201024568 六、發明說明： 【發明所屬之技術領域】 本發明是有關於-種摩擦材料的製造方法 一種具有高性能摩擦材料的製造方法。 符別疋才! 【先前技術】 -般車輛的煞車片是利用摩擦材料所製成 材料是鑄鐵、碳鋼或合金鋼所製成的、然而以 的 製造的成品，具有下列缺點： 胃#料所 ❹ 不耐高溫，易變形，易腐餘、壽命短：當車_ 從高速的情況下煞車時，煞車襯塾將煞車片咬合了 並藉由磨擦力使車辅停止’而在減速磨擦的過程中 有熱產生，使得金屬煞車片容易在高溫下受熱軟化 ’而容易被磨損變形，導致使用壽命降低，加上由 鐵類金制製成的煞車片纟易因環境或渥度等因素 而發生腐蝕與打滑等現象，影響其煞車制動性能之 表現》 ‘ ❿ ，2.質量重··由於煞車片是以金屬材料製成，而金屬的 密度大，且質量重，使得煞車片變重，也使得車輪 相對於整體車輛來說變重許多，然而，對於講求速 度的跑車來說，倘若車輛的重量太重，則會影響跑 車的速度，因此’如何利用減少煞車片的重量，使 跑車的重量下降，也成為製造商考慮的重點之一。 於是，有製造商開發出以陶瓷材料取代金屬材料來製 造煞車片’而陶瓷材料所製成的煞車片，雖然能耐高溫且 3 201024568 不易在高溫下變形，重量又相較於金屬材料輕很多，其煞 車靈敏度亦較佳，但因為以陶瓷材料製成的煞車片製造^ 程不易，且成品的脆性甚高，且呈多孔性，緻密度差因 此在使用過程中容易受到過大的撞擊而碎裂，使得煞車片 的使用壽命下降，太換率變高，是故，如何提升以陶竟材 料所製的煞車片之性能’便成為許多製造商急於解決的 題。 【發明内容】 因此，本發明之目的，即在提供一種可以提高緻密度 的摩擦材料之製造方法。 ^ ^ 於是，本發明具有高性能摩擦材料的製造方法，包含 -準備步驟、一混合步驟、一熱壓步驟、一初胚穩定化步 驟、一高溫熱解步驟、一緻密化步驟、一預型材乾燥、穩 疋化步驟、一熱處理步驟，及一加工成型步驟。 該準備步驟是製備碳纖維、陶瓷粉末、碳原料粉末， 及膠結料；該混合步驟是將上述之碳纖維、陶瓷粉末碳 原，粉末，及膠結料均句混合，得到一混合材；該熱壓步❹ 驟是將該混合材進行熱壓成型，得到一含有該碳纖維陶 瓷粉末、碳原料粉末，及膠結料的初胚；該初胚穩定化步 驟是加熱該初胚，使該初胚中的膠結料將該碳纖維、陶瓷 粉末、碳原料粉末交鏈結合在一起；該高溫熱解步驟是將 經過初胚穩定化步驟的初胚在一保護氣體中加熱，進行熱 解作用，以使該膠結料内所含之非碳物質受熱後自該初胚 分離，形成一具有多孔隙的預型材。 4 201024568 該緻密化步驟是將該預型材置於 力差的容室中，並於該容室中通入一液:=成有1 入材填入該預型材的孔隙中；該預型材錢、渗 是加熱該預型材與該渗入材，使兩二：；疋化㈣ =1將經乾燥、穩定化㈣的㈣材與該滲入材在— 二：體：加熱二進行熱處理’使渗入該預型材孔隙的渗 密材進:機：：传到一敏密材’該加工成型步驟是對該緻 在材進仃機械加工，得到一摩擦材料。201024568 VI. Description of the Invention: [Technical Field] The present invention relates to a method for producing a friction material. A method for manufacturing a high-performance friction material. [Previous technology] The brake film of a general vehicle is made of cast iron, carbon steel or alloy steel, which is made of friction material, but has the following disadvantages: It is not resistant to high temperature, easy to deform, perishable, and short life: when the car _ from the high-speed situation, the brake lining will bite the car and use the friction to stop the car's and slow down the friction There is heat generated in the process, which makes the metal brake piece easy to be softened by heat at high temperature' and is easily deformed by wear and tear, resulting in a decrease in service life. In addition, the brake piece made of ferrous gold is easy to be affected by environment or humidity. Corrosion and slippage occur, which affects the performance of braking performance of the brakes. ' ❿ , 2. Heavy weight · Because the brake slab is made of metal material, and the density of the metal is large, and the weight is heavy, the brake slab becomes heavier. It also makes the wheel a lot heavier than the whole vehicle. However, for a speed-conscious sports car, if the weight of the vehicle is too heavy, it will affect the speed of the sports car, so 'how to use the reduction The weight of the car sheet, so that the weight of the car dropped, has become one of the key manufacturers to consider. Therefore, some manufacturers have developed a brake film made of ceramic material instead of metal material to make a brake piece, and the ceramic material can withstand high temperature and 3 201024568 is not easy to deform at high temperature, and the weight is much lighter than metal material. The brake sensitivity is also better, but the manufacturing process of the brake film made of ceramic material is not easy, and the brittleness of the finished product is very high, and it is porous, and the density is poor, so it is easily broken by excessive impact during use. Therefore, the service life of the brake shoes is reduced, and the conversion rate is too high. Therefore, how to improve the performance of the brake shoes made of ceramic materials has become an issue that many manufacturers are eager to solve. SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a method of manufacturing a friction material which can increase the density. ^ ^ Thus, the present invention has a high-performance friction material manufacturing method, comprising - a preparation step, a mixing step, a hot pressing step, an initial embryo stabilization step, a high temperature pyrolysis step, a uniform densification step, a pre- Profile drying, stabilization step, a heat treatment step, and a processing step. The preparation step is to prepare carbon fiber, ceramic powder, carbon raw material powder, and cement; the mixing step is to uniformly mix the carbon