JPH09136971A - Production of friction material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a process for producing a friction material greatly improved in the effect of brake working when faded without lowering of friction performance and abrasion resistance. SOLUTION: A friction member 2 other than a portion ranging from the outer periphery to at least 1mm and at most 10mm inward from the outer periphery is subjected to scorching treatment. Alternatively, the whole surface of the friction member 2 is subjected to scorching treatment, and the surface of the friction member 2 other than a portion ranging from the outer periphery to at least 1mm and at most 10mm inward from the outer periphery is then subjected to re-scorching treatment.

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 such as a disc brake pad and a brake lining used for braking an automobile.

[0002]

2. Description of the Related Art For example, a disc brake is used as a braking device for automobiles, and a disc brake pad is used as the braking member. Currently, the mainstream of the disc brake pad is Japanese Patent Publication No. 59-4462 and Japanese Patent Laid-Open No.
As disclosed in Japanese Patent Publication No. 184525, etc., as reinforcing fibers, metal fibers such as steel fibers, brass fibers, and copper fibers, organic fibers such as aramid fibers, acrylic fibers, and phenol fibers, alumina silica fibers, rock wool, potassium titanate. A combination of inorganic fibers such as fibers and carbon fibers is used.

The conventional disc brake pad as described above has a problem that the effectiveness of the brake is deteriorated due to the thermal decomposition of the organic matter at the time of fading, and a scorch process has been applied to the entire surface as a countermeasure against the problem. However, in recent years, the absorbed energy during braking has increased more and more as automobiles have become more sophisticated and higher in performance, and the reduction of braking effectiveness during fade has become a more serious problem.

As a measure against the above problems, scorch treatment at higher temperature is considered, but if scorch treatment is performed at too high temperature, thermosetting resin such as phenol resin, organic reinforcing fiber such as Kevlar fiber, etc. It decomposes completely and loses strength, resulting in a decrease in the coefficient of friction and a marked decrease in wear resistance.

[0005]

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention The invention according to claims 1 and 2 of the present invention relates to a friction material in which the effect of braking at the time of fade is significantly improved without lowering the friction performance and wear resistance. It provides a manufacturing method.

[0006]

SUMMARY OF THE INVENTION The present invention has a minimum length of 1 mm from the outer periphery of a friction member toward the inside, and a maximum length of 10 mm.
The present invention relates to a method for manufacturing a friction material in which the other parts are left and the other parts are scorch treated. Further, in the present invention, the entire surface of the friction member is scorch treated, and then the other portion is rescorched while leaving a portion of 1 mm at the shortest and 10 mm at the longest inward from the outer circumference of the friction member. A method for manufacturing a friction material.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION In the present invention, the portion of the friction member to be scorched is 1 mm at the shortest from the outer circumference toward the inside.
And the other part, which leaves the part up to 10 mm long,
It is preferably the shortest 1 mm and the other part that leaves the longest part up to 6 mm, more preferably the shortest 1 mm and the part that leaves the longest 5 mm part, and the shortest part to leave. If it is less than 1 mm, the wear resistance cannot be improved,
On the other hand, if the maximum length of the remaining portion exceeds 10 mm, the fade resistance cannot be improved. The scorch treatment includes a method of pressing a heating plate against the friction member, a method of heating with a direct flame such as a gas flame, and a method of heating with radiant heat such as far infrared rays, and there is no particular limitation. As for the scorch processing conditions, the conditions suitable for the material may be selected and processed.

The friction member may be scorch-processed once on its entire surface. The material of the friction member can be applied to any of semi-metallic type and non-steel type, and is not particularly limited. Further, as the material of the friction member, generally known materials are used, for example, fibers such as steel fiber, brass fiber, copper fiber, aramid fiber, acrylic fiber, phenol fiber, ceramic fiber, rock wool, potassium titanate fiber and carbon fiber. Substances, thermosetting resins such as phenolic resins, epoxy resins, melamine resins, cashew resins and binders containing rubber compositions such as NBR and SBR, organic friction modifiers such as friction dust, barium sulfate, graphite, trisulfide Inorganic friction modifiers such as antimony are used, and metal powders such as brass, brass, and copper are added if necessary.

The content of the fibrous substance in the above is preferably 30 to 50% by weight in the whole composition, and the content of the binder is preferably 10 to 18% by weight in the whole composition. The content of the organic friction modifier is preferably 3 to 18% by weight in the whole composition, and the content of the inorganic friction modifier is preferably 25 to 45% by weight in the whole composition. The disc brake pad before the scorch treatment step is obtained by preforming the friction material composition, then inserting the backing metal and the preform into the mold, and molding by the heat and pressure molding method.

