WO2012066964A1 - Non-asbestos friction-material composition, and friction material and friction member using same - Google Patents

Non-asbestos friction-material composition, and friction material and friction member using same Download PDF

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Publication number
WO2012066964A1
WO2012066964A1 PCT/JP2011/075638 JP2011075638W WO2012066964A1 WO 2012066964 A1 WO2012066964 A1 WO 2012066964A1 JP 2011075638 W JP2011075638 W JP 2011075638W WO 2012066964 A1 WO2012066964 A1 WO 2012066964A1
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Prior art keywords
friction material
friction
copper
fiber
material composition
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PCT/JP2011/075638
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French (fr)
Japanese (ja)
Inventor
一也 馬場
光朗 海野
高史 菊留
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日立化成工業株式会社
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Priority to JP2012521418A priority Critical patent/JP5263454B2/en
Publication of WO2012066964A1 publication Critical patent/WO2012066964A1/en

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/02—Compositions of linings; Methods of manufacturing
    • F16D69/025—Compositions based on an organic binder
    • F16D69/026—Compositions based on an organic binder containing fibres

Definitions

  • the present invention relates to a non-asbestos friction material composition, a friction material using the same, and a friction member. Specifically, it is suitable for friction materials such as disc brake pads and brake linings used for braking in automobiles, etc., and has a low copper content, so it has a low environmental impact, and has shear strength, crack resistance and wear resistance.
  • the present invention relates to a non-asbestos friction material composition having excellent properties, and further to a friction material and a friction member using the non-asbestos friction material composition.
  • friction materials such as disc brake pads and brake linings are used for braking.
  • the friction material plays a role of braking by rubbing against a facing material such as a disk rotor or a brake drum. Therefore, the friction material is required not only to have a high coefficient of friction and stability of the coefficient of friction, but also to make it difficult to scrape the disk rotor that is the facing material (rotor wear resistance) and to make it difficult to squeal (squeal characteristics).
  • a long pad life wear resistance
  • durability performance is required, such as not causing shear fracture during high-load braking (shear strength) and not causing cracks in the friction material due to high-temperature braking history (crack resistance).
  • the friction material includes a binder, a fiber base material, an inorganic filler, an organic filler, and the like, and generally includes one or a combination of two or more in order to exhibit the above characteristics.
  • a fiber base material organic fiber, metal fiber, inorganic fiber, or the like is used.
  • copper or copper alloy fiber is generally used as the metal fiber.
  • a chip or powder of copper or copper alloy may be used.
  • Non-asbestos friction materials are mainly used as friction materials, and copper, copper alloys, and the like are used in large amounts for the non-asbestos friction materials.
  • friction materials containing copper and copper alloys contain copper in the wear powder generated during braking, and it is suggested that it may cause pollution of rivers, lakes, oceans, etc. The movement is growing. Therefore, in order to provide a friction material having good friction coefficient, wear resistance, and rotor wear resistance without including metals such as copper and copper alloys, it is used for brakes including a fiber base material, a binder, and a friction adjusting component. It has been proposed that the friction material does not contain heavy metals or heavy metal compounds, contains magnesium oxide and graphite in an amount of 45 to 80% by volume in the friction material, and the ratio of magnesium oxide and graphite is 1/1 to 4/1. (See Patent Document 1).
  • the present invention is excellent in shear strength, crack resistance, and wear resistance even when the content of copper that may cause pollution of rivers, lakes, and oceans is small.
  • An object is to provide a non-asbestos friction material composition capable of providing a friction material, and a friction material and a friction member using the non-asbestos friction material composition.
  • the non-asbestos friction material composition has a copper content and a content of metal other than copper and copper alloy below a certain level and is fibrillated as a fiber substrate.
  • the inventors have found that the above-mentioned problems can be solved by using acrylic fiber as an essential component, thereby completing the present invention.
  • the present invention is as follows.
  • a non-asbestos friction material composition containing a binder, an organic filler, an inorganic filler, and a fiber base material, wherein the copper content in the friction material composition is 0.5 mass as a copper element %
  • Non-asbestos friction material composition containing 0.5% by mass or less of metal other than copper and copper alloy and containing fibrillated acrylic fiber as a fiber base material.
  • the non-asbestos friction material composition of the present invention when used in friction materials such as automotive disc brake pads and brake linings, has less copper on the abrasion powder generated during braking, and therefore has less environmental impact. Excellent shear strength, crack resistance and wear resistance can be exhibited. Moreover, the friction material and friction member which have the said characteristic can be provided by using the non-asbestos friction material composition of this invention.
  • the non-asbestos friction material composition of the present invention refers to a friction material composition, a friction material, and a friction member substantially not containing asbestos.
  • the non-asbestos friction material composition may be simply referred to as “friction material composition”, the non-asbestos friction material as simply “friction material”, and the non-asbestos friction member as simply “friction member”.
  • the non-asbestos friction material composition of the present invention is a friction material composition containing a binder, an organic filler, an inorganic filler, and a fiber base material, and the copper content in the friction material composition is copper. It is 0.5 mass% or less as an element, content of metals other than copper and a copper alloy is 0.5 mass% or less, and contains a fibrillated acrylic fiber as a fiber base material.
  • the content of copper as a copper element means a copper element contained in a material containing copper as an element, such as copper alone, a copper alloy, and copper oxide, copper sulfide, and a copper complex.
  • the total content of copper By setting the copper content to 0.5% by mass or less as a copper element, the environmental load can be reduced as compared with the conventional friction material.
  • a metal other than copper and a copper alloy refers to a simple metal other than copper and an alloy containing no copper.
  • a single metal such as aluminum, iron, zinc, tin, titanium, zirconium, nickel, chromium, magnesium, silicon, germanium, or an alloy thereof, or a material mainly composed of a metal such as cast iron is applicable.
  • Examples of the form include fibers and powders of the metal simple substance or alloy.
  • the non-asbestos friction material composition of the present invention requires that the content of metals other than copper and copper alloys is 0.5% by mass or less, and is preferably substantially free (content 0% by mass). . Thereby, deterioration of the wear resistance of the friction material can be prevented.
