KR20080021171A - Method for manufacturing friction material of brake pad and apparatus thereof - Google Patents

Abstract

Method and apparatus for manufacturing a friction material of a brake pad is provided to form a preform of friction material cake continuously and automatically by supplying exact measure of friction material powder. A method of manufacturing a friction material of a brake pad provides a pre-molded friction material cake by using a mold assembly(22) formed of lower, middle and upper molds(24,26,28). The method comprises the steps of: preparing the mold assembly formed of the middle and upper molds on the lower mold (waiting step), separating the upper mold to expose the cavity of the middle mold (upper mold separation step), supplying a predetermined amount of friction powder to the cavity (first measure supply step), flattening the surface of the friction material powder (flattening step), pressing the friction material powder to stabilize the friction material powder layer (first pressing step), assembling the upper mold to the flattened mold assembly (upper mold assembling step), and completing the friction material cake by final press-molding of the friction material powder layer in the each cavity (second pressing step).

Description

Method and apparatus for manufacturing friction pad for brake pads {METHOD FOR MANUFACTURING FRICTION MATERIAL OF BRAKE PAD AND APPARATUS THEREOF}

1 is a perspective view of a friction pad for a brake pad manufactured in a cake state before final processing;

FIG. 2 is a plan view showing a brake pad having the friction material shown in FIG. 1 attached to a back plate and completed by surface processing; FIG.

3 is an exploded perspective view of a mold assembly in which the friction material shown in FIG. 1 is molded;

4 is a cross-sectional view of the components of the mold assembly shown in FIG.

5 is a process explanatory diagram of the present invention.

Figure 6 is a schematic overall configuration of the friction material manufacturing apparatus is carried out the method of the present invention.

7 is a cross-sectional view of a mold assembly in standby for friction material production at the atmospheric end of the device of the present invention.

8 is a cross-sectional view of the upper mold separation stage showing that the upper mold is separated from the mold assembly in the next step of FIG.

FIG. 9 is a cross-sectional view of the primary metering supply stage in which a friction material powder is primaryly metered to the lower mold of the mold assembly in the next step of FIG.

10 is a cross-sectional view taken along the line X-X of FIG.

Fig. 11 is a sectional view of the surface leveling end for leveling the surface of the friction material powder layer after the friction material powder has been supplied with the primary measurement.

12 is a cross-sectional view of the primary pressing stage.

Fig. 13 is a cross-sectional view of the secondary measurement supply stage in which a small amount of friction material powder is supplied in the secondary measurement.

14 is a cross-sectional view showing that the upper mold is coupled down in the position of the upper mold separation end to preform the friction material.

15 is a cross-sectional view showing that the friction material is secondary pressed to final molding.

Explanation of Signs of Major Parts of Drawings

10 ... friction cake 22 ... mold assembly

24 ... lower mold 26 ... intermediate mold

28. Upper mold 34 ... Cavity

40 ... Plunger 42 ... Air End

44. Upper mold separation stage 46 ... Primary metering stage

48 ... Equal Surface 50 ... First Pressing Stage

52 ... Secondary metering stage 56 ... Conveyor

58 ... Ram Piston 62 ... Pressure plate

64 ... Hook 106 ... Stirring Rod

116 ... support plate 118 ... plunger

The present invention relates to a method for producing a friction material for a brake pad, and more particularly, to a method for manufacturing a friction material for a brake pad which enables the automatic and continuous production of a friction material preformed in a cake state before the friction material is attached to the back plate. . The present invention also relates to an apparatus for producing a brake pad friction material for performing such a method for producing a brake pad friction material.

Typically, a brake pad consists of a back plate and a friction material attached thereto. The friction material is pre-molded by preforming a powder of the material constituting the friction material into a cake state and then placing it on the back plate. In order to mold the friction material powder into the friction material in the cake state, the friction material powder is accurately weighed and preformed in the mold. In this process, accurate metering of friction ash powder required considerable labor, time and cost. In the related art, by using a precise weighing scale in a production line of a brake pad, an operator has no choice but to measure and supply a friction material powder corresponding to one friction material to a mold.

In the present invention, the production of a friction pad for brake pads is performed continuously and automatically in the entire process of obtaining a preformed friction material cake is made by the accurate metering of the friction material powder to the mold from the preparation of the mold for molding the friction material to pre-molding It provides a method and apparatus.

