には、銅を含有しない組成における強度、耐摩耗性を改善する手法として、複数の凸形状を有するチタン酸カリウムと生体溶解性無機繊維とを含有させることを特徴とする摩擦材が提案されている。 In such a movement to limit the amount of copper used, Patent Document 3 describes potassium titanate having a plurality of convex shapes and biosolubility as a method for improving strength and abrasion resistance in a composition containing no copper. A friction material characterized by containing an inorganic fiber has been proposed.
環境有害性の高い銅を含まない摩擦材は材料強度が低く、錆剥離が問題となる。特許文献１〜２で提案されている防錆効果や、特許文献３で提案されている銅を含有しない組成における摩擦材強度向上では、銅を含有しない摩擦材の錆剥離の改善効果は充分ではなかった。 Friction materials that do not contain copper, which are highly harmful to the environment, have low material strength, and rust peeling becomes a problem. In the rust preventive effect proposed in Patent Documents 1 and 2 and the improvement of the friction material strength in the copper-free composition proposed in Patent Document 3, the effect of improving the rust peeling of the friction material not containing copper is sufficient. There wasn't.
本発明では、上記事情を鑑みなされたもので、環境負荷の高い銅を含有しない、または銅の含有量が０．５質量％以下の摩擦材において、錆固着力、錆剥離の少ない摩擦材を提供することを目的とするものである。 The present invention has been made in view of the above circumstances, and in a friction material which does not contain copper having a high environmental load or has a copper content of 0.5% by mass or less, a friction material having less rust adhesion and rust peeling is provided. It is intended to be provided.
本発明者らは、銅を含有せず、摩擦材の材料強度を向上するためにフィブリル化アラミド繊維を含有する組成において、特定量の水酸化カルシウムと粉末状の亜鉛を組合わせて含有することで、錆固着力を効果的に低減し、錆剥離を抑制させることができることを見出した。 The present inventors shall contain a specific amount of calcium hydroxide and powdered zinc in combination in a composition containing fibrillated aramid fibers in order to improve the material strength of the friction material without containing copper. Therefore, it was found that the rust fixing force can be effectively reduced and the rust peeling can be suppressed.
水酸化カルシウムはｐＨが高く、摩擦対面材の防錆効果があるだけでなく摩擦材の成形時にフェノール樹脂の硬化触媒として作用し、摩擦材強度を向上させるが、過度に添加するとフィブリル化アラミド繊維の強度を低下させることを見出した。この水酸化カルシウムについて、錆固着力と錆剥離の抑制効果が最大となる添加量範囲を検討した。 Calcium hydroxide has a high pH and not only has a rust preventive effect on the friction facing material, but also acts as a curing catalyst for the phenolic resin during molding of the friction material, improving the strength of the friction material. However, if it is added excessively, the fibrillated aramid fiber It was found to reduce the strength of. Regarding this calcium hydroxide, the range of addition amount that maximizes the rust adhesion and the effect of suppressing rust peeling was examined.
また、水酸化カルシウムとともに粉末状の亜鉛を摩擦材中に分散させると、亜鉛が制動により摩擦界面に延展し、摩擦界面に延展した亜鉛の犠牲陽極作用により摩擦界面全体の防錆効果を示すとともに、上記の水酸化カルシウムのｐＨ、摩擦材強度向上効果との相乗効果で、銅を含有しない組成における錆固着力、錆剥離を大幅に抑制させることが可能であることを見出した。 In addition, when powdered zinc is dispersed in the friction material together with calcium hydroxide, the zinc spreads to the friction interface by braking, and the sacrificial anode action of the zinc spread to the friction interface exhibits a rust preventive effect on the entire friction interface. It has been found that the synergistic effect of the above-mentioned pH of calcium hydroxide and the effect of improving the strength of the friction material can significantly suppress the rust fixing force and the rust peeling in the copper-free composition.
さらに、摩擦材強度を向上せしめかつ発錆量が少なくなる特定量のスチール繊維の添加や、同じく摩擦材強度を向上せしめる複数の凸部形状を有するチタン酸カリウム、易溶性で水酸化カルシウムと反応し水酸化ナトリウムを生成することで高い防錆効果を付与する炭酸ナトリウムの添加により、本発明の摩擦材組成における錆固着力、錆剥離の改善効果を更に向上させることができることを見出した。 Furthermore, the addition of a specific amount of steel fiber that improves the strength of the friction material and reduces the amount of rust, potassium titanate having a plurality of convex shapes that also improves the strength of the friction material, and easily soluble and reacts with calcium hydroxide. It has been found that the addition of sodium carbonate, which imparts a high rust preventive effect by producing sodium hydroxide, can further improve the rust adhesion and rust peeling effect in the friction material composition of the present invention.
本発明はこれらの知見に基づくものであり、本発明の摩擦材組成物は、具体的に、結合剤、有機充填材、無機充填材および繊維基材を含む摩擦材組成物であって、該摩擦材組成物中に元素としての銅を含まない、または銅の含有量が０．５質量％以下であり、前記繊維基材としてフィブリル化アラミド繊維を含有するとともに、無機充填材として、粉末状の亜鉛、および水酸化カルシウムを含有し、前記水酸化カルシウムの含有量が２．５〜１０質量％であることを特徴とする。 The present invention is based on these findings, and the friction material composition of the present invention is specifically a friction material composition containing a binder, an organic filler, an inorganic filler and a fiber base material. The friction material composition does not contain copper as an element, or has a copper content of 0.5% by mass or less, contains fibrillated aramid fiber as the fiber base material, and is in powder form as an inorganic filler. It contains zinc and calcium hydroxide, and the content of the calcium hydroxide is 2.5 to 10% by mass.