  • the “content of metals other than copper and copper alloys” does not include the content of metal elements in metal oxides, metal sulfides, metal complexes, and the like.
  • the binding material integrates an organic filler, an inorganic filler, a fiber base, and the like contained in the friction material composition to give strength.
  • the binder contained in the non-asbestos friction material composition of the present invention any thermosetting resin that is usually used as a binder for friction materials can be used without particular limitation.
  • thermosetting resin examples include various elastomer-dispersed phenol resins / acrylic-modified phenol resins such as phenol resin / acrylic elastomer-dispersed phenol resin, silicone elastomer-dispersed phenol resin, silicone-modified phenol resin, cashew-modified phenol resin, and epoxy-modified phenol.
  • Various modified phenol resins such as resins and alkylbenzene-modified phenol resins can be used, and these can be used alone or in combination of two or more.
  • it is preferable to use a phenol resin, an acrylic-modified phenol resin, a silicone-modified phenol resin, or an alkylbenzene-modified phenol resin because good heat resistance, moldability, and friction coefficient are given.
  • the content of the binder in the non-asbestos friction material composition of the present invention is preferably 5 to 20% by mass, more preferably 5 to 15% by mass, and 7 to 15% by mass. Is more preferable.
  • the organic filler is included as a friction modifier for improving the sound vibration performance and wear resistance of the friction material.
  • the organic filler contained in the non-asbestos friction material composition of the present invention is not particularly limited as long as it can exhibit the above performance, and usually uses cashew dust, rubber components, etc., which are used as an organic filler. Can do.
  • the cashew dust is not particularly limited as long as it is obtained by pulverizing a hardened cashew nut shell oil and is usually used for a friction material.
  • the rubber component examples include natural rubber, acrylic rubber, isoprene rubber, polybutadiene rubber (BR), nitrile-butadiene rubber (NBR), and styrene-butadiene rubber (SBR). These may be used alone or in combination. A combination of the above can be used. Cashew dust and a rubber component may be used in combination, or cashew dust coated with a rubber component may be used. As the organic filler, it is preferable to use cashew dust and a rubber component in combination from the viewpoint of sound vibration performance.
  • the content of the organic filler in the non-asbestos friction material composition of the present invention is preferably 1 to 20% by mass, more preferably 1 to 15% by mass, and 5 to 15% by mass. More preferably.
  • the content of the organic filler in the range of 1 to 20% by mass, the elastic modulus of the friction material can be increased, deterioration of sound vibration performance such as squeal can be avoided, heat resistance deterioration, heat It is possible to avoid a decrease in strength due to history.
  • the mass ratio of cashew dust to the rubber component is preferably in the range of 0.2 to 10, preferably 0.3 to 5. A range is more preferable.
  • the inorganic filler is included as a friction modifier for avoiding deterioration of the heat resistance of the friction material.
  • any inorganic filler that is usually used for a friction material can be used without particular limitation.
  • the inorganic filler examples include antimony trisulfide, tin sulfide, molybdenum disulfide, iron sulfide, bismuth sulfide, zinc sulfide, calcium hydroxide, calcium oxide, sodium carbonate, calcium carbonate, magnesium carbonate, barium sulfate, dolomite, Coke, graphite, mica, iron oxide, vermiculite, granular potassium titanate, calcium sulfate, plate-like potassium titanate, talc, clay, zeolite, zirconium silicate, zirconium oxide, mullite, chromite, titanium oxide, magnesium oxide, silica, Examples thereof include activated alumina such as iron oxide and ⁇ -alumina, and these can be used alone or in combination of two or more. From the viewpoint of lowering the aggressiveness to the facing material, it is preferable to contain graphite and barium sulfate.
  • the content of the inorganic filler in the non-asbestos friction material composition of the present invention is preferably 30 to 80% by mass, more preferably 50 to 80% by mass, and 50 to 70% by mass. More preferably. When the content of the inorganic filler is in the range of 30 to 80% by mass, deterioration of heat resistance can be avoided.
  • the fiber base material exhibits a reinforcing action such as improvement of mechanical strength in the friction material.
  • the non-asbestos friction material composition of the present invention contains a fibrillated acrylic fiber, which is an organic fiber, as an essential component as a fiber base material from the viewpoint of improving shear strength and crack resistance.
  • a fibrillated acrylic fiber is an acrylic fiber that is split into fibers and has fluff. Examples of the fibrillated acrylic fiber include Sterling fibers Inc. CFF fiber manufactured by the manufacturer can be mentioned and is commercially available.
  • organic fiber means the fibrous material which has organic substance as a main component other than the carbonaceous fiber mentioned later, and is used for the improvement of crack resistance, abrasion resistance, etc.
  • the freeness of the fibrillated acrylic fiber is preferably 200 to 315 ml, more preferably 220 to 310 ml, and further preferably 250 to 300 ml.
  • the freeness herein means a CSF (Canadian Standard Freeness) value measured according to TAPPIT-227.
  • the average fiber length of the fibrillated acrylic fiber is preferably 3 to 12 mm, and more preferably 5 to 10 mm.
  • the friction material exhibits more excellent shear strength, crack resistance, and wear resistance.
  • the average fiber length refers to a number average fiber length indicating an average value of the lengths of all corresponding fibers.
  • the average fiber length of 200 ⁇ m means that 50 fiber substrates are selected at random, the fiber length is measured with an optical microscope, and the average value is 200 ⁇ m.
  • the content of the fibrillated acrylic fiber in the non-asbestos friction material composition of the present invention is preferably 2 to 8% by mass, more preferably 2 to 7% by mass, and 3 to 7% by mass. More preferably it is.
  • the content of the fibrillated acrylic fiber is 2% by mass or more, excellent shear strength, crack resistance, and wear resistance are exhibited, and when the content is 8% by mass or less, the fibrillated acrylic fiber in the friction material composition And deterioration of shear strength and crack resistance due to uneven distribution of other materials can be further suppressed.
  • a fiber substrate other than the above-described fibrillated acrylic fiber can be further used.