To this end, the present invention provides a method for manufacturing a friction pad for a brake pad to obtain a pre-molded friction material cake by using a mold assembly consisting of a lower mold, an intermediate mold and an upper mold for molding the friction material used in the brake pad. . According to the present invention, a method for manufacturing a friction material for a brake pad includes a standby step of preparing the mold assembly consisting of the intermediate mold and the upper mold on the lower mold in order to be transferred to the next step by a reciprocating conveyor, The upper mold separation step of separating the upper mold so that the cavity of the intermediate mold is exposed in the mold assembly, the primary metering step of supplying a quantity of friction material powder to the cavity of the intermediate mold exposed upward, the intermediate mold A surface leveling step in which the surface of the friction material powder supplied to the cavity of the surface is smoothed, and pressing the friction material powder supplied to the cavity of the intermediate mold so that the friction material powder layer can be stabilized with the same effect as a pseudo-molding. In the first pressing step, the mold bath in which the surface of the friction material powder layer is flattened And an upper mold combination step in which the upper mold is coupled to the body, the friction powder layer of each of the cavities of the intermediate mold is formed the final pressing is characterized by consisting of a second pressing step to which the friction material cake prepared.

In the method of the present invention, after the first pressing step, the secondary metering step of supplying residual friction material powder or friction material powder of different composition on the friction material powder layer in the cavity of the intermediate mold, and the intermediate mold And a second surface leveling step in which the surface of the residual friction material powder or the friction material powder of different composition is smoothly treated.

In another aspect, the present invention is an apparatus for producing a friction material for brake pads to obtain a preformed friction material cake by using a mold assembly consisting of a lower mold for forming the friction material used in the brake pad, an intermediate mold having a cavity and an upper mold having a plunger. The apparatus is characterized in that the mold assembly consisting of the intermediate mold and the upper mold on the lower mold in turn is ready to be transferred to the next stage by the reciprocating conveyor, the ram piston extending from the top of the The upper mold separation stage for separating the upper mold of the mold assembly by the hook of the pressure plate attached to the lower end to expose the cavity of the intermediate mold, the upper mold is separated and the cavity of the intermediate mold to the upper side In the exposed state, the intermediate mold and the lower mold are the convex. A primary metering supply stage which is fed along the air to supply a quantity of friction material powder to the cavity of the intermediate mold, and the friction material powder supplied to the cavity of the intermediate mold in the mold assembly transferred from the primary metering supply stage On the lower side of the support plate having a surface leveling end, the surface of which is smoothly treated by a stirring rod, and the intermediate mold, to which the friction material powder is supplied and treated on the surface, has the same shape as that of the plunger of the upper mold. The friction material powder is aligned and pressed by the plunger of the support plate, characterized in that the friction material powder is composed of a primary pressing end to be stabilized with the same effect as the pseudo-molding.

In the present invention, after the pressing step may include a secondary metering supply stage in which residual friction material powder or friction material powder of different composition is metered on the friction material layer in the cavity metered in the primary metering supply stage. have.

Referring to the present invention in more detail based on the accompanying drawings as follows.

FIG. 1 shows a friction material cake 10 molded according to the present invention, and FIG. 2 shows a brake pad 16 having a friction material 12 attached to the back plate 14 using the friction material cake 10. will be.

In the present invention, the term “friction material cake” means to form a cake to be used as the friction material 12 until the friction material 12 is attached to the back plate 14 to form the brake pad 16. . The friction material cake 10 is attached to the back plate 14, the slot 18 is processed in the center as shown in Figure 2 and the inclined surface 20 is formed on both sides of the friction material 12 of the brake pad 16 It is completed as.

Typically, the friction material cake 10 is molded in a mold assembly 22 as shown in FIGS. 3 and 4. The mold assembly 22 includes a lower mold 24, an intermediate mold 26, and an upper mold 28. In the lower mold 24, several supporting surfaces 30 are formed on the upper surface of the lower mold 24 so as to conform to the bottom shape of the friction material cake 10. As shown in FIG. 3, the lower mold 24 has three support surfaces 30 arranged in two rows at regular intervals, so that six support surfaces 30 are formed as a whole. It will be appreciated by those skilled in the art that the lower mold 24 may have a different arrangement and number of supporting surfaces 30 as necessary. In the intermediate mold 26, several forming pipes 36 having vertically shaped cavities 34 corresponding to the cross-sectional formation of the friction material cake 10 are vertically disposed on the support 32 constituting the intermediate mold 26. When the intermediate mold 26 is disposed on the lower mold 24, the cavity 34 is disposed on the bottom side of the forming tube 36 in which the support surface 30 of the lower mold 24 is disposed on the intermediate mold 26. It can be inserted inside. The upper mold 28 is composed of the upper support zone 38 and several plungers 40 integrally disposed thereunder. The plunger 40 of the upper mold 28 has a horizontal cross-sectional shape coinciding with the cross-sectional shape of the cavity 34 of the intermediate mold 26 and each plunger (when the upper mold 28 is coupled to the intermediate mold 26). 40 can be inserted into the cavity 34 of the intermediate mold 26.