本発明の摩擦材組成物においては、前記粉末状の亜鉛の含有量が１〜１０質量％であることが好ましく、前記粉末状の亜鉛の粒子径が１０〜５００μｍであることが好ましい。また、前記繊維基材としてスチール繊維を２〜８質量％で含有することが好ましく、前記無機充填材として、複数の凸部形状を有するチタン酸カリウムを含有することが好ましい。また、炭酸ナトリウムを含有することが好ましい。 In the friction material composition of the present invention, the content of the powdered zinc is preferably 1 to 10% by mass, and the particle size of the powdered zinc is preferably 10 to 500 μm. Further, it is preferable that the fiber base material contains 2 to 8% by mass of steel fiber, and the inorganic filler preferably contains potassium titanate having a plurality of convex shapes. Moreover, it is preferable to contain sodium carbonate.
本発明の摩擦材は、上記の本発明の摩擦材組成物を成形してなることを特徴とするものであり、本発明の摩擦部材は、上記の本発明の摩擦材組成物を成形してなる摩擦材と裏金とを用いて形成されることを特徴とするものである。 The friction material of the present invention is characterized by molding the above-mentioned friction material composition of the present invention, and the friction member of the present invention is obtained by molding the above-mentioned friction material composition of the present invention. It is characterized in that it is formed by using a friction material and a back metal.
本発明によれば、自動車用ディスクブレーキパッド等の摩擦材に用いた際に、環境負荷の高い銅を用いなくとも、錆固着力が小さく錆剥離の少ない摩擦材組成物、摩擦材および摩擦部材を提供することができる。 According to the present invention, when used as a friction material for automobile disc brake pads and the like, a friction material composition, a friction material and a friction member having a small rust adhesion force and a small amount of rust peeling are used without using copper having a high environmental load. Can be provided.
以下、本発明の摩擦材組成物、これを用いた摩擦材および摩擦部材について詳述する。なお、本発明の摩擦材組成物は、アスベストを含まない、いわゆるノンアスベスト摩擦材組成物である。 Hereinafter, the friction material composition of the present invention, the friction material and the friction member using the friction material composition will be described in detail. The friction material composition of the present invention is a so-called non-asbestos friction material composition that does not contain asbestos.
［摩擦材組成物］
本実施形態の摩擦材組成物は、銅を含有しない、もしくは銅を含有する場合において銅の含有量が０．５質量％以下であることを特徴とする摩擦材組成物である。すなわち、環境有害性の高い銅および銅合金を実質的に含有せず、元素としての銅の含有量が０．５重量％以下であり、好ましくは含有量０質量％の摩擦材である。このため、制動時に摩耗粉が生成しても、河川、湖や海洋汚染の原因とならない。
[Friction material composition]
The friction material composition of the present embodiment is a friction material composition characterized in that it does not contain copper, or when it contains copper, the content of copper is 0.5% by mass or less. That is, it is a friction material that does not substantially contain copper and a copper alloy having high environmental hazards, and has a copper content of 0.5% by weight or less as an element, preferably a content of 0% by mass. Therefore, even if wear debris is generated during braking, it does not cause pollution of rivers, lakes and the ocean.
（フィブリル化アラミド繊維）
本発明の摩擦材組成物は、フィブリル化アラミド繊維を含む。本発明のフィブリル化アラミド繊維とは、複数の枝分かれを有し、ＢＥＴ比表面積が５〜１５ｍ２／ｇであることが特徴であり、帝人株式会社製Ｔｗａｒｏｎ１０９９，１０９５，３０９１、東レ・デュポン株式会社製ケブラー１Ｆ５３８，１Ｆ１７１０などが挙げられる。本発明におけるフィブリル化アラミド繊維は、繊維強度が高く多数の枝分かれを有するため、銅を含有しない組成においても効果的に摩擦材強度を向上させるが、高いｐＨの水溶液に長時間曝露することで、加水分解により強度が低下する。
(Fibrilized aramid fiber)
The friction material composition of the present invention contains fibrillated aramid fibers. The fibrillated aramid fiber of the present invention is characterized by having a plurality of branches and having a BET specific surface area of 5 to 15 m 2 / g, Twaron 1099, 1095, 3091 manufactured by Teijin Limited, and Toray DuPont Co., Ltd. Examples thereof include Kevlar 1F538 and 1F1710. Since the fibrillated aramid fiber in the present invention has high fiber strength and has a large number of branches, the friction material strength is effectively improved even in a composition not containing copper, but by long-term exposure to an aqueous solution having a high pH, The strength is reduced by hydrolysis.
（水酸化カルシウム）
本発明の摩擦材組成物は、特定量の水酸化カルシウムを含む。水酸化カルシウムは、ｐＨが高く、摩擦対面材の防錆効果があるだけでなく摩擦材の成形時にフェノール樹脂の硬化触媒として作用し、摩擦材の強度を向上させる効果がある。この効果を得るため水酸化カルシウムを２．５質量％以上含有させる。その一方で、水酸化カルシウムを過度に添加すると、フィブリル化アラミド繊維の強度が低下することとなる。このため、水酸化カルシウムの含有量は１０質量％以下とする。水酸化カルシウムは、通常摩擦材に用いられる粉末状の水酸化カルシウムを用いることができるが、水溶性の観点で、粒径の細かいもの、特に１００μｍ以下の粉末が好ましい。
(Calcium hydroxide)
The friction material composition of the present invention contains a specific amount of calcium hydroxide. Calcium hydroxide has a high pH and not only has a rust preventive effect on the friction facing material, but also acts as a curing catalyst for the phenol resin during molding of the friction material, and has an effect of improving the strength of the friction material. In order to obtain this effect, calcium hydroxide is contained in an amount of 2.5% by mass or more. On the other hand, excessive addition of calcium hydroxide will reduce the strength of the fibrillated aramid fibers. Therefore, the content of calcium hydroxide is set to 10% by mass or less. As the calcium hydroxide, powdered calcium hydroxide usually used as a friction material can be used, but from the viewpoint of water solubility, a powder having a fine particle size, particularly a powder having a particle size of 100 μm or less is preferable.