fiber, the ceramic powder carbon, the powder, and the binder to obtain a mixed material; the hot pressing step The step of hot pressing the mixture to obtain an initial embryo containing the carbon fiber ceramic powder, the carbon raw material powder, and the binder; the initial embryo stabilization step is to heat the embryo to make the initial embryo. The carbon fiber, the ceramic powder, and the carbon raw material powder are cross-linked together; the high-temperature pyrolysis step is to heat the initial embryo subjected to the initial embryo stabilization step in a protective gas to perform pyrolysis to make the cementation The non-carbon material contained in the material is separated from the blast by heat to form a porous preform. 4 201024568 The densification step is to place the preform in a chamber of poor force and to introduce a liquid into the chamber: = 1 into the pores of the preform; the pre-form money The osmosis is to heat the preform and the infiltrated material to make two or two: 疋 (4) =1 to dry and stabilize the (four) (four) material and the infiltrated material in the second: body: heat two for heat treatment 'to infiltrate the The infiltrated material of the preform pores: machine:: passed to a sensitive material. The processing step is to mechanically process the material into a material to obtain a friction material.
本發明之另—種具有高性能摩擦材料的製造方法，包 含-準備步驟：一混合步驟、一熱壓步驟、一初胚穩定化 步驟、一尚溫熱解步驟、一緻密化步驟，及一加工成型步 驟該準備步驟是製備碳纖維、碳原料粉，及膝結料；該 2合步驟是將上述之碳纖維、碳原料粉，及膠結料均勻混 合，得到一混合材；該熱壓步驟是將該混合材進行熱壓成 型，得到一含有該碳纖維、碳原料粉，及膠結料的初胚； 該初胚穩定化步驟是加熱該初胚，使該初胚中的膠結料將 該碳纖維、碳原料粉交鏈結合在一起。 該高溫熱解步驟是將經過初胚穩定化步驟的初胚在一 保護氣體中加熱，進行高溫熱解作用，以使該膠結料内所 含之非碳物質受熱後自該初胚分離，形成一具有多孔隙的 預型材；該緻密化步驟是將該預型材置於一與外界形成有 一壓力差的容室中，並於該容室中通入一滲入材，進行一 段時間加熱’使該滲入材進行反應滲入該預型材的孔隙中 ;該加工成型步驟是將完成上一步驟的預型材進行機械加 201024568 工’得到一摩擦材料β 本發明之功效在於：在該緻密化步驟中，以外界與該 谷室間所形成的壓力差，使該滲入材強迫填入該預型材的 孔隙中，並藉由該預型材乾燥、穩定化步驟，使滲入材中 的碳能與預型材交鏈結合後，以利於該熱處理步驟的進行 ;而藉由該熱處理步驟，使滲入材中的碳固溶於該預型材 中，填補在預型材的孔隙，並經過多次緻密化處理、熱處 理之進行藉此提高整體的緻密度，強化其機械強度，以使 整體的使用壽命提高。 本發明之另一功效在於：在該緻密化步驟中，利用外 界與該谷室間所形成的壓力差，並對該容室加熱，使該滲 入材以熔滲方式填入該預型材的孔隙中，增加整體的緻密 度，強化其機械強度，以使整體的使用壽命提高。 【實施方式】 有關本發明之前述及其他技術内容、特點與功效，在 以下配合參考圖式之三個較佳實施例的詳細說明中將可 清楚的呈現。 在本發明被詳細描述之前，要注意的是，在以下的說 明内容中，類似的元件與步驟是以相同的編號來表示。 參閱圖1、2,本發明具有高性能摩擦材料的製造方法 之第一較佳實施例，是以製作一碳基的煞車片為代表，然 而可製作的摩擦材料甚多，在此不再一一舉例說明，該製 造方法包含一準備步驟丨、一混合步驟2、一熱壓步驟3、 一初胚穩定化步驟4、一高溫熱解步驟5、一緻密化步驟6 201024568 一熱處理步驟8，及一加 、一預型材乾燥、穩定化步驟7、 工成型步驟^ 1 ’先將PAN系碳纖維剪成5〜Another manufacturing method of the present invention has a high-performance friction material, comprising: a preparation step: a mixing step, a hot pressing step, an initial embryo stabilization step, a still temperature pyrolysis step, a uniform densification step, and a Processing step: the preparation step is to prepare carbon fiber, carbon raw material powder, and knee joint; the 2-step step is to uniformly mix the carbon fiber, the carbon raw material powder and the cement to obtain a mixed material; the hot pressing step is The mixed material is subjected to hot press forming to obtain an initial embryo containing the carbon fiber, the carbon raw material powder, and the cement; the initial embryo stabilization step is to heat the preliminary embryo, so that the cement in the primary embryo is carbon fiber and carbon. The raw material powders are linked together. The high temperature pyrolysis step is to heat the primary embryo subjected to the initial embryo stabilization step in a protective gas to perform high temperature pyrolysis, so that the non-carbon material contained in the cement is heated and separated from the primary embryo. Forming a porous preform; the densifying step is: placing the preform in a chamber having a pressure difference from the outside, and introducing a permeate into the chamber for heating for a period of time The infiltrated material is subjected to reaction and infiltrated into the pores of the preform; the processing forming step is to mechanically add the pre-formed material of the previous step to obtain a friction material β. The effect of the invention is: in the densification step The pressure difference formed between the outside and the valley chamber causes the infiltrated material to be forced into the pores of the preform, and the carbon in the infiltrated material can be combined