JPH05140341A - Production of friction material - Google Patents

Abstract

PURPOSE:To obtain a friction material useful as a controlling material for rotational or sliding motion of especially domestic appliances, machines, automobiles, etc., by impregnating a filler and a resin in a woven cloth composed of at least two specific kinds of fibers, drying the resin and curing the product. CONSTITUTION:The objective friction material is produced by impregnating a filler and a thermosetting resin in a woven cloth (preferably having a mesh diameter of 0.2-2.0mm) composed of two or more kinds (preferably 2-5 kinds) of fibers selected from inorganic fibers (e.g. glass fiber, carbon fiber or ceramic fiber) and organic fibers (e.g. aromatic polyamide fiber), drying the resin and curing the product.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a friction material, and particularly in the fields of home appliances, machines, automobiles, etc.
The present invention relates to a method for manufacturing a friction material used as a control material for rotation or sliding movement.

[0002]

2. Description of the Related Art A friction material of this type has hitherto been mainly composed of asbestos as a main reinforcing fiber material, and a mixture prepared by adding various inorganic fillers and organic fillers to this, and using a thermosetting resin such as phenol resin. Manufactured by pressure molding and solidification.

Among the materials used for manufacturing such conventional friction materials, the inorganic filler is barium sulfate,
Calcium carbonate, carbon, mica, diatomaceous earth, alumina, silica, various metal powders, metal fibers and the like are used, and as organic filler, cashew dust, rubber particles and the like are used. Further, as the fiber material, in addition to asbestos, there are carbon fiber, glass fiber, rock wool, glass wool, ceramics wool, high-strength organic fiber, steel fiber, various whiskers,
Friction materials are manufactured by mixing these in appropriate amounts.

[0004]

As described above, the conventional friction material must have a thickness of 1 mm or more in order to mold and produce a mixture of dozens of materials.
It was difficult to manufacture. Incidentally, the thickness of the conventional friction material provided conventionally is 3 to 10 mm.

On the other hand, a friction material having a small thickness, for example, a friction material having a thickness of 0.3 to 1 mm, is made by a papermaking method, and therefore, its compounding composition is different and it is difficult to obtain high friction performance. there were.

Moreover, conventionally, the strength of the friction material is mainly borne by the fiber portion. Therefore, by adding glass fiber, carbon fiber, steel fiber, Kevlar (a trademark of aromatic polyamide fiber), etc., Although it was supposed to be comparable to asbestos fibers, it is very difficult to add and mix them uniformly. In particular, it was technically very difficult to uniformly disperse these fibers and further to uniformly support them.

The present invention is a method for producing a high-strength friction material which is excellent in friction performance and solves the above-mentioned conventional problems. In particular, a high-strength friction material composed of plural kinds of fibers is relatively thick. An object of the present invention is to provide a method for manufacturing a friction material that can be easily manufactured as a thin friction material.

[0008]

The method for producing a friction material of the present invention is selected from the group consisting of inorganic fibers and organic fibers.
It is characterized in that a woven fabric composed of one or more kinds of fibers is impregnated with a filler and a resin, dried, and then cured.

The present invention will be described in detail below. In the method of the present invention, first, a woven fabric is manufactured using two or more kinds, preferably 2 to 5 kinds of fibers selected from the group consisting of inorganic fibers and organic fibers. The fibers used here may be the same as conventional ones. As the inorganic fibers, glass, carbon or ceramic fibers, metal fibers such as steel fibers, etc., and as the organic fibers, aromatic polyamide fibers, etc. can be used. .

As a method for producing a woven fabric, for example, when three types of fibers such as glass, carbon, and aromatic polyamide fibers are used as fibers, each fiber has a total of 3 fibers.
Woven fabrics are woven using book twists as warp and weft. Alternatively, a set of three yarns, one for each yarn, is woven as warp and weft yarns one by one. In this case, the ratio of the constituent fibers can be easily adjusted by changing the number of fibers used or the weaving ratio.

The fibers used do not have to have the same fiber diameter.

The weave and thickness of the woven fabric produced from these fibers are not particularly limited, but the weave does not impair the strength of the obtained friction material, and the impregnation ratio of the filler or resin is not limited. In order to sufficiently secure the above, it is preferable that the diameter of the weave (mesh) is about 0.2 to 2.0 mm. The thickness is appropriately determined depending on the intended thickness of the friction material and the required strength, but is generally 0.2 to 2.0 mm, preferably 0.2 to 1.0 mm. The thickness of this woven fabric can be appropriately adjusted depending on the fiber diameter of the fibers used.

Next, the weave (mesh) of the obtained woven fabric is wet-impregnated with a mixture of various fillers and a resin, for example, a thermosetting resin such as a phenol resin, to impregnate them. It is supported in a uniformly dispersed state. Here, the fillers are the same as conventional ones, for example, barium sulfate, calcium carbonate, carbon, mica, diatomaceous earth, alumina, silica, various metal powders, inorganic fillers such as metal fibers, or cashew dust, Organic fillers such as rubber particles can be used.