  • the fiber base other than the fibrillated acrylic fiber include inorganic fibers, metal fibers, organic fibers other than the fibrillated acrylic fiber, and carbon-based fibers that are usually used as the fiber base. A combination of more than one species can be used.
  • the inorganic fiber examples include ceramic fiber, biodegradable ceramic fiber, mineral fiber, glass fiber, potassium titanate fiber, silicate fiber, and wollastonite, and these may be used alone or in combination of two or more. Can do. From the viewpoint of reducing environmental load substances, among these inorganic fibers, it is preferable not to contain potassium titanate fibers or ceramic fibers that are easily orally sucked into the human body, and SiO 2 , Al 2 O 3 , CaO, MgO, FeO, Na 2 O biodegradable ceramic fibers and biodegradable mineral fibers containing such in any combination are preferred.
  • the mineral fiber here is a man-made inorganic fiber that is melt-spun mainly composed of blast furnace slag such as slag wool, basalt such as basalt fiber, and other natural rocks, and is more preferably a natural mineral containing Al element.
  • a natural mineral containing Al element preferable.
  • those containing SiO 2 , Al 2 O 3 , CaO, MgO, FeO, Na 2 O, etc., or those containing one or more of these compounds can be used, more preferably.
  • those containing Al element can be used as mineral fibers. Since the adhesive strength with each component in the friction material composition tends to decrease as the average fiber length of the entire mineral fiber contained in the friction material composition increases, the average fiber length of the entire mineral fiber is preferably 500 ⁇ m or less. .
  • the mineral fiber used in the present invention is preferably biosoluble from the viewpoint of human harm.
  • biosoluble mineral fiber refers to a mineral fiber having a characteristic that even if it is taken into the human body, it is partially decomposed and discharged outside the body in a short time.
  • the chemical composition is alkali oxide, alkaline earth oxide total amount (total amount of sodium, potassium, calcium, magnesium, barium oxide) is 18% by mass or more, and in a short-term biopermanent test by respiration, A fiber that has a mass half-life of 20 ⁇ m or more within 40 days or no evidence of excessive carcinogenicity in an intraperitoneal test or that has no associated pathogenicity or tumor development in a long-term respiratory test (EU Directive 97 / 69 / EC Nota Q (carcinogenic exclusion)).
  • biodegradable mineral fibers examples include SiO 2 —Al 2 O 3 —CaO—MgO—FeO—Na 2 O fibers, and the like, including SiO 2 , Al 2 O 3 , CaO, MgO, FeO, Na. the 2 O and the like include fibers containing any combination.
  • LAPINUS FIBRES B For example, V Roxul series. “Roxul” includes SiO 2 , Al 2 O 3 , CaO, MgO, FeO, Na 2 O and the like.
  • copper or copper alloy fibers can be used to improve crack resistance and wear resistance.
  • the copper or copper alloy fibers include copper fibers, brass fibers, bronze fibers, and the like, and these can be used alone or in combination of two or more.
  • the content of the entire copper in the non-asbestos friction material composition of the present invention is in the range of 0.5% by mass or less as the copper element, considering the environmental load. It is necessary to become.
  • metal fibers other than copper and a copper alloy from a viewpoint of a friction coefficient improvement and crack resistance as said metal fiber.
  • metal fibers other than copper and copper alloys include fibers in the form of simple metals or alloys such as aluminum, iron, zinc, tin, titanium, nickel, magnesium, and silicon, and fibers mainly composed of metals such as cast iron fibers. These can be used alone or in combination of two or more.
  • the content of metals other than copper and copper alloy in the non-asbestos friction material composition of the present invention is required to be in a range of 0.5% by mass or less. From the viewpoint of improving wear resistance, it is preferable not to contain metal fibers other than copper and copper alloys (content 0 mass%).
  • organic fibers other than the fibrillated acrylic fibers include aramid fibers, cellulose fibers, phenol resin fibers (having a crosslinked structure), and the like, and these can be used alone or in combination of two or more.
  • carbon-based fibers examples include flame-resistant fibers, pitch-based carbon fibers, polyacrylonitrile (PAN) -based carbon fibers, activated carbon fibers, and the like, and these can be used alone or in combination of two or more.
  • PAN polyacrylonitrile
  • the content of the fiber substrate in the non-asbestos friction material composition of the present invention is preferably 5 to 40% by mass, more preferably 5 to 30% by mass, including fibrillated acrylic fibers. More preferably, it is 10 to 30% by mass.
  • an appropriate porosity as a friction material can be obtained, so that deterioration in sound vibration performance such as squeal due to an increase in elastic modulus can be avoided.
  • appropriate material strength and wear resistance can be obtained, and the moldability can be further improved.
  • organic filler in addition to the binder, the organic filler, the inorganic filler, and the fiber substrate, other materials can be blended as necessary.
  • an organic additive such as a fluorine-based polymer such as polytetrafluoroethylene (PTFE) can be blended for improving wear resistance.
  • PTFE polytetrafluoroethylene
  • the present invention also provides a friction material and a friction member using the above-described non-asbestos friction material composition.
  • a friction material and a friction member using the above-described non-asbestos friction material composition.
  • the non-asbestos friction material composition of the present invention By molding the non-asbestos friction material composition of the present invention, it can be used as a friction material for disc brake pads and brake linings for automobiles. Since the friction material of the present invention exhibits a good coefficient of friction, crack resistance and wear resistance, it is suitable as a friction material for a disk brake pad having a large load during braking. Furthermore, by using the friction material, a friction member formed so that the friction material becomes a friction surface can be obtained. Examples of the friction member of the present invention that can be formed using the friction material include the following configurations.
  • the friction material of the present invention can be produced by a generally used method, and is produced by molding the non-asbestos friction material composition of the present invention, preferably by hot pressing.
  • the non-asbestos friction material composition of the present invention is uniformly mixed using a mixer such as a Readyge mixer, a pressure kneader, or an Eirich mixer, and this mixture is preformed in a molding die.
  • the obtained preform is molded in a molding temperature of 130 to 160 ° C. and a molding pressure of 20 to 50 MPa for 2 to 10 minutes, and the resulting molded product is heat-treated at 150 to 250 ° C. for 2 to 10 hours.