with the preform by the drying and stabilizing step of the preform. After the cross-linking is combined, the heat treatment step is facilitated; and by the heat-treating step, the carbon in the infiltrated material is solid-dissolved in the pre-form, filling the pores of the pre-form and passing through multiple densifications. , For the heat treatment thereby increasing the overall density and enhance its mechanical strength, so that the overall service life. Another effect of the present invention is that in the densification step, the pressure difference formed between the outside and the valley chamber is utilized, and the chamber is heated to fill the pores of the preform by infiltration. In addition, increase the overall density and strengthen its mechanical strength to improve the overall service life. The above and other technical contents, features, and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments of the accompanying drawings. Before the present invention is described in detail, it is to be noted that in the following description, similar elements and steps are denoted by the same reference numerals. Referring to Figures 1 and 2, a first preferred embodiment of the method for manufacturing a high-performance friction material of the present invention is represented by a carbon-based brake sheet. However, there are many friction materials that can be produced, and no longer For example, the manufacturing method includes a preparation step, a mixing step 2, a hot pressing step 3, an initial embryo stabilization step 4, a high temperature pyrolysis step 5, a uniform densification step 6 201024568, and a heat treatment step 8. , and one plus, one preform drying, stabilization step 7, the forming step ^ 1 'cut the PAN carbon fiber into 5~
脂，及呋喃樹脂。 首先’進行該準備步驟1，先 50mm的長度，並備製陶瓷粉末、 其中，在本實施例中，該陶荽格 然後’進行該混合步驟2,將上述材料的組成成分以總 體積百分比為lOOvol%計算，將20〜50v〇1%的碳纖維， 10vol0/〇 的 50vol%的碳化矽粉末、5〜1〇v〇1%的碳黑、 介相瀝青、5〜10v〇l%的石墨，及3〇〜50v〇1%的酚醛樹脂均 勻混合，得到一混合材，其中，每一種組成成份的實際百 刀比例，可依照實際進行時進行添加或減少，但應注意每 〇 一材料的組成成份皆在上述所揭露的範圍之内，且上述材 料的加總成份之體積百分比需達到丨O〇v〇l〇/〇。 接著’進行該熱壓步驟3，將該混合材在溫度介於15〇 〜220°C之間，並持溫在20〜60分鐘的溫度條件下，以熱 壓成型的方式’得到一含有該碳纖維、陶瓷粉末、碳原料 粉末，及膠結料的初胚。 而後，進行該初胚穩定化步驟4，將該初胚置於高溫爐 中，以180〜200。(：間的加熱溫度，並施予30分鐘〜6小時 7 201024568 進行穩疋化過程’在穩定化過程中，該初胚中的膠結材料 ，受熱後將該碳纖維、碳原料粉末交鏈結合在一起。 接著，進行該高溫熱解步驟5,將經過穩定化步驟4的 初胚在一保護氣體中加熱，以進行熱解作用。在本實施例 中’該初胚;I：置於一高溫爐巾，而該保護氣想是氮氣並 以每分鐘3〜20C的升溫速率，加熱至75〇〜15〇(Γ(：間然後 持溫1〜6小時，而在該初胚中的膠結料内所含之非碳物質 因受熱後熱解，並自該初胚中分離，如此，形成一具有多 孔隙的預型材。在此，應注意的是，該高溫熱解步驟5中 所通入的保護氣體也可以是氦氣或氬氣。 然後，進行該緻密化步驟6，在一真空含浸設備61中 進行，該真空含浸設備61具有一與外界形成有壓力差的容 室611、一連通該容室的抽氣段612、一連通該容室6ΐι並 與該抽乳段612間隔設置的漏斗613、一設於該漏斗613和 各室611間的流量控制閥614，及一設於該抽氣段612和容 室611間的壓力控制閥615。 接著將該預型材51是置於該容室611中，該抽氣段 612與一真空幫浦機（圖未示）連接，並將一液相滲入材62置 於該漏斗613内，在本較佳實施例中是以液相碳前驅體作 為液相滲入材6^的實施態樣。 由於煤塔瀝青具有較好的潤滑效果，且成品的壽命較 高’所造成的異音也較少，故選擇以煤塔瀝青作滲入材62 ’然而，除了以煤塔瀝青作為滲入材62之外，也可以選擇 例如是酚醛樹脂、呋喃樹脂作為液相碳前驅體，故並不以 201024568 本較佳實施例的說明為限。另外值得一提的是，若選擇以 煤塔瀝青作滲入材62須先使煤塔瀝青加熱軟化以降低其黏 性，利於後續加壓含浸程序之進行。 配合參閱圖3’打開該流量控制閥614,使該液相滲入 材62流入該容室611之中，打開該壓力控制閥6丨5，使真 工幫浦機對該抽乳段612和該容室611抽氣至真空狀態，如 此可使該容室611與外界形成一壓力差，而利用該壓力差將 該液相滲入材62強迫填入該預型材51的孔隙之中。 φ 在此說明的是，’該敏密化步驟6在該容室611中所形成 的壓力差，除了本較佳實施例中述明是以抽真空的方式使 該谷至611與外界形成壓力差之外，也可以使用加壓的方式 ，由外界對該容室施予介於20〜l〇〇Mpa之間的壓力，達到 加壓含浸的效果。 然後，進行該預型材乾燥、穩定化步驟7，在一高溫爐 中，以180〜20(TC間的溫度加熱，並持續進行3〇分鐘〜6 小時，以使該液相滲入材62中的液相碳前驅體能與該預型 ® 材51充分結合一起，使該液相滲入材62穩定的置於該預 型材51的孔隙内。 接著，進订該熱處理步，驟8，{將經乾燥、穩定化的預 型材51與該液相滲入材62在保護氣體中以每分鐘3〜聰 的升溫速率，加熱至750〜·。c之間，然後持溫3〇分鐘 6小時’進订熱處理。在本較佳實施例中，該預型材η 液相滲人材62是置於高温爐内加熱，所使用的保護氣 體疋氮氣，並以每分鐘的升溫速率，加熱至議代， 9 201024568 然後持溫2小時，進行熱處理，如此，可使滲入該預型材 51孔隙的液相滲入材62進行反應生成碳基材，如此使預型 材51上的孔隙進一步被填補，因而滅少了孔隙的產生得 到一敏密材。 在此’應注意的是，如果該敏密材的敏密化程度仍舊 不符合作業要求，可重新回到該緻密化步驟6,並依序以真 空液相含浸進行緻密化，並經由該預型材穩定化步驟7和 熱處理步驟8提高整體的緻密化程度，在本較佳實施例中 疋一共反覆進行了四次的循環，但實際實施時當不以此為 限。 败 最後，進行該加工成型步驟9，對該緻密材進行機械加 工，該機械加工法是一般產業界所慣用的方式，例如使用 鑽石刀切割出所需的尺寸形狀，再以磨床加工該緻密材， 最後便可得到一摩擦材料成品。 值得一提的是，相較於習知以鑄鐵所製成之煞車材料 ，本發明具有高性能摩擦材料的優點在於，本發明之摩擦 :料是使用碳基材，其抗腐蝕能力、硬度及耐磨性較鑄“ 网，因此本發明摩擦材料之使用壽命相較於以鑄鐵所製成 之煞車材料提高有1G倍的壽命，再者，本發明的摩擦材料 具有耐高溫且穩定性佳的性質，在煞車時的高溫環境下也 可容易達到煞車效果’任何環境條件下，煞車反應均靈敏 。此外，碳基材的重量相較於鑄鐵來說比較輕可以使得 整體的重量減少，有利於降低車輛整體的重量，因此更具 有商業上實施的價值。 