In the general molding process of the friction material cake 10, the intermediate mold 26 is coupled to the lower mold 24, and the friction material powder accurately weighed into the cavity 34 of the forming tube 36 of the intermediate mold 26 is introduced. The friction material cake 10 will be formed by inserting the plunger 40 of the upper mold 28 into the cavity 34 of the intermediate mold 26 and pressing the upper mold 28 against the lower mold 24. Can be.

The present invention provides a method and apparatus for enabling continuous and automatic molding of a friction material cake (10) using such a mold assembly (22).

In the drawings, FIG. 5 is a process explanatory diagram of the present invention, and FIG. 6 shows an overall schematic diagram of an apparatus in which the method of the present invention is performed. Before describing the method of the present invention, a description of the apparatus on which the method is performed will be needed.

As shown in FIG. 6, the apparatus of the present invention, in turn, is a standby stage 42 in which the mold assembly 22 waits to prepare for molding of the friction material cake 10, the upper mold 28 in the mold assembly 22. Friction material powder supplied to the primary metering supply stage 46 and the cavity 34 for metering and supplying a substantial amount of the entire friction material powder to the cavity 34 of the upper mold separation stage 44 for separating the The surface leveling stage 48 uniformly selects the uneven surface in the layer of, the primary pressing stage 50 for prepressurizing the friction material powder layer F supplied to the cavity 34, and the primary metering supply stage 46. And a secondary metering supply stage 52 for metering and supplying the residual friction material powder or the friction material powder of different composition on the friction material powder layer F in the cavity 34 metered and supplied. Each of these stages 42-52 is arranged on a reciprocating conveyor 56 installed in the frame 54 of the apparatus as shown in FIG. 6. In addition, the mold assembly 22 transported to perform the process at each stage 42 to 52 may be performed by the conveyor 56 controlled by the servomotor for the designated process at each stage. have. This process is well known in the field of automation technology and will not be described in detail.

As shown in FIG. 5, the method performed by each stage 42 to 52 of the apparatus includes a standby stage performed at the standby stage 42, an upper mold separation stage formed at the upper mold separation stage 44, and a primary metering supply. The first measurement supply step made in the stage 46, the surface selection step made in the surface leveling stage 48, the first pressing step made in the primary pressing stage 50, the secondary made in the secondary metering supply stage 52 Secondary pressing, which is a weighing supply step, a secondary surface leveling step made at the surface leveling end 48, a preforming step made at the upper mold separation step 44, and a final molding step made by a separate molding press outside the apparatus. It consists of steps.

Each step 42-52 of the device of the present invention will describe each step of the method.

Atmospheric stage (42)

The atmospheric stage 42 corresponds to the starting position of the reciprocating conveyor 56 installed in the frame 54 of the apparatus, and the mold in which the intermediate mold 26 and the upper mold 28 are combined on the lower mold 24 in turn. The assembly 22 (see FIG. 7) is placed by a robot (not shown) or the like and is prepared for forming a friction material or friction material cake. In this case, the reciprocating conveyor 56 transfers the mold assembly 22 or a part of the atmospheric stage 42 to the secondary measurement supply stage 52 and then returns to the atmospheric stage 42.

Upper mold separation stage (44)

The upper mold separating end 44 is disposed on the conveyor 56 and attached to the lower end of the ram piston 58 extending from the upper ram (not shown), as described in detail in FIG. It consists of a pressure plate 62 guided by a vertical guide rod 60 fixed to the frame 54. On the other hand, on both sides of the bottom surface of the pressure plate 62, for example, a hook 64 operated by a solenoid actuator or a pneumatic actuator (not shown) is disposed.

