JPH02300532A - Friction pad and manufacture thereof - Google Patents

Abstract

PURPOSE:To easily obtain a friction pad having a satisfactory rust resistance by filling a frictional member in several storage holes in a frictional surface of a planar member, and by integrally incorporating the frictional material with the planar member. CONSTITUTION:In a friction pad in which a planar member 4 made of heat- hardenable resin as a main component is made into close contact with a metal plate 1 formed therein one or a plurality of through-holes, being fitted in the through-holes 3, a frictional material 5 is filled in a several storage holes formed in a friction surface of the planar member 4, and this frictional member is integrally incorporated with the planar member 4. With this arrangement, since heat-hardenable materials are in general non-water permeable resin, the through- holes 3 in the plate 1 are blocked substantially by the planar member 4 made of such heat-hardenable materials so that moisture which enters into a pad layer 2 by way of the through-holes 3 is shut off, and thereby it is possible to prevent the inside of the pad layer 2 and the fastened interface between the pad layer 2 and the plate 1 from rusting and so forth.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a friction pad and a method for manufacturing the same, and more particularly to a method for manufacturing a friction pad and 7 used for automobile disc brakes and the like.

(Prior Art) Friction pads conventionally used for automobile disc brakes, etc., consist of a metal plate (hereinafter sometimes referred to as a plate) and a lining layer (hereinafter referred to as a pad) containing metal powder as a friction material. Friction pads are commonly used that have attached layers (sometimes referred to as layers).

In such a friction pad, a part of the pad layer is fitted into one or more through holes drilled in the plate, and the two are integrally connected, so that the surface of the pad layer when braking the automobile. comes into contact with the disc of a disc brake, etc.

By the way, such a friction pad is manufactured by the method shown in FIG. That is, the plate and the pad layer (lining layer) are each manufactured separately in separate steps, and then the resulting plate and pad layer are molded under heat and pressure to integrate them.

For this reason, in the friction pad obtained, the density of the pad layer that fits into the through hole is lower than the density of the pad layer in other parts of the plate, so moisture enters the friction pad through the through hole of the plate. As a result, rust is generated within the pad layer and/or on the plate surface that is in contact with the pad layer, making it easy for the pad layer and the plate to separate.

In order to eliminate the drawbacks of such conventional friction pads, Japanese Patent Publication No. 50-37350 discloses a method in which the through-holes of the plate are filled with a filler having the same composition as the pad layer in advance.
A manufacturing method has been proposed in which the plate-shaped body that will become the pad layer and the plate are then integrally formed by heating and pressure molding.

(Problems to be Solved by the Invention) The rust resistance etc. of the friction pad obtained by the above manufacturing method can be achieved by heating and pressure molding without filling the through holes of Plate 1 with a filler having the same composition as the pad layer in advance. Although the improvement is improved compared to conventional friction pads obtained by the above methods, the degree of improvement is not sufficient and further improvement is desired.

In addition, this method requires that the plate-shaped body serving as the pad layer be formed in advance, and furthermore, that the through-holes of the plate must be filled with a filler in advance, resulting in poor workability.

In addition, when the friction material used for the pad layer is a semi-metallic friction material containing metal powder,
As described in Publication No. 536, a heat insulating layer made of asbestos or the like is provided between the pad layer and the plate in order to block the transfer of frictional heat generated by contact between the surface of the pad layer and the disk to the plate. Since it is necessary to form
Furthermore, the workability of the friction pad manufacturing process is deteriorated.

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a friction pad that has sufficient rust resistance and can be easily obtained, and a method for manufacturing the same.

(Means for Solving the Problems) As a result of intensive studies to achieve the above object, the inventors have found that:
A convex portion is formed on one side of a plate-like body made of a thermosetting resin, and a storage hole is formed on the other side, and the convex portion formed on the plate-like body is fitted into a through-hole of a metal plate. We have discovered that a friction pad in which the friction material is firmly bound to the thermosetting resin can be obtained by integrating the two and filling the recess with the friction material and then subjecting it to heat and pressure treatment. We have arrived at the present invention.

That is, the present invention provides a metal plate in which one or more through holes and/or recesses are formed, and a plate-like body mainly composed of a thermosetting resin is provided in the through holes and/or recesses. Friction pads that are fitted and in close contact, each of which is filled with a friction material in a plurality of storage holes provided in the friction surface of the plate-shaped body, and the friction material is integrated with the plate-shaped body. The friction pad is characterized by:

In addition, a plurality of storage holes are formed on one side of a plate-like body whose main component is a thermosetting resin, and one or more convex portions are formed on the other side, and the convex portions are replaced with metal. The storage hole of the plate-shaped body is filled with powdered friction material while fitting it into one or more through holes and/or recesses previously drilled in the metal plate, and then the plate-shaped body and the metal plate are fitted. There is a method for manufacturing a friction pad characterized in that heat and pressure treatment is performed in an integrated state.