（亜鉛粉）
本発明の摩擦材組成物は、粉末状の亜鉛を含む。粉末状の亜鉛は、制動により摩擦材の摩擦界面に延展して摩擦界面を被覆する状態となるが、亜鉛は酸化しやすいことから摩擦界面を被覆した亜鉛が、犠牲陽極作用により選択的に酸化されることで、摩擦材中の他の成分の酸化すなわち発錆を防止して摩擦界面全体の防錆を行う。粉末状の亜鉛としては、アトマイズなどで製造される通常摩擦材に用いられる粉末状の亜鉛を用いることができるが、摩擦材表面での延展による防錆効果の観点で粒径は細かいほどよく、１０〜５００μｍが好ましく、１０〜１００μｍがより好ましい。また、亜鉛の添加量は、防錆効果の観点で１質量％以上が好ましく、２質量％がより好ましい。また、亜鉛の過剰添加は、高温使用時における摩擦材の耐摩耗性の悪化を引き起こすため、１０質量％以下の添加量で用いることが好ましく、８質量％がより好ましい。
(Zinc powder)
The friction material composition of the present invention contains powdered zinc. Powdered zinc spreads to the friction interface of the friction material by braking and covers the friction interface, but since zinc is easily oxidized, the zinc covering the friction interface is selectively oxidized by the sacrificial anode action. By doing so, oxidation of other components in the friction material, that is, rusting is prevented, and the entire friction interface is prevented from rusting. As the powdered zinc, powdered zinc usually used for friction materials manufactured by atomization or the like can be used, but the finer the particle size, the better from the viewpoint of the rust preventive effect due to the spread on the friction material surface. 10 to 500 μm is preferable, and 10 to 100 μm is more preferable. The amount of zinc added is preferably 1% by mass or more, more preferably 2% by mass, from the viewpoint of rust preventive effect. Further, excessive addition of zinc causes deterioration of wear resistance of the friction material at the time of high temperature use, so it is preferable to use it in an addition amount of 10% by mass or less, and more preferably 8% by mass.
（スチール繊維）
本発明の摩擦材組成物は、スチール繊維を含むことが好ましい。スチール繊維は、びびり振動切削法などで得られるストレート繊維と、長繊維のカットなどで得られるカール状繊維がある。ストレート繊維が直線状の繊維形状なのに対し、カール状繊維は曲線部を有する形状を示すものであり、単純な円弧状のものや、うねったもの、螺旋状あるいは渦巻き状に曲がったもの等を含む。スチール繊維は、ストレート繊維やカール状繊維のいずれのものであっても、摩擦界面で摩擦熱を拡散し、不均一な温度上昇を抑制するだけでなく、摩擦界面で生成する有機分解物を適度にクリーニングする効果を有するため、制動中に発生するブレーキトルクの変動が小さくなり、ブレーキ振動を発生しにくくして抑制することができる。ただし、カール状繊維のほうが摩擦界面において摩擦材からの脱落が少なく、高温制動における摩擦特性保持の観点で好ましい。さらに、カール状繊維としては、曲率半径が１００μｍ以下の部分を含むものであると、摩擦材への固着がより強固となり、摩擦界面における摩擦材の脱落がより少なくなるので、より好ましい。カール状のスチール繊維は、日本スチールウール株式会社製カットウールなど、市販されているものを使用することができる。
(Steel fiber)
The friction material composition of the present invention preferably contains steel fibers. Steel fibers include straight fibers obtained by chatter vibration cutting and the like, and curled fibers obtained by cutting long fibers. While straight fibers have a linear fiber shape, curled fibers have a curved portion, and include simple arc-shaped fibers, undulating fibers, spiral fibers, and spiral fibers. .. Whether the steel fiber is a straight fiber or a curled fiber, it not only diffuses frictional heat at the frictional interface and suppresses a non-uniform temperature rise, but also moderately produces organic decomposition products at the frictional interface. Since it has the effect of cleaning, the fluctuation of the brake torque generated during braking is reduced, and the brake vibration is less likely to be generated and can be suppressed. However, curled fibers are less likely to fall off from the friction material at the friction interface, and are preferable from the viewpoint of maintaining friction characteristics during high-temperature braking. Further, it is more preferable that the curled fiber includes a portion having a radius of curvature of 100 μm or less because the adhesion to the friction material becomes stronger and the friction material does not fall off at the friction interface. As the curled steel fiber, commercially available one such as cut wool manufactured by Nippon Steel Wool Co., Ltd. can be used.
スチール繊維は、摩擦材の強度を向上させ錆剥離を抑制するが、スチール繊維自体が錆びることで、多量の添加により錆固着力を増加させてしまう。スチール繊維の含有量を２〜８質量％とすることで、本発明の摩擦材組成において、錆固着力と錆剥離を両立して抑制することができる。スチール繊維の繊維径は、高温における耐摩耗性の観点で１００μｍ以下が好ましい。スチール繊維の繊維長は、高温における耐摩耗性の観点で２５００μｍ以下が好ましい。 Steel fiber improves the strength of the friction material and suppresses rust peeling, but when the steel fiber itself rusts, the rust adhesion is increased by adding a large amount. By setting the content of the steel fiber to 2 to 8% by mass, the friction material composition of the present invention can suppress both rust adhesion and rust peeling at the same time. The fiber diameter of the steel fiber is preferably 100 μm or less from the viewpoint of wear resistance at high temperatures. The fiber length of the steel fiber is preferably 2500 μm or less from the viewpoint of wear resistance at high temperatures.