When the mold assembly 22 conveyed by the conveyor 56 reaches the upper mold separation stage 44, the mold assembly 22 stops and the pressing plate 62 is lowered by the operation of the ram piston 58 to lower the upper portion. Upon reaching the support 38 of the mold 28, the hook 64 is coupled to the side of the support 38 of the upper mold 28. Then, when the pressing plate 62 is raised by the operation of the ram piston 58, the upper mold 28 is separated upward from the mold assembly 22 (FIG. 8). Therefore, in the mold assembly 22, the upper mold 28 is separated and the cavity 34 of the intermediate mold 26 is exposed upward, and the upper mold 28 remains in the upper mold separation end 44 and the intermediate mold. 26 and the lower mold 24 are conveyed along the conveyor 56 to the next primary metering feed stage 46.

Primary metering supply stage (46)

The primary metering stage 46 is located downstream of the upper mold separation stage 44 as seen from the operating direction of the conveyor 56 as shown. The intermediate mold 26 of the mold assembly 22 having the upper portion of the cavity 34 exposed to the primary metering supply stage 46 and the lower mold 24 to which the intermediate mold 26 is coupled are transferred. In the primary metering supply stage 46, the friction material carrier assembly guided up and down by the vertical guide rod 66 fixed to the frame 54 on the upper side of the intermediate mold 26, the upper portion of the cavity 34 is exposed. 68 is disposed, and the friction material powder single carrier 70 that is movable up, down, left, right and front and rear as shown in the figure is disposed on the upper side thereof, and the powder metering feeder 72 is disposed on the single carrier 70. The powder weighing device 72 is similar to the configuration of the powder automatic weighing device described, for example, in Japanese Patent Application Laid-open No. 1996-0018530 published on June 17, 1996.

As shown in FIG. 10, the powder weighing device 72 is composed of two rollers 74a and 74b which rotate outwardly from each other and a roller housing 76 in which these rollers 74a and 74b are accommodated. It is composed of a supply unit 78, the lower side of the fixed-quantity supply unit 78 has a measuring cup 82, which is coupled to the opening and closing plate 80 at the lower end on the support 84 installed on the frame 54, such as a load cell, for example It is installed through the sensor 86. And the opening and closing plate 80 is composed of a solenoid type or pneumatic type actuator 88 mounted on the support (84) is coupled. The powder metering supply device 72 is capable of supplying friction material powder from an upper friction material powder supply tank 90 (shown schematically in FIG. 6).

The operation of the powder metering device 72 is as follows.

First, the opening and closing plate 80 of the measuring cup 82 in the powder metering supply device 72 is empty in the state where the end is closed by the opening and closing actuator 88, in this state, the upper friction ash powder supply tank 90 The friction material powder supplied from is supplied onto the two rollers 74a and 74b of the fixed-quantity supply unit 78, and the friction material powder is supplied to the measuring cup 82 by the rotation of these rollers 74a and 74b, and the friction material powder of the fixed amount is supplied. When this is supplied to the measuring cup 82, the weight sensor 86 of the support 84 is detected. When only the correct amount of friction material that is equal to the weight of the friction material cake 10 is weighed by the weight sensor 86, the solenoid type or pneumatic type actuator 88 operates according to the signal detected by the weight sensor 86. As a result, the opening and closing plate 80 closing the lower opening of the measuring cup 82 is opened, so that the friction material powder having a fixed quantity is supplied to the friction material powder single carrier 70 located below the powder metering device 72.

As described above, the friction ash powder single carrier 70 disposed below the powder metering device 72 is movable left, right, up and down as well as back and forth. The friction material powder single carrier 70 has a rectangular cross-sectional chute structure, and has opening and closing plates 92a and 92b disposed on the lower side thereof. And the z-direction guide 96 to move left, right, up and down and back and forth. Since the three-axis linear motion guide is well known in the field of automation equipment will not be described in detail.

The friction material powder carrier assembly 68 disposed below the friction material powder single carrier 70 has a chute 98 shaped like the chute-shaped friction material powder single carrier 70 and formed in each of the intermediate molds 26. A plurality of joints are arranged to match the arrangement of the pipes 36. Each chute 98 is provided with respective opening and closing plates 100a and 100b, which can be opened and closed in conjunction with each other, and the whole is focused on the support 102 and the support 102 is the frame 54 as mentioned above. It moves up and down along the guide rod 66 fixed to the back side). The vertical movement of the friction material powder carrier assembly 68 may be made by, for example, a pneumatic cylinder (not shown) as will be appreciated by those skilled in the art.