(Function) - Since the thermosetting resin is a water-impermeable resin, the friction pad of the present invention in which the through holes etc. of the plate are substantially blocked by the plate-like body made of the thermosetting resin According to this method, it is possible to prevent moisture from entering the pad layer through the through holes, etc., and it is possible to prevent rust, etc., from occurring within the pad layer and/or at the binding interface between the pad layer and the plate. can.

In addition, a friction layer can be formed by filling the plurality of storage holes in the plate-like body with powdered friction material.
Elimination of the need for measuring and preforming operations performed after mixing materials during the forming process of the lining layer (pad layer) shown in Figure 5;
Furthermore, since a heat insulating layer mainly composed of thermosetting resin is formed between the friction material layer and the plate, it is possible to eliminate the need for forming a heat insulating layer with a separate material, and the friction pad The workability of the manufacturing process can be significantly improved.

In addition, moisture near the friction surface of the pad layer is easily evaporated and dissipated due to frictional heat generated during automobile brake operation, so rust, etc. may occur near the friction surface of the pad layer due to the accumulation of moisture. It's difficult.

(Example) The present invention will be explained using the drawings.

FIG. 1(a) is a front view showing one embodiment of the friction pad of the present invention, and FIG. 1(b) is a sectional view taken along the line A--A.

As is clear from FIGS. 1(a) and 1(b), in the friction pad of this embodiment, two through holes 3.3 are bored in an iron plate 1, and each of the through holes 3.3 is The plate 1 and the pad layer 2 are integrated with a part of the pad layer 2 fitted therein.

The pad layer 2 is composed of a plate-like body 4 made of a thermosetting resin and a friction material 5 filled in a plurality of storage holes provided on the friction surface of the plate-like body 4.

In this embodiment, the friction material 5 is a semi-metallic friction material whose main component is metal powder made of iron and/or copper.

The bottom positions of the plurality of storage holes provided in the plate-like body 4 are substantially constant, and a part of the plate-like body 4 is located in the through-hole 3.3.
is fitted.

Therefore, plate-like body 4 is plate 1 and JP! While forming a layer of plate-like body 4, that is, a heat insulating layer, between the friction material 5 and the friction material 5, the through hole 3.3 of the plate 1 is substantially sealed.

Therefore, heat transfer such as frictional heat to the plate 1 can be blocked, and moisture can be prevented from entering through the through holes 3.3.

Further, a part of the thermosetting resin forming the plate-like body 4 enters the friction material 5 filled in each of the storage holes formed in the plate-like body 4, and the friction material 5 between the plate-like body 4 and the friction material 5 enters. It is integrated with Ha.

The holes 20 formed in the plate 1 are for attaching friction pads to calipers and the like constituting the brakes of automobiles.

Such a friction pad can be easily obtained by using a plate-shaped body made of a thermosetting adhesive having the shape shown in FIG.

FIG. 2(a) is a front view of the plate-like body 14 for obtaining the friction pad shown in FIG. 1, and FIG. 2(b) is the B of FIG. 2(a).
It is a sectional view in -8 plane.

The plate-like body 14 is made of thermosetting resin, and one side of the plate-like body 14 is provided with a plurality of storage holes 7, 7, etc. in a cluster shape p3, and the other side is provided with two convex holes. Section 8.8 is provided.

Such a plate-like body 14 can be obtained by filling a mold with thermosetting resin powder, molding it while applying heat, and suppressing the degree of hardening due to crosslinking reaction or the like.

As such thermosetting resin, phenol resin is preferable, and examples thereof include novolak phenol resin, resol phenol resin, and the like.

The content of the thermosetting resin in the plate-shaped body 14 is preferably 25% by weight or more based on the plate-shaped body 14, and fibers such as aramid fibers for reinforcement and/or a friction material to be described later are included. may have been done.

In addition, in the pad layer that makes up a normal friction pad,
- The amount of the thermosetting resin to be blended is usually about 12% by weight, as described in the above-mentioned Japanese Patent Publication No. 37350/1983.

The convex portion 8.8 of the plate-like body 14 obtained in this way is the third
As shown in the figure, the plate-shaped body 14 and the plate 1 are integrated by being fitted into the through hole 3.3 that is previously drilled in the plate 1.

As shown in FIG. 5, the plate 1 is provided with through holes, subjected to various surface treatments, and further dried.

This surface treatment step includes a degreasing step for degreasing the plate 1, a shot processing step for injecting granules toward the plate surface to increase the adhesive strength between the plate member 14 and the plate 1, and a shot processing step for increasing the adhesive strength between the plate member 14 and the plate 1. An adhesive application step is included in which a thermosetting adhesive for bonding the plate 1 is applied to the plate surface.

Storage hole 7.7 of plate-like body 14 integrated with plate 1
- is filled with powdered = vibration material 15.

The friction material 15 is mainly composed of metal powders such as iron and copper, inorganic compounds such as graphite and antimony oxide, and inorganic fillers such as barium sulfate.

Since the friction material 15 is in powder form, a predetermined amount of the friction material is filled by filling the storage holes 7, 7... of the plate-like body 14 with the friction material and then cutting the friction material without preforming. be able to.