Embodiments of the present invention will be described in detail below with reference to the drawings. FIG. 1 is a plan view of a disc brake pad according to an embodiment of the present invention. In FIG. 1, 1 is a back metal, and the friction member 2 is formed on one surface of the back metal 1. In the present invention, as shown in FIG. 1, the distance from the outer circumference of the friction member 2 is 1 mm at the shortest and 10 at the longest.
The other parts are scorch-processed 3 to leave the parts up to mm and made into friction members.

[0011]

Embodiments of the present invention will be described below. Example 1 After blending the components shown in Table 1 and uniformly mixing with a mixer,
Preform, then insert the back metal and preform into the mold, then heat and pressure mold for 5 minutes under the conditions of 152.5 ± 2.5 ° C. and a pressure of 49 MPa, and further bake at 200 ° C. for 5 hours, After cooling, polish to 127mm from end to end
Was obtained.

[0012]

[Table 1]

Next, as shown in FIG. 1, a heating plate heated to 500 ± 10 ° C. is left with a portion of 6 mm from the outer periphery of the friction member 2 of the disc brake pad A obtained above to the inner side.
The disc brake pad B was obtained by pressing for a minute to carry out a partial scorch treatment. Reference numeral 3 in FIG. 1 is a scorch processing portion.

Example 2 The entire surface of the disc brake pad A obtained in Example 1 is 50
A hot platen heated to 0 ± 10 ° C. was pressed for 3 minutes to scorch the entire surface. Then, inward from the outer circumference of the disc brake pad A, which was scorched on the entire surface.
A disc brake pad C was obtained by performing a partial scorch treatment by pressing a heating plate heated to 500 ± 10 ° C. for 5 minutes while leaving the mm portion.

Example 3 A disc was obtained by pressing a hot platen heated to 500 ± 10 ° C. for 8 minutes while leaving a 1 mm portion from the outer circumference of the disc brake pad A obtained in Example 1 toward the inside to perform disc scorch treatment. The brake pad D was obtained.

Example 4 A disc was obtained by pressing a heating plate heated to 500 ± 10 ° C. for 8 minutes while leaving a 10 mm portion inward from the outer circumference of the disc brake pad A obtained in Example 1 for partial scorch treatment. I got the brake pad E.

Comparative Example 1 The entire surface of the disc brake pad A obtained in Example 1 was 50
A hot plate heated to 0 ± 10 ° C. was pressed for 8 minutes to perform scorch treatment on the entire surface to obtain a disc brake pad F.

Comparative Example 2 A partial scorch treatment was performed by pressing a hot platen heated to 500 ± 10 ° C. for 8 minutes while leaving a 0.5 mm portion from the outer periphery of the disc brake pad A obtained in Example 1 toward the inside. I got a disc brake pad G.

Comparative Example 3 A disc was obtained by pressing a heating plate heated to 500 ± 10 ° C. for 8 minutes while leaving a 20 mm portion inward from the outer periphery of the disc brake pad A obtained in Example 1 to perform a partial scorch treatment. Brake pad H was obtained.

Next, the disc brake pads according to the present invention (Examples 1 to 4) and the disc brake pads not included in the present invention (Comparative Examples 1 to 3) were subjected to wear resistance with an inertia dynamometer under the conditions shown in Table 2. Performance and JASO C406
Fade characteristics were measured according to 82. The results are shown in Table 3.

[0021]

[Table 2]

[0022]

[Table 3]

As shown in Table 3, it can be seen that the disc brake pad according to the present invention has a small amount of wear while maintaining the fade characteristics.

[0024]

The friction material obtained by the method according to the first and second aspects of the present invention can greatly improve the effect of braking during fade without lowering the friction performance and wear resistance. It is an industrially very suitable friction material.

[Brief description of the drawings]

FIG. 1 is a plan view of a disc brake pad according to an embodiment of the present invention.

[Explanation of symbols]

 1 Back metal 2 Friction member 3 Scorch treated part

Claims (2)

[Claims] 1. A method for producing a friction material, characterized in that a portion having a minimum length of 1 mm from the outer periphery of the friction member toward the inside and a maximum length of 10 mm is left and the other portion is subjected to scorch treatment. 2. Scorching the entire surface of the friction member, and then rescorching the other part of the friction member from the outer periphery to the inner side, with a minimum length of 1 mm and a maximum length of 10 mm. And a method for manufacturing a friction material.