（複数の凸形状を有するチタン酸カリウム）
本発明の摩擦材組成物は、通常の摩擦材組成物において用いられるチタン酸塩を用いることができる。チタン酸塩は、銅を含有しない組成における高温制動におけるブレーキ振動低減とロータ摩耗量の低減に寄与する。このようなチタン酸塩としては、複数の凸形状を有するチタン酸塩を含むことが好ましい。本発明の複数の凸形状を有するチタン酸カリウムとは、不規則な方向に複数の凸部が延びる形状を有する不定形のチタン酸カリウムのことで、摩擦調整剤として用いることができることが知られている（特許文献３）。例えば、大塚化学株式会社製「テラセスＪＰ」が挙げられる。このような不規則な方向に複数の凸部が延びる形状を有する不定形のチタン酸カリウムは、凸部が摩擦材の強度向上に効果的であり、特に本発明の摩擦材組成物の錆剥離の抑制に効果的である。本発明の摩擦材組成物中における複数の凸形状を有するチタン酸カリウムの含有量は、錆剥離抑制の観点で１〜３０質量％が好ましく、１〜２０質量％であることがより好ましい。
(Potassium titanate with multiple convex shapes)
As the friction material composition of the present invention, the titanate used in a normal friction material composition can be used. Titanate contributes to the reduction of brake vibration and the amount of rotor wear in high temperature braking in a copper-free composition. Such a titanate preferably contains a titanate having a plurality of convex shapes. The potassium titanate having a plurality of convex shapes of the present invention is an amorphous potassium titanate having a shape in which a plurality of convex portions extend in irregular directions, and it is known that it can be used as a friction modifier. (Patent Document 3). For example, "Terases JP" manufactured by Otsuka Chemical Co., Ltd. can be mentioned. The amorphous potassium titanate having a shape in which a plurality of convex portions extend in such irregular directions is effective in improving the strength of the friction material, and in particular, rust peeling of the friction material composition of the present invention. It is effective in suppressing rust. The content of potassium titanate having a plurality of convex shapes in the friction material composition of the present invention is preferably 1 to 30% by mass, more preferably 1 to 20% by mass from the viewpoint of suppressing rust peeling.
（炭酸ナトリウム）
本発明の摩擦材組成物は炭酸ナトリウムを含むことが好ましい。炭酸ナトリウムは、ｐＨが水酸化カルシウムより低いが、易溶性であるため、水酸化ナトリウムと併用することで、水酸化カルシウムによる防錆効果および摩擦材の強度向上効果をより高め、銅を含有しない組成における錆固着力を大幅に低減し、錆剥離を効果的に抑制することができるようになる。炭酸ナトリウムを併用する場合、上記効果を得るため炭酸ナトリウムの含有量は０．２質量％以上とすることが好ましい。その一方で、炭酸ナトリウムの含有量が過多となると、ｐＨが高くなって、フィブリル化アラミド繊維の強度が低下することとなるため、炭酸ナトリウムの含有量は２質量％以下とすることが好ましい。炭酸ナトリウムは、通常摩擦材に用いられる粉末状の炭酸ナトリウムを用いることができるが、水溶性の観点で、粒径の細かいもの、特に１００μｍ以下の粉末が好ましい。
(sodium carbonate)
The friction material composition of the present invention preferably contains sodium carbonate. Sodium carbonate has a lower pH than calcium hydroxide, but is easily soluble. Therefore, when used in combination with sodium hydroxide, the rust preventive effect of calcium hydroxide and the effect of improving the strength of the friction material are further enhanced, and copper is not contained. The rust sticking force in the composition can be significantly reduced, and rust peeling can be effectively suppressed. When sodium carbonate is used in combination, the content of sodium carbonate is preferably 0.2% by mass or more in order to obtain the above effects. On the other hand, if the sodium carbonate content is excessive, the pH will increase and the strength of the fibrillated aramid fiber will decrease. Therefore, the sodium carbonate content is preferably 2% by mass or less. As the sodium carbonate, powdered sodium carbonate usually used as a friction material can be used, but from the viewpoint of water solubility, a powder having a fine particle size, particularly a powder having a particle size of 100 μm or less is preferable.
（結合材）
結合剤は、摩擦材組成物に含まれる有機充填材、無機充填材および繊維基材などを一体化し、強度を与えるものである。本発明の摩擦材用組成物に含まれる結合材としては、特に制限は無く、通常、摩擦材の結合材として用いられる熱硬化性樹脂を用いることができる。
(Binder)
The binder integrates the organic filler, the inorganic filler, the fiber base material, and the like contained in the friction material composition to give strength. The binder contained in the composition for friction material of the present invention is not particularly limited, and a thermosetting resin usually used as a binder for friction material can be used.
上記熱硬化性樹脂としては、例えば、フェノール樹脂；アクリルエラストマー分散フェノール樹脂およびシリコーンエラストマー分散フェノール樹脂などの各種エラストマー分散フェノール樹脂；アクリル変性フェノール樹脂、シリコーン変性フェノール樹脂、カシュー変性フェノール樹脂、エポキシ変性フェノール樹脂およびアルキルベンゼン変性フェノール樹脂などの各種変性フェノール樹脂などが挙げられ、これらを単独でまたは２種類以上を組み合わせて使用することができる。特に、良好な耐熱性、成形性および摩擦係数を与えることから、フェノール樹脂、アクリル変性フェノール樹脂、シリコーン変性フェノール樹脂、アルキルベンゼン変性フェノール樹脂を用いることが好ましい。 Examples of the thermosetting resin include phenolic resins; various elastomer-dispersed phenolic resins such as acrylic elastomer-dispersed phenolic resins and silicone elastomer-dispersed phenolic resins; acrylic-modified phenolic resins, silicone-modified phenolic resins, cashew-modified phenolic resins, and epoxy-modified phenolic resins. Examples thereof include resins and various modified phenolic resins such as alkylbenzene-modified phenolic resins, and these can be used alone or in combination of two or more. In particular, it is preferable to use a phenol resin, an acrylic-modified phenol resin, a silicone-modified phenol resin, or an alkylbenzene-modified phenol resin because it provides good heat resistance, moldability, and a coefficient of friction.