In addition, short fibers that can be treated as powder,
For example, short fibers having a length of about 2 to 3 m can be filled into the storage holes 7, 7, etc. together with the powder as a reinforcing material. Aramid fibers are suitable as such short fibers.

Also, the storage hole 7 formed in the plate-shaped body 14 to be filled.
7... is large and if the thermosetting resin that penetrates into the friction material from the plate-like body 14 does not sufficiently adhere the friction materials to each other, a small amount of the thermosetting resin forming the plate-like body 14 (
(approximately 12% by weight or less) mixed friction material may be used.

After the plate 14 and the plate 1, in which the friction material 15 is filled in the storage holes 7, 7, are integrated, as shown in FIG. The product is made by firing and post-processing.

In this process, heating and pressure molding can be easily performed by using the apparatus shown in FIG.

This device is composed of a press die 16, an upper die 17, and a lower die 18, and the lower die 18 is provided with one convex portion.

To perform heating and pressure molding using such a device, first set the plate 1 in the upper mold 17 and press the convex portion 1 of the lower mold 18.
9 to fit the through hole 3 of the plate 1 into the lower mold 18.
set on top.

Note that the tip of the convex portion 19 is adjusted so that it is located approximately in the middle of the through hole 3.

Next, by heating the plate-shaped body 4 while pressurizing it with the press mold 16, the thermosetting resin of the plate-shaped body 4 and/or the thermosetting resin mixed in the friction material in advance is fluidized by the heat, and the plate-shaped body 4 is heated. The plate-shaped body 4 and the plate 1 are bonded together, and the plate-shaped body 4 and the friction material 5 are bonded together by the thermosetting resin that has entered the friction material and/or the thermosetting resin that has been mixed in advance.
And the rubbing materials are firmly bonded to each other.

In this example, in order to further perfect the binding of the friction material obtained by heating and pressure molding,
Bake for about 9 hours in a hot air oven maintained at about 0 to 230°C. The friction pad that has undergone this firing process can be made into a product through post-processing processes such as flat polishing and painting, which polish the surface of the pad 2.

In the embodiments described above, the through holes are provided in the plate, but the through holes may be recessed portions without penetrating the plate, or recessed portions and through holes may be mixed. In short, it is sufficient if the plate-like body can be integrally bonded to the plate.

Moreover, the shape of the storage hole provided in the plate-like body can be any shape, and may be polygonal, such as a triangle, quadrangle, pentagon, or hexagon, circular, or a mixture of various shapes.

(Effects of the Invention) According to the present invention, the pad layer integrated with the plate is a plate-like body made of a thermosetting resin, and the plate-like body substantially closes the through holes etc. of the plate. Since there are multiple storage holes filled with friction material, it is possible to block moisture from entering the pad layer through the through holes, etc., and prevent moisture from entering the pad layer and/or between the pad layer and the plate. It is possible to prevent rust from forming on the interface.

Therefore, according to the friction pad of the present invention, it is possible to eliminate concerns about peeling between the pad layer and the plate due to rust.

In addition, there is no need to preform the pad layer or form a heat insulating layer on the plate using a separate material, and the workability of the friction pad manufacturing process can be greatly improved. Productivity can be significantly improved compared to conventional friction pad manufacturing methods.

[Brief explanation of the drawing]

FIG. 1 is a front view and a cross-sectional view showing an embodiment of the friction pad of the present invention, FIG. 2 is a front view and a cross-sectional view of a plate-like body used for manufacturing the friction pad of the present invention, and FIG. 4 is a cross-sectional view showing the state of integration of the plate-like body 4 and the plate 1, FIG. Each of the process diagrams for manufacturing the pad is shown. In the figure, 1... Plate, 2... Pad layer of product friction pad, 3... Through hole of plate 1, 4... Plate body of product friction pad, 5... Friction material, 14. ... Plate-shaped body before heating and pressure forming, 7... Accommodation hole provided in plate-shaped body 14, 8... Convex portion provided in plate-shaped body 14, 15. - Accommodation hole 7 friction material filled in. Drawing number
1 Figures (a) and (b)
2 Figures (a) (b) δ d Drawing surface 3
Figure No. 4

Claims (1)

[Scope of Claims] A metal plate in which one or more through holes and/or recesses are formed, and a plate-like body mainly composed of a thermosetting resin is provided in the through holes and/or recesses. A friction pad that fits into the recess and is in close contact with the plate-shaped body, wherein each of a plurality of storage holes provided in the friction surface of the plate-shaped body is filled with a friction material, and the friction material is connected to the plate-shaped body. A friction pad characterized by being integrated. 2. Form a plurality of storage holes on one side of a plate-like body whose main component is a thermosetting resin, and form one or more convex parts on the other side, and replace the convex parts with metal. The storage hole of the plate-shaped body is filled with powdered friction material while fitting it into one or more through holes and/or recesses previously drilled in the metal plate, and then the plate-shaped body and the metal plate are fitted. A method for producing a friction pad characterized by applying heat and pressure treatment to the integrated state.