  • a friction material can be manufactured by performing coating, scorch treatment, and polishing treatment as necessary.
  • the friction material formed by molding the non-asbestos friction material composition of the present invention is excellent as a coefficient of friction, crack resistance and wear resistance, and thus is useful as a “upper material” for friction members such as disc brake pads and brake linings. Furthermore, since it has high crack resistance as a friction material, it can be molded and used as a “underlay material” of a friction member.
  • the “upper material” is a friction material that becomes the friction surface of the friction member
  • the “underlay material” is a friction material that is interposed between the friction material that becomes the friction surface of the friction member and the back metal. It is a layer for the purpose of improving the shear strength and crack resistance in the vicinity of the adhesion part with the back metal.
  • non-asbestos friction material composition the friction material, and the friction member of the present invention will be described in more detail using Examples and Comparative Examples, but the present invention is not limited to these.
  • Examples 1 to 5 and Comparative Examples 1 to 5 (Production of disc brake pad) The materials were blended according to the blending ratio shown in Table 1, and the friction material compositions of Examples 1 to 5 and Comparative Examples 1 to 5 were obtained.
  • the friction material composition was mixed with a Readyge mixer (manufactured by Matsubo Co., Ltd., trade name: Ladyge mixer M20), and the mixture was preformed with a molding press (Oji Machinery Co., Ltd.).
  • the obtained preform was heated together with an iron backing (manufactured by Hitachi Automotive Systems) using a molding press (manufactured by Sanki Seiko Co., Ltd.) for 5 minutes at a molding temperature of 145 ° C. and a molding pressure of 30 MPa. Press molded.
  • the obtained molded product was heat-treated at 200 ° C. for 4.5 hours, polished using a rotary polishing machine, and subjected to scorch treatment at 500 ° C., so that the disc brake pads of Examples 1 to 5 and Comparative Examples 1 to 5 were obtained. Obtained.
  • a disc brake pad having a back metal thickness of 6 mm, a friction material thickness of 11 mm, and a friction material projection area of 52 cm 2 was produced.
  • the shear strength was measured based on Japanese Industrial Standard JIS D4422.
  • Level 1 No occurrence of cracks
  • Level 2 Cracks to the extent that a 0.1 mm thickness gauge does not enter the friction surface or side surface of the friction material
  • Level 3 0.1 mm thickness gauge is generated on the friction surface or side surface of the friction material If a crack that does not contain a thickness gauge is generated on one of the friction surface and the side surface of the friction material and a crack that contains a thickness gauge is generated on the other side, the level 3 is set.
  • the wear resistance was measured based on the Japan Society of Automotive Engineers standard JASO C427, and the wear amount of the friction material corresponding to 1000 brakings at a brake temperature of 100 ° C and 300 ° C was evaluated. Evaluation of the friction coefficient, wear resistance, and crack resistance according to the above-mentioned JASO C406 and JASO C427 was performed using a dynamometer (manufactured by Sanki Seiko Co., Ltd.) and an inertia of 7 kgf ⁇ m ⁇ s 2 . The evaluation was performed using a ventilated disc rotor (material: FC190, manufactured by Kiriu Co., Ltd.) and a general pin slide type collet type caliper.
  • Examples 1 to 5 showed the same level of shear strength, crack resistance, and wear resistance as Comparative Examples 1 and 5 containing a large amount of copper.
  • Examples 1 to 5 do not contain copper, the content of metals other than copper and copper alloys is 0.5% by mass or less, and comparative example 2 containing aramid fibers instead of fibrillated acrylic fibers.
  • the content of metals other than copper and copper alloys is 0.5 mass% or less, and contains 0.5 mass% as a metal other than copper and copper alloys.
  • Comparative Example 4 containing iron fibers in an amount exceeding 1 the shear strength, crack resistance, and wear resistance are excellent.
  • Examples 1 to 4 containing a fibrillated acrylic fiber content in the range of 2 to 7% by mass are more excellent in abrasion resistance than Example 5.
  • the non-asbestos friction material composition of the present invention, the friction material using the non-asbestos friction material composition, and the friction member have less impact on the environment because of less copper in the wear powder generated during braking compared to conventional products, and are excellent. It can exhibit shear strength, crack resistance, and wear resistance, and is suitable for brake pads for passenger cars.

Abstract

Provided are: a non-asbestos friction-material composition that yields a friction material with excellent shear strength and resistance to cracking and wear, even with a low copper content; and a friction material and friction member using said non-asbestos friction-material composition. Said non-asbestos friction-material composition, which contains a binder, an organic filler, an inorganic filler, and a fibrous base material, contains fibrillated acrylic fibers as said fibrous base material and contains, by mass, no more than 0.5% copper atoms and no more than 0.5% of metals other than copper and copper alloys.

Description

ノンアスベスト摩擦材組成物、これを用いた摩擦材及び摩擦部材Non-asbestos friction material composition, friction material and friction member using the same
　本発明は、ノンアスベスト摩擦材組成物、これを用いた摩擦材及び摩擦部材に関する。詳しくは、自動車などの制動に用いられるディスクブレーキパッドやブレーキライニングなどの摩擦材に適しており、銅の含有量が少ないため、環境への負荷が少なく、かつ剪断強度、耐クラック性及び耐摩耗性に優れたノンアスベスト摩擦材組成物、さらに該ノンアスベスト摩擦材組成物を用いた摩擦材及び摩擦部材に関する。 The present invention relates to a non-asbestos friction material composition, a friction material using the same, and a friction member. Specifically, it is suitable for friction materials such as disc brake pads and brake linings used for braking in automobiles, etc., and has a low copper content, so it has a low environmental impact, and has shear strength, crack resistance and wear resistance. The present invention relates to a non-asbestos friction material composition having excellent properties, and further to a friction material and a friction member using the non-asbestos friction material composition.