10 201024568Lipid, and furan resin. First, the preparation step 1 is carried out, first with a length of 50 mm, and a ceramic powder is prepared, wherein, in the present embodiment, the ceramic lattice is then subjected to the mixing step 2, and the composition of the above materials is taken as a total volume percentage. lOOvol% calculation, 20~50v〇1% carbon fiber, 10vol0/〇 50vol% niobium carbide powder, 5~1〇v〇1% carbon black, mesophase pitch, 5~10v〇l% graphite, And 3〇~50v〇1% phenolic resin is uniformly mixed to obtain a mixed material, wherein the actual ratio of each component can be added or reduced according to the actual progress, but attention should be paid to the composition of each material. The ingredients are all within the scope disclosed above, and the volume percentage of the total components of the above materials is required to reach 〇O〇v〇l〇/〇. Then, the hot pressing step 3 is carried out, and the mixed material is obtained by hot press molding at a temperature between 15 〇 and 220 ° C and at a temperature of 20 to 60 minutes. Carbon fiber, ceramic powder, carbon raw material powder, and the initial embryo of cement. Then, the preliminary embryo stabilization step 4 is carried out, and the initial embryo is placed in a high temperature furnace at 180 to 200. (: between the heating temperature, and apply for 30 minutes to 6 hours 7 201024568 to carry out the stabilization process 'in the stabilization process, the cement material in the primordial, after the heat, the carbon fiber, carbon raw material powder is cross-linked Next, the high temperature pyrolysis step 5 is performed, and the initial embryo subjected to the stabilization step 4 is heated in a shielding gas to perform pyrolysis. In the present embodiment, the embryo is placed; High temperature towel, and the protective gas is nitrogen and heated to 75 〇 15 每 at a heating rate of 3 to 20 C per minute (Γ (: then holding the temperature for 1 to 6 hours, and the cementation in the blast) The non-carbon material contained in the material is pyrolyzed by heat and separated from the initial embryo, thus forming a porous preform. Here, it should be noted that the high temperature pyrolysis step 5 The pass-through shielding gas may also be helium or argon. Then, the densification step 6 is carried out in a vacuum impregnation apparatus 61 having a chamber 611 which is formed with a pressure difference from the outside, a pumping section 612 that communicates with the chamber, and a chamber that is connected to the chamber The funnel 613 is disposed at intervals between the pumping section 612, a flow control valve 614 disposed between the funnel 613 and each of the chambers 611, and a pressure control valve 615 disposed between the pumping section 612 and the chamber 611. The preform 51 is placed in the chamber 611. The pumping section 612 is connected to a vacuum pump (not shown), and a liquid phase infiltrated material 62 is placed in the funnel 613. In the embodiment, the liquid phase carbon precursor is used as the liquid phase infiltrated material 6^. Since the coal tower bitumen has a good lubricating effect, and the life of the finished product is higher, the abnormal noise caused by the process is less, so The coal tower bitumen is selected as the infiltrated material 62. However, in addition to the coal tower bitumen as the infiltrated material 62, for example, a phenolic resin or a furan resin may be selected as the liquid phase carbon precursor, and thus the present invention is not preferably implemented in 201024568. The description of the example is limited. It is also worth mentioning that if the coal tower asphalt is selected as the infiltrated material 62, the coal tower asphalt should be heated and softened first to reduce its viscosity, which is beneficial to the subsequent pressurized impregnation process. 