The friction material powder is supplied in the primary metering supply stage 46 as follows.

First, before the supply of the friction material powder is started, the friction material powder single carrier 70 disposed below the powder weighing device 72 is placed in a state where the opening and closing plates 92a and 92b are closed. In addition, the opening / closing plate 80 of the measuring cup 82 constituting the fixed quantity supply part 78 of the powder measuring supply device 72 is also placed in the closed state. The friction material carrier assembly 68 is also placed in a state where the opening and closing plates 100a and 100b in each chute 98 are closed and moved upward along the vertical guide rod 66.

In this state, in the friction material powder supply tank 90 as shown in FIG. 6, the friction material powder is supplied to the roller housing 76 side of the fixed quantity supply part 78 constituting the powder weighing supply device 72, and the roller housing 76 The rollers 74a and 74b are rotated in the direction as shown by the arrows in FIG. 10 to supply the friction material powder corresponding to the weight of the friction material cake 10 to the lower measuring cup 82. When the correct amount of friction material powder is supplied to the measuring cup 82, the load of the measuring cup 82 including the friction material powder is sensed by the weight sensor 86 of the support 84 to which the measuring cup 82 is coupled. When it is confirmed that the correct amount of friction material powder is supplied by the weight sensor 86, the opening and closing actuator 88 coupled to the opening and closing plate 80 is operated to close the lower side of the measuring cup 82 ( 80) is open. Thereby, the quantity of friction ash powder is supplied from the measuring cup 82 to the friction ash powder single carrier 70 side. Thereafter, the friction material powder single carrier 70 supplied with the quantity of friction material powder supplies the quantity of friction material powder in one chute 98 of the friction material powder carrier assembly 68 located below. The friction material powder supplied in the chute 98 of the friction material carrier assembly 68 has not been supplied with the friction material powder since the opening and closing plate 80 is closed. In this process, that is, the friction material powder is accurately metered from the measuring cup 82 and supplied to the friction material powder single carrier 70, and the friction material powder is then supplied from each friction material powder carrier assembly 68 from the friction material powder single carrier 70. The process supplied to 98 is repeated until a quantity of friction material powder is supplied to all chutes 98 of the friction material carrier assembly 68. For example, in the process of supplying the friction material powder single carrier 70 to the chute 98 of the next friction material powder carrier assembly 68, the friction material powder single carrier 70 is the x direction guide 94 and the y direction guide (not shown). And the z-direction guide 96 to feed the chute 98 with a fixed amount of friction material while moving left, right, up and down and back and forth in the drawing.

In this way, the friction material carrier assembly 68 supplied with a quantity of friction material powder to all the chutes 98 moves downward along the vertical guide rod 66 to form a mold assembly disposed below the friction material powder carrier assembly 68. 22 on the intermediate mold 26. That is, each chute 98 of the friction material powder carrier assembly 68 has its lower end aligned with the cavity 34 of each forming tube 36 of the intermediate mold 26.

Subsequently, each chute 98 of the friction material powder carrier assembly 68 is opened to each cavity 34 of the intermediate mold 26 by collectively opening and closing the respective opening and closing plates 100a and 100b, which can be opened and closed in conjunction with each other. It will supply the friction material powder of each quantity.

Surface leveling end (48)

The mold assembly 22, in which the friction material powder is supplied to the intermediate mold 26 of the mold assembly 22 in the primary metering feed end 46, is transferred to the next surface leveling end 48 along the conveyor 56. .

The friction material powder supplied to each cavity 34 of the intermediate mold 26 in the primary metering supply stage 46 is supplied from the friction material powder as the friction material powder is dropped from the chute 98 of the friction material carrier assembly 68. The upper surface of the powder layer F may not be flat and, for example, the middle portion may be convex. In this state, when press-molded by the upper mold, the density of the friction cake may be different from the middle portion and the edge portion. In order to prevent this, it is necessary to flatten the surface of the friction material powder layer F supplied to each cavity 34. For this purpose, surface smoothing 48 is required.