　自動車などには、その制動のためにディスクブレーキパッドやブレーキライニングなどの摩擦材が使用されている。摩擦材は、ディスクローターやブレーキドラムなどの対面材と摩擦することにより、制動の役割を果たしている。そのため、摩擦材には、高い摩擦係数と摩擦係数の安定性が求められるだけでなく、対面材であるディスクローターを削り難いこと（耐ローター摩耗性）、鳴きが発生しにくいこと（鳴き特性）、パッド寿命が長いこと（耐摩耗性）などが要求される。また、高負荷の制動時に剪断破壊を起こさないこと（剪断強度）や、高温の制動履歴によって摩擦材に亀裂を生じないこと（耐クラック性）などの耐久性能も要求される。 In automobiles, friction materials such as disc brake pads and brake linings are used for braking. The friction material plays a role of braking by rubbing against a facing material such as a disk rotor or a brake drum. Therefore, the friction material is required not only to have a high coefficient of friction and stability of the coefficient of friction, but also to make it difficult to scrape the disk rotor that is the facing material (rotor wear resistance) and to make it difficult to squeal (squeal characteristics). In addition, a long pad life (wear resistance) is required. Further, durability performance is required, such as not causing shear fracture during high-load braking (shear strength) and not causing cracks in the friction material due to high-temperature braking history (crack resistance).
　摩擦材には、結合材、繊維基材、無機充填材及び有機充填材などが含まれ、前記特性を発現させるために、一般的に、それぞれ１種もしくは２種以上を組み合わせたものが含まれる。繊維基材としては、有機繊維、金属繊維、無機繊維などが用いられ、耐クラック性、耐摩耗性を向上させるために、金属繊維として銅や銅合金の繊維が一般的に用いられる。さらに、耐摩耗性を向上させるために銅や銅合金のチップや粉末が用いられることもある。また、摩擦材として、ノンアスベスト摩擦材が主流となっており、このノンアスベスト摩擦材には銅や銅合金などが多量に使用されている。
　しかし、銅や銅合金を含有する摩擦材は、制動時に生成する摩耗粉に銅を含み、河川、湖、及び海洋などの汚染の原因となる可能性が示唆されているため、使用を抑制する動きが高まっている。そこで、銅及び銅合金などの金属を含まずに、摩擦係数、耐摩耗性、耐ローター摩耗性が良好な摩擦材を提供するために、繊維基材、結合材及び摩擦調整成分を含むブレーキ用摩擦材において、重金属や重金属化合物を含有せず、酸化マグネシウムと黒鉛を摩擦材中に４５～８０体積％含有し、酸化マグネシウムと黒鉛の比を１／１～４／１とすることが提案されている（特許文献１参照）。 The friction material includes a binder, a fiber base material, an inorganic filler, an organic filler, and the like, and generally includes one or a combination of two or more in order to exhibit the above characteristics. . As the fiber base material, organic fiber, metal fiber, inorganic fiber, or the like is used. In order to improve crack resistance and wear resistance, copper or copper alloy fiber is generally used as the metal fiber. Furthermore, in order to improve wear resistance, a chip or powder of copper or copper alloy may be used. Non-asbestos friction materials are mainly used as friction materials, and copper, copper alloys, and the like are used in large amounts for the non-asbestos friction materials.
However, friction materials containing copper and copper alloys contain copper in the wear powder generated during braking, and it is suggested that it may cause pollution of rivers, lakes, oceans, etc. The movement is growing. Therefore, in order to provide a friction material having good friction coefficient, wear resistance, and rotor wear resistance without including metals such as copper and copper alloys, it is used for brakes including a fiber base material, a binder, and a friction adjusting component. It has been proposed that the friction material does not contain heavy metals or heavy metal compounds, contains magnesium oxide and graphite in an amount of 45 to 80% by volume in the friction material, and the ratio of magnesium oxide and graphite is 1/1 to 4/1. (See Patent Document 1).
特開２００２－１３８２７３号公報JP 2002-138273 A
　しかしながら、特許文献１のブレーキ用摩擦材では、剪断強度、耐クラック性及び耐摩耗性の全てを満足させる優れた摩擦材を得ることは困難である。
　一方、摩擦材に含まれる銅以外の金属繊維として、スチール繊維や鋳鉄繊維などの鉄系繊維が耐クラック性改善の目的で用いられるが、鉄系繊維は対面材への攻撃性が高いという欠点がある。また、銅以外の金属繊維として一般的に摩擦材に用いられる、亜鉛繊維やアルミニウム繊維などの非鉄金属繊維は、銅や鉄系繊維と比較して耐熱温度が低いものが多く、摩擦材の耐摩耗性を悪化させるという問題がある。
　また、摩擦材の耐クラック性を向上するための方法として無機繊維を用いる方法がある。しかし十分な耐クラック性を得るためには、多量の無機繊維を添加する必要があり、多量の無機繊維を用いれば耐クラック性は改善できるものの、耐摩耗性が悪化してしまうという問題が生じる。 However, with the brake friction material of Patent Document 1, it is difficult to obtain an excellent friction material that satisfies all of shear strength, crack resistance, and wear resistance.
On the other hand, as metal fibers other than copper contained in the friction material, steel fibers such as steel fibers and cast iron fibers are used for the purpose of improving crack resistance, but the disadvantage that iron fibers are highly aggressive against facing materials. There is. In addition, non-ferrous metal fibers such as zinc fibers and aluminum fibers, which are generally used for friction materials as metal fibers other than copper, often have lower heat resistance temperatures than copper and iron-based fibers. There is a problem of worsening wear.
In addition, there is a method using inorganic fibers as a method for improving the crack resistance of the friction material. However, in order to obtain sufficient crack resistance, it is necessary to add a large amount of inorganic fiber, and if a large amount of inorganic fiber is used, crack resistance can be improved, but there is a problem that wear resistance deteriorates. .
　また、黒鉛を用いると、摩擦材の耐摩耗性を向上できることが知られている。しかし十分な耐摩耗性を得るためには、多量に黒鉛を添加する必要があり、多量の黒鉛を用いれば耐摩擦性は改善できるものの、摩擦係数が大きく低下してしまうという問題が生じる。
　前述したように、銅の含有量を少なくした摩擦材は、剪断強度、耐摩耗性及び耐クラック性が悪く、剪断強度、耐クラック性及び耐摩耗性の全てを満足させる優れた摩擦材を得ることは困難であった。 It is also known that the use of graphite can improve the wear resistance of the friction material. However, in order to obtain sufficient wear resistance, it is necessary to add a large amount of graphite. If a large amount of graphite is used, although the friction resistance can be improved, there arises a problem that the friction coefficient is greatly reduced.