'Open the flow control valve 614 to allow the liquid phase to penetrate 62 flows into the chamber 611, opens the pressure control valve 6丨5, and causes the pumping section 612 and the chamber 611 to be evacuated to a vacuum state, so that the chamber 611 and the outside world can be A pressure difference is formed, and the liquid phase infiltrated material 62 is forcibly filled into the pores of the preform 51 by using the pressure difference. φ Here, 'the densification step 6 is in the chamber 611. The pressure difference formed is not only described in the preferred embodiment, but also the pressure difference between the valley and the 611 is formed by vacuuming, and the pressure can be used to apply the chamber to the outside. The pressure between 20~l〇〇Mpa is achieved to achieve the effect of pressurized impregnation. Then, the preform is dried and stabilized in step 7, in a high temperature furnace, heated at a temperature between 180 and 20 (TC), and The liquid phase carbon precursor in the liquid phase infiltrated material 62 can be sufficiently combined with the pre-formed material 51 to allow the liquid phase infiltrated material 62 to be stably placed in the pre-shaped material 51 for 3 minutes to 6 hours. Within the pores. Next, the heat treatment step is carried out, step 8, {heating the stabilized preform 51 and the liquid phase infiltrated material 62 in a protective gas at a heating rate of 3 to kr. per minute to 750 〜. Between c, then hold the temperature for 3 〇 minutes 6 hours to order heat treatment. In the preferred embodiment, the preform η liquid phase infiltrated material 62 is heated in a high temperature furnace, the protective gas used is nitrogen gas, and is heated to the temperature at a rate of temperature per minute, 9 201024568 After heating for 2 hours, heat treatment is performed. Thus, the liquid phase infiltrated into the pores of the preform 51 can be reacted to form a carbon substrate, so that the pores on the preform 51 are further filled, thereby eliminating the generation of voids. A sensitive material. Here, it should be noted that if the degree of densification of the sensitive material still does not meet the operational requirements, it can be returned to the densification step 6 and sequentially densified by vacuum liquid phase impregnation, and through the pre-prevention The profile stabilization step 7 and the heat treatment step 8 increase the overall degree of densification. In the preferred embodiment, the crucible is repeatedly repeated four times, but in practice, it is not limited thereto. Finally, the processing step 9 is performed to mechanically process the dense material, which is a method commonly used in the industry, for example, using a diamond knife to cut a desired size and shape, and then processing the dense material by a grinding machine. Finally, a finished friction material can be obtained. It is worth mentioning that the advantage of the high-performance friction material of the present invention is that the friction material of the present invention uses a carbon substrate, and its corrosion resistance and hardness are compared with those of the brake material made of cast iron. The wear resistance is better than that of the cast wire. Therefore, the service life of the friction material of the present invention is 1 G times longer than that of the brake material made of cast iron. Furthermore, the friction material of the present invention has high temperature resistance and good stability. The nature is also easy to achieve the braking effect in the high temperature environment when driving. 'The brake reaction is sensitive under any environmental conditions. In addition, the weight of the carbon substrate is lighter than that of cast iron, which can reduce the overall weight, which is beneficial to the whole. Reducing the overall weight of the vehicle is therefore more commercially valuable. 10 201024568
參閱圖4,為本發明具有高性能摩擦材料之製造方法的 ::較佳實施例，該第二較佳實施例大致上是與該第一較 :實施例相同，不相同之處在於：第二較佳實施例是以製 作陶是基的煞車片為代表，在該準備步驟丄巾該陶竟 粉末是選自於下列之—群組：金屬碳化物'金屬氮化物、 金屬氧化物、碳切、氮化石夕、氧化銘、富链紅柱石。而 該碳原料粉末是選自於下列之—群組：碳黑、介相遞青、 石墨，及此等之組合。而在該緻密化步驟6中，是使用液 相陶竞前驅體作為液相滲人# 62。該液相料前驅體是選 自於下列所構成之群組·金屬碳化物 '金屬I化物、金屬 氧化物、碳化梦、氦化石々、备^ k 虱化矽氧化鋁、富鋁紅柱石及此等之 一組合。 然後，在該緻密化步驟6中，將該預型材51置於該模 具64之中，並將該液相滲入材62灌入該模具内再以 一油壓機65自® 4巾由上至下的方向，施加2〇〜i〇〇Mpa 之間的壓力’使滲人材62強迫灌人該預型材51的孔隙之 中。接著，進行該預型材乾燥、穩定化步驟7，將含有該液 相滲入材62的預型材51置於空氣中乾燥，然後再置入7〇 〜120 C的烘箱中，使其完全乾燥硬化，如此同樣可以製造 出陶瓷基的摩擦材料成品。 由於該第二較佳實施例中諸多步驟皆與第一較佳實施 例相同’僅在使用之原料及含浸滲入的方式不同，在該第 一較佳實施例揭露利用真空含浸方式，使液相碳前驅體滲 入該預型材51中’而該第二較佳實施例揭露利用加壓含浸 11 201024568 方式，使液相陶瓷前驅體滲入該預型材51中，然而，在實 際操作上也可以依使用時的需求而改變加壓方式，例如： 在該第較佳實施例利用加壓含浸方式，使液相碳前驅體 滲入該預型材中，或在該第二較佳實施例利用真空含浸方 式，使液相陶瓷前驅體滲入該預型材51中，如此皆能達到 相同的效果，本發明之第一、二較佳實施例，僅是分別實 際操作上的舉例說明，不應以此為限。 參閱圖5’本發明具有高性能摩擦材料之製造方法的第 三較佳實施例，大致上是與該第二較佳實施例相同，不同鲁 之處在於：在該準備步驟丨中，該陶瓷粉末是碳化矽，該 碳原料粉末是選自於下列之一群組：碳黑、介相瀝青、石 墨’及此等之組合。