本発明の摩擦材組成物中における、結合材の含有量は、５〜２０質量％であることが好ましく、５〜１０質量％であることがより好ましい。結合材の含有量を５〜２０質量％の範囲とすることで、摩擦材の強度低下をより抑制でき、また、摩擦材の気孔率が減少し、弾性率が高くなることによる鳴きなどの音振性能悪化をより抑制できる。 The content of the binder in the friction material composition of the present invention is preferably 5 to 20% by mass, and more preferably 5 to 10% by mass. By setting the content of the binder in the range of 5 to 20% by mass, it is possible to further suppress the decrease in the strength of the friction material, and the porosity of the friction material is reduced and the elastic modulus is increased, resulting in noise such as squealing. Deterioration of vibration performance can be further suppressed.
（有機充填剤）
有機充填材は、摩擦材の音振性能や耐摩耗性などを向上させるための摩擦調整剤として含まれるものである。本発明の摩擦材組成物に含まれる有機充填材としては、上記性能を発揮できるものであれば特に制限はなく、通常、有機充填材として用いられる、カシューダストやゴム成分などを用いることができる。
(Organic filler)
The organic filler is contained as a friction modifier for improving the sound vibration performance and wear resistance of the friction material. The organic filler contained in the friction material composition of the present invention is not particularly limited as long as it can exhibit the above performance, and cashew dust, a rubber component, or the like, which is usually used as an organic filler, can be used. ..
上記カシューダストは、カシューナッツシェルオイルを硬化させたものを粉砕して得られる、通常、摩擦材に用いられるものであればよい。 The cashew dust may be any one usually used as a friction material, which is obtained by crushing a hardened cashew nut shell oil.
上記ゴム成分としては、例えば、タイヤゴム、アクリルゴム、イソプレンゴム、ＮＢＲ（ニトリルブタジエンゴム）、ＳＢＲ（スチレンブタジエンゴム）、塩素化ブチルゴム、ブチルゴム、シリコーンゴム、などが挙げられ、これらを単独でまたは２種類以上を組み合わせて使用される。 Examples of the rubber component include tire rubber, acrylic rubber, isoprene rubber, NBR (nitrile butadiene rubber), SBR (styrene butadiene rubber), chlorinated butyl rubber, butyl rubber, silicone rubber, and the like, and these may be used alone or 2 Used in combination of more than one type.
本発明の摩擦材組成物中における、有機充填材の含有量は、１〜２０質量％であることが好ましく、１〜１０質量％であることがより好ましく、３〜８質量％であることが特に好ましい。有機充填材の含有量を１〜２０質量％の範囲とすることで、摩擦材の弾性率が高くなること、鳴きなどの音振性能の悪化を避けることができ、また耐熱性の悪化、熱履歴による強度低下を避けることができる。 The content of the organic filler in the friction material composition of the present invention is preferably 1 to 20% by mass, more preferably 1 to 10% by mass, and preferably 3 to 8% by mass. Especially preferable. By setting the content of the organic filler in the range of 1 to 20% by mass, the elastic modulus of the friction material becomes high, deterioration of sound vibration performance such as squeal can be avoided, and deterioration of heat resistance and heat can be avoided. It is possible to avoid a decrease in strength due to history.
（無機充填材）
無機充填材は、摩擦材の耐熱性の悪化を避けるためや、耐摩耗性を向上させるため、摩擦係数を向上する目的で添加される摩擦調整剤として含まれるものである。本発明の摩擦材用組成物は、通常、摩擦材に用いられる無機充填剤であれば特に制限はない。
(Inorganic filler)
The inorganic filler is contained as a friction modifier added for the purpose of improving the friction coefficient in order to avoid deterioration of the heat resistance of the friction material and to improve the wear resistance. The composition for a friction material of the present invention is not particularly limited as long as it is an inorganic filler usually used for the friction material.
上記無機充填材としては、例えば、マイカ、硫化錫、二硫化モリブデン、硫化鉄、三硫化アンチモン、硫化ビスマス、硫化亜鉛、酸化カルシウム、硫酸バリウム、コークス、黒鉛、マイカ、バーミキュライト、硫酸カルシウム、タルク、クレー、ゼオライト、ムライト、クロマイト、酸化チタン、酸化マグネシウム、シリカ、ドロマイト、炭酸カルシウム、炭酸マグネシウム、γアルミナ、珪酸ジルコニウム、二酸化マンガン、酸化亜鉛、酸化セリウム、ジルコニア、酸化鉄などを用いることができ、これらを単独でまたは２種類以上を組み合わせて使用することができる。また、前記複数の凸形状を有するチタン酸カリウムの他に粒状または板状のチタン酸塩を組合わせて用いることができる。粒状または板状のチタン酸塩としては、６チタン酸カリウム、８チタン酸カリウム、チタン酸リチウムカリウム、チタン酸マグネシウムカリウム、チタン酸ナトリウムなどを用いることができる。 Examples of the inorganic filler include mica, tin sulfide, molybdenum disulfide, iron sulfide, antimony trisulfide, bismuth sulfide, zinc sulfide, calcium oxide, barium sulfate, coke, graphite, mica, vermiculite, calcium sulfate, talc, and the like. Clay, zeolite, mullite, chromate, titanium oxide, magnesium oxide, silica, dolomite, calcium carbonate, magnesium carbonate, γ alumina, zirconium silicate, manganese dioxide, zinc oxide, cerium oxide, zirconia, iron oxide, etc. can be used. These can be used alone or in combination of two or more. Further, in addition to the above-mentioned potassium titanate having a plurality of convex shapes, granular or plate-shaped titanate can be used in combination. As the granular or plate-shaped titanate, potassium hexatitanate, potassium octatate, lithium titanate, magnesium magnesium titanate, sodium titanate and the like can be used.