As described above, the friction material with a reduced copper content has poor shear strength, wear resistance and crack resistance, and obtains an excellent friction material satisfying all of the shear strength, crack resistance and wear resistance. It was difficult.
　このような背景を鑑み、本発明は、河川、湖、及び海洋などの汚染の原因となる可能性のある銅の含有量が少なくても、剪断強度、耐クラック性及び耐摩耗性に優れた摩擦材を与えることができるノンアスベスト摩擦材組成物、さらに該ノンアスベスト摩擦材組成物を用いた摩擦材及び摩擦部材を提供することを目的とする。 In view of such a background, the present invention is excellent in shear strength, crack resistance, and wear resistance even when the content of copper that may cause pollution of rivers, lakes, and oceans is small. An object is to provide a non-asbestos friction material composition capable of providing a friction material, and a friction material and a friction member using the non-asbestos friction material composition.
　本発明者等は、鋭意検討を重ねた結果、ノンアスベスト摩擦材組成物において、銅の含有量、及び、銅及び銅合金以外の金属の含有量を一定以下とし、かつ繊維基材としてフィブリル化アクリル繊維を必須成分とすることで、上記課題を解決できることを見出し、本発明を完成した。 As a result of intensive studies, the present inventors have determined that the non-asbestos friction material composition has a copper content and a content of metal other than copper and copper alloy below a certain level and is fibrillated as a fiber substrate. The inventors have found that the above-mentioned problems can be solved by using acrylic fiber as an essential component, thereby completing the present invention.
　すなわち、本発明は以下の通りである。
　（１）結合材、有機充填材、無機充填材、及び繊維基材を含有するノンアスベスト摩擦材組成物であって、該摩擦材組成物中の銅の含有量が銅元素として０．５質量％以下であり、銅及び銅合金以外の金属の含有量が０．５質量％以下であり、かつ、繊維基材としてフィブリル化アクリル繊維を含有するノンアスベスト摩擦材組成物。
　（２）上記フィブリル化アクリル繊維の含有量が２～８質量％である上記（１）に記載のノンアスベスト摩擦材組成物。
　（３）上記（１）又は（２）に記載のノンアスベスト摩擦材組成物を成形してなる摩擦材。
　（４）上記（１）又は（２）に記載のノンアスベスト摩擦材組成物を成形してなる摩擦材と裏金とを用いて形成される摩擦部材。 That is, the present invention is as follows.
(1) A non-asbestos friction material composition containing a binder, an organic filler, an inorganic filler, and a fiber base material, wherein the copper content in the friction material composition is 0.5 mass as a copper element % Non-asbestos friction material composition containing 0.5% by mass or less of metal other than copper and copper alloy and containing fibrillated acrylic fiber as a fiber base material.
(2) The non-asbestos friction material composition according to (1), wherein the content of the fibrillated acrylic fiber is 2 to 8% by mass.
(3) A friction material formed by molding the non-asbestos friction material composition according to (1) or (2).
(4) A friction member formed using a friction material obtained by molding the non-asbestos friction material composition according to (1) or (2) and a back metal.
　本発明のノンアスベスト摩擦材組成物は、自動車用ディスクブレーキパッドやブレーキライニングなどの摩擦材に用いた際に、制動時に生成する摩耗粉中の銅が少ないことから環境への負荷が少なく、かつ優れた剪断強度、耐クラック性及び耐摩耗性を発現することができる。また、本発明のノンアスベスト摩擦材組成物を用いることにより、上記特性を有する摩擦材及び摩擦部材を提供できる。 The non-asbestos friction material composition of the present invention, when used in friction materials such as automotive disc brake pads and brake linings, has less copper on the abrasion powder generated during braking, and therefore has less environmental impact. Excellent shear strength, crack resistance and wear resistance can be exhibited. Moreover, the friction material and friction member which have the said characteristic can be provided by using the non-asbestos friction material composition of this invention.
　以下、本発明のノンアスベスト摩擦材組成物、これを用いた摩擦材及び摩擦部材について詳述する。なお、本発明において、ノンアスベスト摩擦材組成物、ノンアスベスト摩擦材及びノンアスベスト摩擦部材とは、アスベストを実質的に含まない摩擦材組成物、摩擦材及び摩擦部材をいう。また、以下の記述において、それぞれノンアスベスト摩擦材組成物を単に「摩擦材組成物」、ノンアスベスト摩擦材を単に「摩擦材」、ノンアスベスト摩擦部材を単に「摩擦部材」と称することがある。
［ノンアスベスト摩擦材組成物］
　本発明のノンアスベスト摩擦材組成物は、結合材、有機充填材、無機充填材、及び繊維基材を含有する摩擦材組成物であって、該摩擦材組成物中の銅の含有量が銅元素として０．５質量％以下であり、銅及び銅合金以外の金属の含有量が０．５質量％以下であり、かつ、繊維基材としてフィブリル化アクリル繊維を含有することを特徴とする。
　上記構成により、本発明のノンアスベスト摩擦材組成物を用いた摩擦材及び摩擦部材は、従来品と比較して制動時に生成する摩耗粉中の銅が少ないことから環境への負荷が少なく、かつ優れた剪断強度、耐クラック性、及び耐摩耗性を発現する。 Hereinafter, the non-asbestos friction material composition of the present invention, the friction material using the same, and the friction member will be described in detail. In the present invention, the non-asbestos friction material composition, the non-asbestos friction material, and the non-asbestos friction member refer to a friction material composition, a friction material, and a friction member substantially not containing asbestos. Further, in the following description, the non-asbestos friction material composition may be simply referred to as “friction material composition”, the non-asbestos friction material as simply “friction material”, and the non-asbestos friction member as simply “friction member”.