在該混合步驟2是以總體積百分比為 100vol°/❶計算，將20〜50vol%的碳纖維、〇〜4〇v〇l%的碳化 石夕粉末、5〜lOvol%的碳黑、5〜2〇ν〇ι%的石墨，及3〇〜 50vol%的紛駿樹脂以球磨機均勻混合，得到一混合材。 配合參閲圖6，該第三較佳實施例之緻密化步驟6是在 一尚溫反應設備63 (例如石墨坩鍋）中進行’該高溫反應_ 設備63具有一與外界形成有壓力差的容室631、分別封住 該容室631的一頂模632和一底模633，及一設於該容室 631側部的加熱器634。 以該底模633封住該容室631底端，並填入該滲入材 62 ’在本實施例中該滲入材62是多數個矽塊，然後將該預 型材51置於該容室631中且置放於該滲入材62上，然後 將滲入材62再一次地置於該預型材51上，使該滲入材62 12 201024568 均勻地舖設於該該預型材51上下，接著通入該保護氣體， 然後封緊該頂模632使該容室631與外界隔離。在此，應 注意的疋，該保護氣體可以疋氮氣、氮氣或是氨氣，也可 以是無保護氣體在真空環境下進行。 然後’打開該南溫反應設備63的加熱器634，使滲入 材62受高溫加熱後熔化’其加熱溫度為14〇〇〜i8〇〇t：之間 ’並持溫5分鐘〜16小時，在該第三較佳實施例中，是將 加熱溫度設定在1500°C，以使矽塊熔化而呈液態狀，進而 滲入預型材51之中，與預型材51中的碳成份進行固液相 反應，而形成碳化妙。 在該第三較佳實施例中為了增加矽塊的滲入效率，還 另外自圖5中所示之箭頭方向，施加〇〜5〇Mpa之間的壓力 ’在該第三較佳實施例中是以3OMpa的壓力作說明，利用 壓力對該頂模632施壓，使該容室631與外界形成一壓力 差，並利用該壓力差將熔融的矽塊強迫填入該預型材51的 孔隙之中。 如上所述，藉由高溫高壓的環境，使滲入材62能更有 效率的滲入預型材51之中，而盡量地填入該預型材51的 孔隙之中，以提升整體的緻密化程度，依此方式，可以製 造出具有熔滲矽的摩擦材料成品。 由於該第二較佳實施例中諸多步驟皆與第一或第二較 佳實施例相同，相同之處於此不再多加贅述，其不同之處 僅在使用之原料及滲入的方式不同，在第一較佳實施例為 真空含浸，而該第二較佳實施例為加壓含浸，該第三較佳 13 201024568 實施例為高溫高壓熔滲，然而，在實際操作上也可以依使 用時的需求而改變加壓方式’例如：在該第一較佳實施例 中也可利用加壓含浸方式進行，同樣地，在該第二較佳實 施例中也可利用真空含浸方式進行，再者，在該第三較佳 實施例中的加壓方式可以利用真空熔滲方式，而其製造流 程相同，故不在此在多加贅述。 綜上所述，本發明具有高性能摩擦材料的製造方法利 用不同的材料可以製造出陶瓷基與碳基的摩擦材料更揭 露了不同的含浸滲入製程，在該緻密化步驟6中以外界 與該容室間所形成的壓力差，使該滲入材62強迫填入該預 型材51的孔隙中，並經過該預型材51乾燥、穩定化步驟7 ，使該滲入材62與該預型材51進一步結合，然後在該熱 處理步驟8以熱處理方式使滲人該預型材51孔隙的渗入材 可進行反應生成陶瓷基與碳基的緻密材，如此可提升整體 的緻密化程度，以獲得較佳的抗腐蝕能力、硬度及耐磨性 ，因此本發明摩擦材料之使用壽命相較於習知可以提高ι〇 倍的壽命，再者，本發明的摩擦材料具有耐高溫且穩定性❹ 佳的性質，在煞車時的高溫環境下也可容易達到煞車效果 ，且在任何環境條件下，煞車反應均靈敏，故確實能達成 本發明之目的。 惟以上所述者，僅為本發明之三個較佳實施例而已， 當不能以此限定本發明實施之範圍，即大凡依本發明申請 專利範圍及發明說明内容所作之簡單的等效變化與修飾， 皆仍屬本發明專利涵蓋之範圍内。 14 201024568 【圖式簡單說明】 圖1是一流程圖，說明本發明具有高性能摩擦材料的 製造方法之一第一較佳實施例； 圖2是一側視示意圖，說明該緻密化步驟的真空液相 含浸法在施壓之前的態樣； 圖3是一側視示意圖，說明該緻密化步驟的真空液相 含浸法在抽真空的態樣； 圖4是一側視示意圖，說明本發明具有高性能摩擦材 料的製造方法之一第二較佳實施例，說明該緻密化步驟是 由外界對容室内預型材加壓的態樣； 圖5是一流程圖，說明本發明具有高性能摩擦材料的 製造方法之一第三較佳實施例；及 圖6考一立體分解示意圖，說明該第三較佳實施例中 緻密化步驟是以高溫高壓對容室内之矽塊熔滲進入預型材 的態樣。 15 201024568 【主要元件符號說明】 1… …準備步驟 62…… 滲入材 2 ···. …混合步驟 63…… _同 >皿反應ό又備 3… …熱壓步驟 63 1 — 容室 4 ··.. …初胚穩定化步驟 632 ··· 頂模 5 •… …高溫熱解步驟 63 3 — 底模 51 ··· …預型材 634 — 加熱器 6… …緻密化步驟 64…… 模具 61.·. …真空含浸設備 65…… 油壓機 611 · …容室 7 ....... 預型材乾燥、穩定 612 · …抽氣段 化步驟 613 · …漏斗 8 ....... 熱處理步驟 614 ·. …流量控制閥 9 ....... 加工成型步驟 615 ·. …壓力控制閥Referring to FIG. 4, it is a preferred embodiment of the method for manufacturing a high performance friction material according to the present invention. The second preferred embodiment is substantially the same as the first embodiment: The second preferred embodiment is represented by the manufacture of a ceramic-based brake sheet. In the preparation step, the ceramic powder is selected from the group consisting of metal carbides, metal nitrides, metal oxides, and carbon. Cut, nitrided eve, oxidized Ming, rich chain andalusite. The carbon raw material powder is selected from the group consisting of carbon black, mesophase, graphite, and combinations thereof. In the densification step 6, a liquid phase precursor is used as the liquid phase infiltration #62. The liquid phase precursor is selected from the group consisting of metal carbides, metal oxides, metal oxides, carbonized dreams, strontium fossils, bismuth alumina, mullite and One of these combinations. Then, in the densification step 6, the preform 51 is placed in the mold 64, and the liquid phase infiltrated material 62 is poured into the mold and then from a top to bottom by a hydraulic press 65 from the 4 In the direction, a pressure between 2 〇 and i 〇〇 Mpa is applied to force the infiltrated material 62 into the pores of the preform 51. Next, the preform drying and stabilizing step 7 is performed, and the pre-form 51 containing the liquid phase infiltrated material 62 is dried in the air, and then placed in an oven of 7 〇 to 120 C to be completely dried and hardened. In this way, a ceramic-based friction material can also be produced. Since many steps in the second preferred embodiment are the same as in the first preferred embodiment, 'only in the manner in which the raw materials used and the impregnation are infiltrated, the first preferred embodiment discloses that the liquid phase is utilized by vacuum impregnation. The carbon precursor penetrates into the preform 51' and the second preferred embodiment discloses that the liquid phase ceramic precursor is infiltrated