本発明の摩擦材組成物中における、無機充填材の含有量は、３０〜８０質量％であることが好ましく、４０〜７０質量％であることがより好ましく、５０〜６０質量％であることが特に好ましい。無機充填材の含有量を３０〜８０質量％の範囲とすることで、耐熱性の悪化を避けることができ、摩擦材のその他成分の含有量バランスの点でも好ましい。 The content of the inorganic filler in the friction material composition of the present invention is preferably 30 to 80% by mass, more preferably 40 to 70% by mass, and preferably 50 to 60% by mass. Especially preferable. By setting the content of the inorganic filler in the range of 30 to 80% by mass, deterioration of heat resistance can be avoided, and it is also preferable in terms of the content balance of other components of the friction material.
（繊維基材）
繊維基材は、摩擦材において補強作用を示すものである。
(Fiber base material)
The fiber base material exhibits a reinforcing action in the friction material.
本発明の摩擦材組成物は、通常、繊維基材として用いられる、無機繊維、金属繊維、有機繊維、炭素系繊維などを用いることができ、これらを単独でまたは二種類以上を組み合わせて使用することができる。 In the friction material composition of the present invention, inorganic fibers, metal fibers, organic fibers, carbon-based fibers and the like, which are usually used as a fiber base material, can be used, and these are used alone or in combination of two or more. be able to.
上記無機繊維としては、セラミック繊維、生分解性セラミック繊維、鉱物繊維、ガラス繊維、シリケート繊維などを用いることができ、１種または２種以上を組み合わせて用いることができる。これら、無機繊維の中では、ＳｉＯ２、Ａｌ２Ｏ３、ＣａＯ、ＭｇＯ、ＦｅＯ、Ｎａ２Ｏなどを任意の組み合わせで含有した生分解性鉱物繊維が好ましく、市販品としてはLAPINUS FIBERS B.V製のＲｏｘｕｌシリーズなどが挙げられる。 As the inorganic fiber, ceramic fiber, biodegradable ceramic fiber, mineral fiber, glass fiber, silicate fiber and the like can be used, and one kind or a combination of two or more kinds can be used. Among these inorganic fibers, biodegradable mineral fibers containing SiO 2 , Al 2 O 3 , CaO, MgO, FeO, Na 2 O, etc. in any combination are preferable, and commercially available products are manufactured by LAPINUS FIBERS BV. The Rockul series and the like can be mentioned.
上記金属繊維としては、通常、摩擦材に用いられるものであれば特に制限はないが、例えば、前記亜鉛粉末以外に、アルミニウム、鉄、錫、チタン、ニッケル、マグネシウム、シリコンなどの銅および銅合金以外の金属単体または合金形態の繊維や、鋳鉄繊維などの金属を主成分とする繊維が挙げられる。 The metal fiber is not particularly limited as long as it is usually used as a friction material. For example, in addition to the zinc powder, copper and copper alloys such as aluminum, iron, tin, titanium, nickel, magnesium and silicon are used. Examples thereof include fibers in the form of simple substances or alloys other than metals, and fibers containing a metal as a main component, such as cast iron fibers.
なお、本発明品は、環境有害性の高い銅および銅合金を実質的に含有せず、元素としての銅の含有量が０．５重量％以下であり、好ましくは含有量０質量％である。 The product of the present invention does not substantially contain copper and copper alloy, which are highly harmful to the environment, and the content of copper as an element is 0.5% by weight or less, preferably 0% by mass. ..
上記有機繊維としては、前記フィブリル化アラミド繊維以外に、チョップドアラミド繊維などの枝分かれを持たないアラミド繊維、セルロース繊維、アクリル繊維、フェノール樹脂繊維などを用いることができ、これらを単独でまたは２種類以上を組み合わせて使用することができる。 As the organic fiber, in addition to the fibrillated aramid fiber, aramid fiber having no branching such as chopped aramid fiber, cellulose fiber, acrylic fiber, phenol resin fiber and the like can be used, and these may be used alone or in combination of two or more. Can be used in combination.
上記炭素系繊維としては、耐炎化繊維、ピッチ系炭素繊維、ＰＡＮ系炭素繊維、活性炭繊維などを用いることができ、これらを単独でまたは２種類以上を組み合わせて使用することができる。 As the carbon-based fiber, flame-resistant fiber, pitch-based carbon fiber, PAN-based carbon fiber, activated carbon fiber and the like can be used, and these can be used alone or in combination of two or more.
本発明の摩擦材組成物における、繊維基材の含有量は、摩擦材組成物において５〜４０質量％であることが好ましく、５〜２０質量％であることがより好ましく、５〜１５質量％であることが特に好ましい。繊維基材の含有量を５〜４０質量％の範囲とすることで、摩擦材としての最適な気孔率が得られ、鳴き防止ができ、適正な材料強度が得られ、耐摩耗性を発現し、成形性をよくすることができる。 The content of the fiber base material in the friction material composition of the present invention is preferably 5 to 40% by mass, more preferably 5 to 20% by mass, and 5 to 15% by mass in the friction material composition. Is particularly preferable. By setting the content of the fiber base material in the range of 5 to 40% by mass, the optimum porosity as a friction material can be obtained, squeal can be prevented, appropriate material strength can be obtained, and wear resistance is exhibited. , The moldability can be improved.