[Non-asbestos friction material composition]
The non-asbestos friction material composition of the present invention is a friction material composition containing a binder, an organic filler, an inorganic filler, and a fiber base material, and the copper content in the friction material composition is copper. It is 0.5 mass% or less as an element, content of metals other than copper and a copper alloy is 0.5 mass% or less, and contains a fibrillated acrylic fiber as a fiber base material.
With the above configuration, the friction material and the friction member using the non-asbestos friction material composition of the present invention have less load on the environment because there is less copper in the wear powder generated during braking than in the conventional product, and Excellent shear strength, crack resistance, and wear resistance are exhibited.
　本発明において、「銅元素としての銅の含有量」とは、銅単体及び銅合金、更には酸化銅や硫化銅、銅錯体などの、銅を元素として含む材料に含有される、銅元素としての銅の総含有量をいう。銅の含有量を銅元素として０．５質量％以下とすることで、従来の摩擦材と比較して環境負荷の少ないものとすることができる。 In the present invention, “the content of copper as a copper element” means a copper element contained in a material containing copper as an element, such as copper alone, a copper alloy, and copper oxide, copper sulfide, and a copper complex. The total content of copper. By setting the copper content to 0.5% by mass or less as a copper element, the environmental load can be reduced as compared with the conventional friction material.
　また、本発明において、「銅及び銅合金以外の金属」とは、銅以外の金属単体、及び銅を含有しない合金をいう。例えば、アルミニウム、鉄、亜鉛、錫、チタン、ジルコニウム、ニッケル、クロム、マグネシウム、シリコン、ゲルマニウム等の金属単体又はこれらの合金、もしくは、鋳鉄などの金属を主成分とする材料などが該当し、その形態としては、例えば、上記金属単体又は合金の繊維や粉末などが挙げられる。
　本発明のノンアスベスト摩擦材組成物は、銅及び銅合金以外の金属の含有量が０．５質量％以下であることを要し、実質的に含有しないこと（含有量０質量％）が好ましい。これにより、摩擦材の耐摩耗性の悪化を防ぐことができる。
　なお、本発明において、「銅及び銅合金以外の金属の含有量」には、金属酸化物や金属硫化物、金属錯体などにおける金属元素の含有量は含まれない。 In the present invention, “a metal other than copper and a copper alloy” refers to a simple metal other than copper and an alloy containing no copper. For example, a single metal such as aluminum, iron, zinc, tin, titanium, zirconium, nickel, chromium, magnesium, silicon, germanium, or an alloy thereof, or a material mainly composed of a metal such as cast iron is applicable. Examples of the form include fibers and powders of the metal simple substance or alloy.
The non-asbestos friction material composition of the present invention requires that the content of metals other than copper and copper alloys is 0.5% by mass or less, and is preferably substantially free (content 0% by mass). . Thereby, deterioration of the wear resistance of the friction material can be prevented.
In the present invention, the “content of metals other than copper and copper alloys” does not include the content of metal elements in metal oxides, metal sulfides, metal complexes, and the like.
　次に、本発明の摩擦材組成物に含有される各成分について説明する。
（結合材）
　結合材は、摩擦材組成物に含まれる有機充填材、無機充填材及び繊維基材などを一体化し、強度を与えるものである。本発明のノンアスベスト摩擦材組成物に含まれる結合材としては、通常、摩擦材の結合材として用いられる熱硬化性樹脂であれば特に制限なく用いることができる。
　上記熱硬化性樹脂としては、例えば、フェノール樹脂／アクリルエラストマー分散フェノール樹脂、シリコーンエラストマー分散フェノール樹脂等の各種エラストマー分散フェノール樹脂／アクリル変性フェノール樹脂、シリコーン変性フェノール樹脂、カシュー変性フェノール樹脂、エポキシ変性フェノール樹脂、アルキルベンゼン変性フェノール樹脂等の各種変性フェノール樹脂などが挙げられ、これらを単独で又は２種以上を組み合わせて用いることができる。特に、良好な耐熱性、成形性及び摩擦係数を与えることから、フェノール樹脂、アクリル変性フェノール樹脂、シリコーン変性フェノール樹脂、アルキルベンゼン変性フェノール樹脂を用いることが好ましい。 Next, each component contained in the friction material composition of the present invention will be described.
(Binder)
The binding material integrates an organic filler, an inorganic filler, a fiber base, and the like contained in the friction material composition to give strength. As the binder contained in the non-asbestos friction material composition of the present invention, any thermosetting resin that is usually used as a binder for friction materials can be used without particular limitation.
Examples of the thermosetting resin include various elastomer-dispersed phenol resins / acrylic-modified phenol resins such as phenol resin / acrylic elastomer-dispersed phenol resin, silicone elastomer-dispersed phenol resin, silicone-modified phenol resin, cashew-modified phenol resin, and epoxy-modified phenol. Various modified phenol resins such as resins and alkylbenzene-modified phenol resins can be used, and these can be used alone or in combination of two or more. In particular, it is preferable to use a phenol resin, an acrylic-modified phenol resin, a silicone-modified phenol resin, or an alkylbenzene-modified phenol resin because good heat resistance, moldability, and friction coefficient are given.
　本発明のノンアスベスト摩擦材組成物中の上記結合材の含有量は、５～２０質量％であることが好ましく、５～１５質量％であることがより好ましく、７～１５質量％であることが更に好ましい。結合材の含有量を５～２０質量％の範囲とすることで、摩擦材の強度低下をより抑制でき、また、摩擦材の気孔率が減少し、弾性率が高くなることによる鳴きなどの音振性能悪化をより抑制できる。 The content of the binder in the non-asbestos friction material composition of the present invention is preferably 5 to 20% by mass, more preferably 5 to 15% by mass, and 7 to 15% by mass. Is more preferable. By setting the binder content in the range of 5 to 20% by mass, the strength of the friction material can be further suppressed, and the porosity of the friction material is reduced and noise such as squeal due to an increase in elastic modulus. Vibration performance deterioration can be further suppressed.