into the preform 51 by means of pressurized impregnation 11 201024568, however, it can also be used in practice. Changing the pressurization mode as required, for example: in the preferred embodiment, the liquid phase carbon precursor is infiltrated into the preform by a pressurized impregnation method, or in a vacuum impregnation manner in the second preferred embodiment, The liquid crystal ceramic precursor is infiltrated into the pre-form 51, so that the same effect can be achieved. The first and second preferred embodiments of the present invention are merely examples of actual operation, and should not be limited thereto. Referring to Figure 5, a third preferred embodiment of the method for manufacturing a high performance friction material of the present invention is substantially the same as the second preferred embodiment, and the difference is that in the preparation step, the ceramic The powder is tantalum carbide, and the carbon raw material powder is selected from the group consisting of carbon black, mesophase pitch, graphite 'and combinations thereof. In the mixing step 2, 20 to 50 vol% of carbon fiber, 〇4 〇v〇l% of carbon carbide powder, 5 to 10% of carbon black, 5 to 2 are calculated as a total volume percentage of 100 vol/min. 〇ν〇ι% of graphite, and 3〇~50vol% of Junjun resin are uniformly mixed by a ball mill to obtain a mixed material. Referring to Figure 6, the densification step 6 of the third preferred embodiment is performed in a temperature-responsive reaction device 63 (e.g., a graphite crucible). The high temperature reaction _ device 63 has a pressure difference from the outside. The chamber 631 seals a top mold 632 and a bottom mold 633 of the chamber 631, respectively, and a heater 634 disposed at a side of the chamber 631. The bottom end of the chamber 631 is sealed by the bottom mold 633, and the infiltrated material 62' is filled in the embodiment. In the present embodiment, the infiltrated material 62 is a plurality of crucible blocks, and then the pre-shaped material 51 is placed in the chamber 631. And placed on the infiltrated material 62, and then the infiltrated material 62 is placed on the pre-formed material 51 again, and the infiltrated material 62 12 201024568 is evenly laid on the top and bottom of the pre-formed material 51, and then the protective gas is introduced. Then, the top mold 632 is sealed to isolate the chamber 631 from the outside. Here, it should be noted that the shielding gas may be nitrogen, nitrogen or ammonia, or may be carried out in a vacuum environment without a protective gas. Then, the heater 634 of the south temperature reaction device 63 is turned on, and the infiltrated material 62 is heated by high temperature and melted. The heating temperature is between 14 〇〇 and i8 〇〇 t: between and held for 5 minutes to 16 hours. In the third preferred embodiment, the heating temperature is set at 1500 ° C so that the crucible is melted to be in a liquid state, and then infiltrated into the preform 51 to carry out a solid-liquid phase reaction with the carbon component in the preform 51. And the formation of carbonization is wonderful. In the third preferred embodiment, in order to increase the penetration efficiency of the block, a pressure between 〇5 and 5 MPa is additionally applied from the direction of the arrow shown in Fig. 5, which is in the third preferred embodiment. The pressure of 3 MPa is used to apply pressure to the top mold 632 to cause a pressure difference between the chamber 631 and the outside, and the molten slab is forcibly filled into the pores of the preform 51 by the pressure difference. . As described above, the infiltrated material 62 can be more efficiently infiltrated into the preform 51 by the high temperature and high pressure environment, and filled into the pores of the preform 51 as much as possible to enhance the overall degree of densification. In this way, a finished friction material having a bleed enthalpy can be produced. Since many steps in the second preferred embodiment are the same as those in the first or second preferred embodiment, the same points are not described herein again, and the differences are only in the manner in which the materials used and the manner of