［摩擦材］
本実施形態の摩擦材は、本発明の摩擦材組成物を一般に使用されている方法で成形して製造することができ、好ましくは加熱加圧成形して製造される。詳細には、例えば、本発明の摩擦材組成物をレーディゲミキサー（「レーディゲ」は登録商標）、加圧ニーダー、アイリッヒミキサー（「アイリッヒ」は登録商標）等の混合機を用いて均一に混合し、この混合物を成形金型にて予備成形し、得られた予備成形物を成形温度１３０〜１６０℃、成形圧力２０〜５０ＭＰａ、成形時間２〜１０分間の条件で成形し、得られた成形物を１５０〜２５０℃で２〜１０時間熱処理することで製造される。また更に、必要に応じて塗装、スコーチ処理、研磨処理を行うことで製造される。
[Friction material]
The friction material of the present embodiment can be produced by molding the friction material composition of the present invention by a commonly used method, and is preferably produced by heat and pressure molding. Specifically, for example, the friction material composition of the present invention is uniformly mixed using a mixer such as a Raydige mixer (“Ledigge” is a registered trademark), a pressurized kneader, and an Erich mixer (“Eirich” is a registered trademark). This mixture is premolded with a molding die, and the obtained premolded product is molded under the conditions of a molding temperature of 130 to 160 ° C., a molding pressure of 20 to 50 MPa, and a molding time of 2 to 10 minutes. It is produced by heat-treating the molded product at 150 to 250 ° C. for 2 to 10 hours. Furthermore, it is manufactured by performing painting, scorch treatment, and polishing treatment as necessary.
［摩擦部材］
本実施形態の摩擦部材は、上記の本実施形態の摩擦材を摩擦面となる摩擦材として用いてなる。上記摩擦部材としては、例えば、下記の構成が挙げられる。
（１）摩擦材のみの構成。
（２）裏金と、該裏金の上に摩擦面となる本発明の摩擦材組成物からなる摩擦材とを有する構成。
（３）上記（２）の構成において、裏金と摩擦材との間に、裏金の接着効果を高めるための表面改質を目的としたプライマー層、および、裏金と摩擦材との接着を目的とした接着層を更に介在させた構成。
[Friction member]
The friction member of the present embodiment uses the above-mentioned friction material of the present embodiment as a friction material serving as a friction surface. Examples of the friction member include the following configurations.
(1) Consists of only friction material.
(2) A configuration having a back metal and a friction material made of the friction material composition of the present invention serving as a friction surface on the back metal.
(3) In the configuration of (2) above, the purpose is to bond a primer layer between the back metal and the friction material for the purpose of surface modification to enhance the adhesive effect of the back metal, and to bond the back metal and the friction material. A structure in which the adhesive layer is further interposed.
上記裏金は、摩擦部材の機械的強度の向上のために、通常、摩擦部材として用いるものであり、材質としては、金属または繊維強化プラスチック等、具体的には、鉄、ステンレス、無機繊維強化プラスチック、炭素繊維強化プラスチック等が挙げられる。プライマー層および接着層は、通常、ブレーキシュー等の摩擦部材に用いられるものであればよい。 The back metal is usually used as a friction member in order to improve the mechanical strength of the friction member, and the material is metal, fiber reinforced plastic, or the like, specifically, iron, stainless steel, or inorganic fiber reinforced plastic. , Carbon fiber reinforced plastic and the like. The primer layer and the adhesive layer may be those usually used for friction members such as brake shoes.
本実施形態の摩擦材組成物は、錆固着力が小さく、錆剥離が少ないため、自動車等のディスクブレーキパッドやブレーキライニング等の上張り材として特に有用であるが、摩擦部材の下張り材として成形して用いることもできる。なお、「上張り材」とは、摩擦部材の摩擦面となる摩擦材であり、「下張り材」とは、摩擦部材の摩擦面となる摩擦材と裏金との間に介在する、摩擦材と裏金との接着部付近のせん断強度、耐クラック性向上等を目的とした層のことである。 The friction material composition of the present embodiment is particularly useful as an upholstery material for disc brake pads and brake linings of automobiles and the like because it has a small rust adhesion force and little rust peeling. Can also be used. The "upholstery material" is a friction material that serves as a friction surface of the friction member, and the "underlay material" is a friction material that is interposed between the friction material that is the friction surface of the friction member and the back metal. It is a layer for the purpose of improving shear strength and crack resistance in the vicinity of the adhesive portion with the back metal.
以下、本発明の摩擦材組成物、摩擦材および摩擦部材について、実施例および比較例を用いて更に詳細に説明するが、本発明は何らこれらに制限されるものではない。 Hereinafter, the friction material composition, the friction material, and the friction member of the present invention will be described in more detail with reference to Examples and Comparative Examples, but the present invention is not limited thereto.
［実施例１〜８および比較例１〜４］（ディスクブレーキパッドの作製）
表１および表２に示す配合比率に従って材料を配合し、実施例１〜８および比較例１〜４の摩擦材組成物を得た。表中の配合比率は質量％である。
[Examples 1 to 8 and Comparative Examples 1 to 4] (Preparation of disc brake pads)
The materials were blended according to the blending ratios shown in Tables 1 and 2 to obtain friction material compositions of Examples 1 to 8 and Comparative Examples 1 to 4. The compounding ratio in the table is mass%.