The surface leveling end 48 is composed of a mold assembly 22 conveyed thereto, that is, a stirring rod assembly 104 disposed on an upper portion of a mold assembly 22 composed of an intermediate mold 26 and a lower mold 24. . This stirring rod assembly 104 is composed of several stirring rods 106, as shown in Figure 6, the x-direction guide 108, and the y-direction guide 110 coupled to the x-direction guide 108 In addition, a linear motion guide robot composed of a z direction guide 112 coupled to a y direction guide 110 is coupled to the z direction guide 112 of the robot. Therefore, the stirring rod 106 of the stirring rod assembly 104 of the friction material powder layer F supplied in each cavity 34 of the intermediate mold 26 of the mold assembly 22 transferred to the surface leveling end 48. The top can be stirred sequentially to make the leveling work smooth.

As such, the mold assembly 22 in which the upper surface of the friction material powder layer F supplied to each cavity 34 of the intermediate mold 26 at the surface leveling end 48 is evenly surfaced has a primary pressing end ( 50).

Primary pressing stage (50)

The primary pressing stage 50 is to enable a pressing process for stabilizing the friction material powder layer (F) supplied in each cavity 34 of the intermediate mold (26). The primary pressing end 50 is composed of a support plate 116 that moves up and down in the vertical guide rod 114 installed on the frame 54 and the upper mold of the mold assembly 22 below the support plate 116. Several plungers 118 which are the same as the plunger 40 comprised by 28 are arrange | positioned.

In addition, a ram piston 120 of a ram (not shown) mounted on the frame 54 is connected to the upper portion of the support plate 116 so that the plunger 118 is lowered into the cavity 34 of the mold assembly 22 when the lower portion is lowered. By pressing the supplied friction material powder layer F, the friction material powder layer F can be stabilized by the same effect as the pseudo-molding.

The mold assembly 22 in which the friction material powder layer F stabilized in the pressing process in the primary pressing stage 50 is conveyed by the conveyor 56 to the next secondary metering supply stage 52.

Secondary measurement supply stage (52)

The secondary metering supply 52 is similar to the primary metering supply 46, and the secondary metering supply 52 is devoid of the friction material powder carrier assembly 68 of the primary metering supply 46. Except for the same configuration as the primary metering supply stage 46 except for the same configuration as that of the primary metering supply stage 46 in each of the components of the secondary metering supply stage 52, the prime (') Are shown and description of each component is omitted.

The secondary metering end 52 is for metering and supplying residual friction material powder or friction material powder of different composition on the friction material powder layer F in the cavity 34 metered and supplied by the primary metering supply end 46. .

The supply of the friction material powder in the secondary metering supply stage 52 is as follows.

First, before the supply of the friction material powder is started, the friction material powder single carrier 70 'disposed below the powder metering device 72' has an internal opening and closing plate 92a '(only one is shown in FIG. 13). It is in a closed state. In addition, the opening / closing plate 80 'of the measuring cup 82' constituting the fixed quantity feeding part 78 'of the powder measuring device 72' is also in a closed state.

In this state, in the friction material powder supply tank 90 'as shown in FIG. 6, the friction material powder is supplied to the roller housing 76' side of the fixed quantity supply part 78 'constituting the powder metering supply device 72' and the rollers. A roller 74a '(only one is shown in FIG. 13) of the housing 76' is rotated to supply residual friction material powder or friction material powder of different composition to the lower measuring cup 82 '. When the correct amount of residual friction ash powder or friction powder of different composition is supplied to the weighing cup 82 ', the load of the measuring cup 82' containing the friction ash powder is sensed by a weight sensor (not shown) and the weight When it is confirmed that the correct amount is supplied by the sensor, the opening and closing plate 80 'closing the lower side of the measuring cup 82' is opened. Thus, the correct amount of residual friction ash powder or friction ash powder of different composition is supplied from the measuring cup 82 'to the friction ash powder single carrier 70' side. Thereafter, the friction material powder single carrier 70 'supplied with the friction material powder is supplied to one cavity 34 of the intermediate mold 26 of the mold assembly 22 positioned below the intermediate powder 26. It is repeated until the remaining friction material powder or the friction material powder of a different composition is supplied to each cavity 34 of. For example, in the process of supplying the residual friction ash powder or the friction ash powder of different composition from the friction ash powder single carrier 70 'to each cavity 34 of the intermediate mold 26, the friction ash powder single carrier 70' is guided in the x direction. 94 ', the y-direction guide (not shown) and the z-direction guide 96', the remaining friction ash powder or different from all the cavities 34 of the intermediate mold 26 while moving left, right, up and down in the figure It is to supply the friction material powder of the composition. FIG. 13 shows the friction material powder layer F, which is already supplied to each cavity 34 of the intermediate mold 26, and the residual friction material powder or the different composition supplied from the secondary meter feed end 52 thereon. It is seen that the layer F 'of the friction material powder is formed.