The impregnation ratio of the fillers and the resin into the woven fabric is not particularly limited and is appropriately determined depending on the required friction performance, strength, moldability, thickness of the friction material and the like.
Usually, 10 g of fillers is added to 100 g of woven cloth.
It is preferable to impregnate 70 g and about 10 to 60 g of resin.

After impregnating the woven cloth with the fillers and the resin, the woven cloth is dried at about 80 to 120 ° C., heated to the curing conditions of the resin used, and optionally pressure-molded to be cured. For example, when a phenol resin is used as the thermosetting resin, the heating and solidifying conditions are a temperature of 250 to 350 ° C. and a pressure of 100 to 500 kg / cm ² .

This makes it possible to easily manufacture a desired friction material having various shapes such as a sheet shape.

[0017]

Since the fibers have different friction coefficients and physical properties depending on their materials, it is possible to arbitrarily control the physical properties of the obtained friction material by using plural kinds of fibers in an appropriate ratio.

In the present invention, a woven fabric as a base material is obtained by weaving plural kinds of fibers selected from the group consisting of inorganic fibers and organic fibers. Therefore, it is possible to obtain a friction material in which various fibers are dispersed in a uniform dispersion state at an arbitrary ratio according to the purpose.

In the present invention, since the woven fabric composed of such plural kinds of fibers is used as the base material, a friction material having high strength and strong against tensile stress in the longitudinal and transverse directions can be obtained.

However, since various kinds of fillers are impregnated in such a woven fabric, the filler can be uniformly and firmly dispersed and carried on the fibers. Therefore, a friction material having a large friction coefficient and excellent homogeneity of friction performance can be obtained. Moreover, since the woven cloth carrying the fillers is formed in the weave, it has good moldability and can be easily formed into a sheet shape or the like.

In particular, in the present invention, the type of fibers used, the size and thickness of the texture of the woven cloth, the type of fillers,
The compounding amount and the like can be variously changed, and a friction material having a desired thickness, friction performance and strength can be easily manufactured. In particular, a friction material having arbitrary physical properties can be obtained by appropriately setting the type of fiber to be used, the combination, the usage ratio, and the like.

The method of manufacturing the friction material of the present invention has a thickness of 1 mm.
Hereinafter, for example, it is effective for manufacturing a thin sheet-like friction material having a thickness of 0.4 to 1.0 mm, but it goes without saying that it is also applicable to manufacturing a friction material having a thickness of more than 1 mm.

[0023]

EXAMPLES The present invention will be described in more detail with reference to the following examples.

Example Using a glass fiber, a Kevlar fiber (trademark of DuPont: aromatic polyamide fiber) and a carbon fiber in a ratio shown in Table 1, a woven fabric (5 cm × 5 c) having a weave (mesh) of 0.5 mm.
m) was produced, and 100 g of this woven fabric was impregnated with a slurry in which the amounts of the filler and the phenolic resin shown in Table 1 were mixed at a ratio of 1: 1 (weight ratio) as shown in Table 1. Next, this was dried at 120 ° C., and then hot-pressed at a temperature and a pressure shown in Table 1 to be pressure-molded and cured to produce a sheet-shaped friction material. The thickness, friction coefficient and wear amount of the obtained sheet-like friction material were measured, and the results are shown in Table 1. The amount of wear is the amount of weight loss when rubbing for 1 hour.

For comparison, the conventional method has a thickness of 0.4 mm.
Table 1 (No. 5) also shows the friction coefficient and the wear amount of the friction material of No. 1.

From Table 1, according to the method of the present invention, 1 mm
It is clear that even the following thin friction materials can be manufactured as friction materials having excellent friction performance, and the wear amount thereof is significantly smaller than that of conventional products. Each friction material had a uniform surface and was of good quality.

[0027]

[Table 1]

[0028]

As described above in detail, according to the method for manufacturing a friction material of the present invention, the friction material is a thin friction material having a thickness of 1 mm or less, and the strength and friction performance are significantly improved as compared with the conventional products. The friction material can be manufactured easily and efficiently. In particular, since a plurality of types of fibers are contained in a uniform composition and in a dispersed state, friction stability is high and the effect of improving strength by blending different types of fibers is also excellent. Further, since the woven cloth is used as the base material, a large friction material can be easily manufactured.

Since the thin friction material produced by the present invention has a small thickness, it can be easily and firmly adhered to the friction substrate, and due to its excellent friction performance and high strength, it has a remarkably good friction characteristic for a long period of time. Exert.

Claims (1)

[Claims] 1. A friction characterized in that a woven fabric composed of two or more kinds of fibers selected from the group consisting of inorganic fibers and organic fibers is impregnated with a filler and a resin, dried, and then cured. Method of manufacturing wood.