この摩擦材組成物をレーディゲミキサー（株式会社マツボー製、商品名：レーディゲミキサーＭ２０）で混合し、得られた混合物を成形プレス（王子機械工業株式会社製）で予備成形した。得られた予備成形物を成形温度１４０〜１６０℃、成形圧力３０ＭＰａ、成形時間５分間の条件で、成形プレス（三起精工株式会社製）を用いて鉄製の裏金（日立オートモティブシステムズ株式会社製）と共に加熱加圧成形した。得られた成形品を２００℃で４．５時間熱処理し、ロータリー研磨機を用いて研磨し、実施例１〜８および比較例１〜４のディスクブレーキパッドを得た。なお、実施例および比較例では、裏金の厚さ６ｍｍ、摩擦材の厚さ１１ｍｍ、摩擦材投影面積５２ｃｍ２のディスクブレーキパッドを作製した。 This friction material composition was mixed with a Ladyge mixer (manufactured by Matsubo Co., Ltd., trade name: Ladyge mixer M20), and the obtained mixture was premolded with a molding press (manufactured by Oji Kikai Kogyo Co., Ltd.). An iron backing metal (manufactured by Hitachi Automotive Systems Co., Ltd.) was used to mold the obtained preformed product under the conditions of a molding temperature of 140 to 160 ° C., a molding pressure of 30 MPa, and a molding time of 5 minutes using a molding press (manufactured by Sanki Seiko Co., Ltd.). And heat and pressure molding. The obtained molded product was heat-treated at 200 ° C. for 4.5 hours and polished using a rotary polishing machine to obtain disc brake pads of Examples 1 to 8 and Comparative Examples 1 to 4. In the examples and comparative examples, disc brake pads having a back metal thickness of 6 mm, a friction material thickness of 11 mm, and a friction material projection area of 52 cm 2 were produced.
（錆固着力および錆剥離の評価）
ＪＩＳ Ｄ４４１４「さび固着試験方法」に準拠し、錆固着試験を行い、錆固着力を下記基準にて評価を行い、錆固着力５０Ｎ未満のものを「◎」、錆固着力５０Ｎ以上かつ１００Ｎ未満のものを「○」、錆固着力１００Ｎ以上のものを「×」として評価し、表１および表２に併せて記載した。
(Evaluation of rust adhesion and rust peeling)
In accordance with JIS D4414 "Rust adhesion test method", a rust adhesion test is conducted, the rust adhesion is evaluated according to the following criteria, and those with a rust adhesion of less than 50N are "◎", and those with a rust adhesion of 50N or more and less than 100N. Those with a rust adhesion of 100 N or more were evaluated as "○", and those with a rust adhesion of 100 N or more were evaluated as "x", and are described together with Tables 1 and 2.
また、上記錆固着試験後、摩擦材の表面が剥離してロータ表面に転移しているかどうかを確認し、錆剥離として評価し、錆剥離が生じていないものを「○」、錆剥離が生じているものを「×」として評価し、この評価結果を表１および表２に併せて記載した。 In addition, after the above rust adhesion test, it is confirmed whether the surface of the friction material is peeled off and transferred to the rotor surface, evaluated as rust peeling, and those without rust peeling are marked with "○", and rust peeling occurs. The rust was evaluated as "x", and the evaluation results are shown in Tables 1 and 2.
本発明の実施例１〜８は、銅を含有する比較例２と同様、錆剥離は発生せず、小さい錆固着力を示した。また、銅を含有せず水酸化カルシウムの含有量が本発明の特定量を満足しない比較例１，３，４に対し、本発明の摩擦材組成物は錆固着力が小さく、錆剥離が発生しにくいことは明らかである。 In Examples 1 to 8 of the present invention, similar to Comparative Example 2 containing copper, rust peeling did not occur and a small rust fixing force was exhibited. Further, compared with Comparative Examples 1, 3 and 4 which do not contain copper and the content of calcium hydroxide does not satisfy the specific amount of the present invention, the friction material composition of the present invention has a small rust fixing force and rust peeling occurs. It is clear that it is difficult to do.
本発明の摩擦材組成物は、従来品と比較して、環境負荷の高い銅を用いなくとも、錆固着力が小さく、錆剥離も起こしにくいため、該摩擦材組成物は乗用車用ブレーキパッド等の摩擦材および摩擦部材に好適である。 Compared with conventional products, the friction material composition of the present invention has a small rust adhesion force and is less likely to cause rust peeling even if copper, which has a high environmental load, is not used. Suitable for friction materials and friction members.
Claims (9)
該摩擦材組成物中に元素としての銅を含まない、または銅の含有量が０．５質量％以下であり、
前記繊維基材としてフィブリル化アラミド繊維を含有するとともに、
無機充填材として、粉末状の亜鉛、水酸化カルシウム、および炭酸ナトリウムを含有し、
前記水酸化カルシウムの含有量が２．５〜１０質量％であり、
前記炭酸ナトリウムの含有量が０．２〜４質量％であり、
さらにスチール繊維を２〜８質量％含有することを特徴とする摩擦材組成物。 A friction material composition containing a binder, an organic filler, an inorganic filler and a fiber base material.
The friction material composition does not contain copper as an element, or the copper content is 0.5% by mass or less.
In addition to containing fibrillated aramid fiber as the fiber base material,
As the inorganic filler, it contains powdered zinc, water calcium oxide and sodium carbonate,
The content of the calcium hydroxide is 2.5 to 10% by mass.
The content of the sodium carbonate is 0.2 to 4% by mass, and the content is 0.2 to 4% by mass.
A friction material composition further containing 2 to 8% by mass of steel fibers.
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