Post-process of the secondary metering stage 52

In the secondary metering supply section 52, a quantity of friction material powder and residual friction material powder or friction material powder of different composition is supplied to each cavity 34 of the intermediate mold 26 so that the friction material powder layer F (F ') is formed. The molded assembly 22 is conveyed in a direction opposite to the direction that is advanced from the standby stage 42 to the secondary metering supply stage 52 by the return operation of the conveyor 56.

The mold assembly 22 conveyed in the opposite direction is stopped at the surface leveling end 48 and the surface of the friction material powder layer F 'of the upper layer laminated in each cavity 34 of the intermediate mold 26 is preceded. As described above, the surface of the friction material powder layer F is treated by the stirring rod 106 in the same manner as that which is treated to be flat at the surface leveling end 48.

Thereafter, the mold assembly 22 having the surface of the friction material powder layer F ′ of the upper layer flattened is transferred from the surface leveling end 48 to the upper mold separation end 44. In the upper mold separation stage 44, the upper mold 28 from the original mold assembly 22 is coupled to the lower side of the pressing plate 62 by the hook 64 of the pressing plate 62 and is molded by the ram piston 58. It is in an upwardly separated state from the intermediate mold 26 of the assembly 22.

When the mold assembly 22 in which the friction material powder layers F and F 'are laminated in each cavity 34 of the intermediate mold 26 is transferred to the upper mold separation end 44, the ram piston 5 is lowered. As the pressure plate 62 is lowered and the upper mold 28 coupled thereto is lowered, each plunger 40 extending below the upper mold 28 is inserted into each cavity 34 of the intermediate mold 26 aligned therewith. Is inserted. In the bonding process of the upper mold 28, the pressing plate 62 presses the upper mold 28 to preform the pressing of the friction material powder layer (F) (F '), and then the lower portion of the pressing plate 62 The upper mold 28 is coupled to the intermediate mold 26 while the hooks 64 formed at both sides are released, and the pressing plate 62 is raised by the rising of the ram piston 5 so that the mold assembly 22 is formed by the upper mold ( 28), the intermediate mold 26 and the lower mold 24 is in a combined state.

In the final stage, when the mold assembly 22 in which the friction material powder layers F and F 'are laminated in each cavity 34 of the intermediate mold 26 reaches the atmospheric stage 42, a robot device (not shown) is shown. The friction material cake 10 is manufactured as it is conveyed to the secondary pressing equipment side installed outside the apparatus of the present invention, and the final pressing molding is performed by the pressing means 122.

Thus, in the present invention, the mold assembly 22 in which the intermediate mold 26 and the upper mold 28 are combined on the lower mold 24 in the atmospheric stage 42 is moved to the next step by the reciprocating conveyor 56. The mold assembly 22, which is ready to be transported and transferred to the upper mold separation end 44 by the conveyor 56, has a hook of the pressing plate 62 attached to the lower end of the ram piston 58 extending from the top. As the upper mold 28 is separated by the 64, the cavity 34 of the intermediate mold 26 is exposed, the upper mold 28 is separated, and the cavity 34 of the intermediate mold 26 is exposed upward. In the intermediate mold 26 and the lower mold 24 is conveyed along the conveyor 56 to the primary metering supply stage 46, the cavity 34 of the intermediate mold 26 in the primary metering supply stage 46 A quantity of friction material powder is supplied to the mold assembly, and in the mold assembly 22 transferred from the primary weighing feed end 46 to the surface leveling end 48, a cavity of the intermediate mold 26 is supplied. The surface of the friction material powder supplied to the 34 is treated by the stirring rod 106 to be flat, and the mold assembly 22 moves the primary pressing end 50 from the surface leveling end 48 where the surface of the friction material powder is flat. ) Is aligned with the lower side of the support plate 116 having the plunger 118 in the same shape as that of the plunger 40 of the upper mold 28 and the plunger 118 of the support plate 116 is an intermediate mold 26. By pressing the friction material powder supplied to the cavity 34 of the) to enable the friction material powder layer (F) to be stabilized by the same effect as the pseudo-molding, the mold assembly 22 is transferred to the secondary metering supply (52) Residual friction material powder or friction material powder of different composition is metered on the friction material powder layer F in the cavity 34 metered by the primary metering supply stage 46, and each cavity 34 of the intermediate mold 26 is metered. Do not supply quantitative friction powder and residual friction powder or friction powder of different composition to The mold assembly 22 having the re-powder layer F (F ') layered thereon is transferred back to the surface leveling end 48 by the return operation of the conveyor 56, so that the friction ash powder layer F' of each cavity 34 is formed. ) And the mold assembly 22 having the surface of the friction material powder layer F ′ flattened is transferred from the surface leveling end 48 to the upper mold separation end 44 so that the upper mold 28 ) Is bonded to the intermediate mold 26, and in the final step, the friction material powder layer F (F ') of each cavity 34 of the intermediate mold 26 is finally pressed molded to produce the friction material cake 10.