infiltration are different. A preferred embodiment is vacuum impregnation, and the second preferred embodiment is pressurized impregnation. The third preferred embodiment 13 201024568 is a high temperature and high pressure infiltration, however, in actual operation, it can also be used according to the requirements. And changing the pressurization mode 'for example, in the first preferred embodiment, the pressure impregnation method can also be used. Similarly, in the second preferred embodiment, the vacuum impregnation method can also be used, and further, The pressurization method in the third preferred embodiment can utilize the vacuum infiltration method, and the manufacturing process is the same, so it will not be repeated here. In summary, the method for manufacturing a high-performance friction material of the present invention utilizes different materials to produce a ceramic-based and carbon-based friction material, and exposes different impregnation and infiltration processes. In the densification step 6, the outside is The pressure difference formed between the chambers causes the infiltrated material 62 to be forced into the pores of the preform 51, and through the drying and stabilizing step 7 of the preform 51, the infiltrated material 62 is further combined with the pre-form 51. Then, in the heat treatment step 8, the infiltrated material infiltrating the pores of the preform 51 can be reacted to form a ceramic-based and carbon-based dense material, thereby improving the overall degree of densification and obtaining better corrosion resistance. The ability, hardness and wear resistance, therefore, the service life of the friction material of the present invention can increase the life of ι times compared with the conventional ones. Furthermore, the friction material of the present invention has the properties of high temperature resistance and good stability in the brakes. In the high temperature environment, the braking effect can be easily achieved, and the braking reaction is sensitive under any environmental conditions, so the object of the present invention can be achieved. However, the above description is only for the three preferred embodiments of the present invention, and the scope of the present invention is not limited thereto, that is, the simple equivalent change of the patent application scope and the description of the invention is Modifications are still within the scope of the invention. 14 201024568 BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a flow chart illustrating a first preferred embodiment of a method for manufacturing a high performance friction material of the present invention; FIG. 2 is a side elevational view showing the vacuum of the densification step FIG. 3 is a side view showing the vacuum liquid phase impregnation method of the densification step in a vacuumed state; FIG. 4 is a side view showing the present invention having A second preferred embodiment of the method for manufacturing a high-performance friction material, wherein the densification step is a state in which the preform is pressurized by the outside; FIG. 5 is a flow chart illustrating the high-performance friction material of the present invention. A third preferred embodiment of the manufacturing method; and a schematic exploded perspective view of FIG. 6 , illustrating that the densification step in the third preferred embodiment is a state in which the crucible in the chamber is infiltrated into the pre-form by high temperature and high pressure. kind. 15 201024568 [Description of main component symbols] 1...Preparation step 62... Infiltration material 2 ···. ...mixing step 63... _ same > dish reaction ό and 3... hot pressing step 63 1 — chamber 4 ··.. ... priming stabilization step 632 ··· top mold 5 •... high temperature pyrolysis step 63 3 — bottom mold 51 ···...preform 634 —heater 6...densification step 64... Mold 61.....vacuum impregnation equipment 65...Hydraulic press 611 · ... chamber 7 .... Preform drying, stabilization 612 · ... pumping step 613 · ... funnel 8 ...... Heat treatment step 614 ·. ... flow control valve 9 .. processing forming step 615 ·. ... pressure control valve
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