In the present invention as described above, the entire process of obtaining the preformed friction material cake is continuously and automatically performed from the preparation of the mold for molding the friction material used in the brake pad to the accurate metering of the friction material powder to the mold and the preforming. Provided are a method and an apparatus for producing a friction material for a brake pad.

Claims (4)

A method for producing a friction pad for a brake pad, wherein the method for producing a friction pad for a preformed friction material is obtained by using a mold assembly composed of a lower mold, an intermediate mold and an upper mold for molding a friction material used in a brake pad. A standby step in which the mold assembly consisting of the intermediate mold and the upper mold is prepared to be transferred to the next step by a reciprocating conveyor, and the upper mold is separated so that the cavity of the intermediate mold is exposed from the mold assembly. The upper mold separation step, the primary metering supply step of supplying a quantity of friction material powder to the cavity of the intermediate mold exposed to the upper surface, the surface of the friction material powder supplied to the cavity of the intermediate mold is a surface treated Selecting step, the friction material powder supplied to the cavity of the intermediate mold A first pressing step for pressing the friction material powder layer to be stabilized by an effect such as caustic molding, an upper mold bonding step in which the upper mold is coupled to the mold assembly in which the surface of the friction material powder layer is flattened, and the And a second pressing step in which the friction material powder layer of each cavity of the intermediate mold is finally pressed and manufactured to produce the friction material cake. The secondary metering supplying step of claim 1, wherein after the first pressing step, a residual metering material powder or a friction material powder having a different composition is metered on the friction material layer in the cavity of the intermediate mold, and the secondary mold supplying step is performed. And a second surface leveling step in which the surface of the residual friction material powder or the friction material powder having a different composition is smoothly supplied to the cavity. By using a mold assembly 22 composed of a lower mold 24 for forming a friction material used in a brake pad, an intermediate mold 26 having a cavity 34 and an upper mold 28 having a plunger 40. In the apparatus for manufacturing a brake pad friction material for obtaining a preformed friction material cake (10), the apparatus comprising the mold assembly consisting of the intermediate mold (26) and the upper mold (28) on the lower mold (24) in turn. On the hook 64 of the pressurizing plate 62 attached to the lower end of the air stage 42, the ram piston 58 extending from the top, where the 22 is prepared to be transferred to the next stage by the reciprocating conveyor 56. By separating the upper mold 28 of the mold assembly 22 by separating the upper mold separation stage 44, the upper mold 28 to expose the cavity 34 of the intermediate mold 26 In the state where the cavity 34 of the intermediate mold 26 is exposed upward The intermediate mold 26 and the lower mold 24 are transported along the conveyor 56 so that a quantity of friction material powder is supplied to the cavity 34 of the intermediate mold 26. ), The surface of the friction material powder supplied to the cavity 34 of the intermediate mold 26 in the mold assembly 22 transferred from the primary metering supply stage 46 is flattened by the stirring rod 106. The plunger (48), which is smoothly treated, and the intermediate mold (26), to which the friction material powder is supplied and which are treated on the surface, have the same shape as that of the plunger (40) of the upper mold (28). Aligned with the lower side of the support plate 116 having 118 so that the friction material powder is pressed by the plunger 118 of the support plate 116 so that the friction material powder layer F can be stabilized with the same effect as the provisional molding. Brake pad, characterized in that consisting of a pressing end (50) Apparatus for manufacturing a friction material. 4. The friction material of claim 3 or the friction material having a different composition on the friction material powder layer F in the cavity 34, which is metered and fed from the primary metering supply terminal 46 after the pressing end 50. Apparatus for producing a friction pad for a brake pad, characterized in that it comprises a secondary metering supply stage (52) through which powder is metered.

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