（有機充填材）
　有機充填材は、摩擦材の音振性能や耐摩耗性などを向上させるための摩擦調整剤として含まれるものである。
　本発明のノンアスベスト摩擦材組成物に含まれる有機充填材としては、上記性能を発揮できるものであれば特に制限はなく、通常、有機充填材として用いられる、カシューダストやゴム成分などを用いることができる。
　上記カシューダストは、カシューナッツシェルオイルを硬化させたものを粉砕して得られる、通常、摩擦材に用いられるものであればよい。
　上記ゴム成分としては、例えば、天然ゴム、アクリルゴム、イソプレンゴム、ポリブタジエンゴム（ＢＲ）、ニトリル－ブタジエンゴム（ＮＢＲ）、スチレン－ブタジエンゴム（ＳＢＲ）等が挙げられ、これらを単独で又は２種以上を組み合わせて用いることができる。
　また、カシューダストとゴム成分とを併用してもよく、カシューダストをゴム成分で被覆したものを用いてもよい。有機充填材としては、音振性能の観点から、カシューダストとゴム成分とを併用することが好ましい。 (Organic filler)
The organic filler is included as a friction modifier for improving the sound vibration performance and wear resistance of the friction material.
The organic filler contained in the non-asbestos friction material composition of the present invention is not particularly limited as long as it can exhibit the above performance, and usually uses cashew dust, rubber components, etc., which are used as an organic filler. Can do.
The cashew dust is not particularly limited as long as it is obtained by pulverizing a hardened cashew nut shell oil and is usually used for a friction material.
Examples of the rubber component include natural rubber, acrylic rubber, isoprene rubber, polybutadiene rubber (BR), nitrile-butadiene rubber (NBR), and styrene-butadiene rubber (SBR). These may be used alone or in combination. A combination of the above can be used.
Cashew dust and a rubber component may be used in combination, or cashew dust coated with a rubber component may be used. As the organic filler, it is preferable to use cashew dust and a rubber component in combination from the viewpoint of sound vibration performance.
　本発明のノンアスベスト摩擦材組成物中の上記有機充填材の含有量は、１～２０質量％であることが好ましく、１～１５質量％であることがより好ましく、５～１５質量％であることが更に好ましい。有機充填材の含有量を１～２０質量％の範囲とすることで、摩擦材の弾性率が高くなること、鳴きなどの音振性能の悪化を避けることができ、また耐熱性の悪化、熱履歴による強度低下を避けることができる。また、カシューダストとゴム成分とを併用する場合、カシューダストとゴム成分との質量比（カシューダスト／ゴム成分）は、０．２～１０の範囲であることが好ましく、０．３～５の範囲であることがより好ましい。 The content of the organic filler in the non-asbestos friction material composition of the present invention is preferably 1 to 20% by mass, more preferably 1 to 15% by mass, and 5 to 15% by mass. More preferably. By setting the content of the organic filler in the range of 1 to 20% by mass, the elastic modulus of the friction material can be increased, deterioration of sound vibration performance such as squeal can be avoided, heat resistance deterioration, heat It is possible to avoid a decrease in strength due to history. When cashew dust and a rubber component are used in combination, the mass ratio of cashew dust to the rubber component (cashew dust / rubber component) is preferably in the range of 0.2 to 10, preferably 0.3 to 5. A range is more preferable.
（無機充填材）
　無機充填材は、摩擦材の耐熱性の悪化を避けるための摩擦調整剤として含まれるものである。本発明のノンアスベスト摩擦材組成物に含まれる無機充填材としては、通常、摩擦材に用いられる無機充填材であれば特に制限なく用いることができる。
　上記無機充填材としては、例えば、三硫化アンチモン、硫化スズ、二硫化モリブデン、硫化鉄、硫化ビスマス、硫化亜鉛、水酸化カルシウム、酸化カルシウム、炭酸ナトリウム、炭酸カルシウム、炭酸マグネシウム、硫酸バリウム、ドロマイト、コークス、黒鉛、マイカ、酸化鉄、バーミキュライト、粒状チタン酸カリウム、硫酸カルシウム、板状チタン酸カリウム、タルク、クレー、ゼオライト、ケイ酸ジルコニウム、酸化ジルコニウム、ムライト、クロマイト、酸化チタン、酸化マグネシウム、シリカ、酸化鉄、γ－アルミナ等の活性アルミナなどが挙げられ、これらを単独で又は２種以上を組み合わせて用いることができる。対面材への攻撃性低下の観点から、黒鉛、硫酸バリウムを含有することが好ましい。 (Inorganic filler)
The inorganic filler is included as a friction modifier for avoiding deterioration of the heat resistance of the friction material. As the inorganic filler contained in the non-asbestos friction material composition of the present invention, any inorganic filler that is usually used for a friction material can be used without particular limitation.
Examples of the inorganic filler include antimony trisulfide, tin sulfide, molybdenum disulfide, iron sulfide, bismuth sulfide, zinc sulfide, calcium hydroxide, calcium oxide, sodium carbonate, calcium carbonate, magnesium carbonate, barium sulfate, dolomite, Coke, graphite, mica, iron oxide, vermiculite, granular potassium titanate, calcium sulfate, plate-like potassium titanate, talc, clay, zeolite, zirconium silicate, zirconium oxide, mullite, chromite, titanium oxide, magnesium oxide, silica, Examples thereof include activated alumina such as iron oxide and γ-alumina, and these can be used alone or in combination of two or more. From the viewpoint of lowering the aggressiveness to the facing material, it is preferable to contain graphite and barium sulfate.
　本発明のノンアスベスト摩擦材組成物中の上記無機充填材の含有量は、３０～８０質量％であることが好ましく、５０～８０質量％であることがより好ましく、５０～７０質量％であることが更に好ましい。無機充填材の含有量を３０～８０質量％の範囲とすることで、耐熱性の悪化を避けることができる。 The content of the inorganic filler in the non-asbestos friction material composition of the present invention is preferably 30 to 80% by mass, more preferably 50 to 80% by mass, and 50 to 70% by mass. More preferably. When the content of the inorganic filler is in the range of 30 to 80% by mass, deterioration of heat resistance can be avoided.
（繊維基材）
　繊維基材は、摩擦材において機械的強度の向上などの補強作用を示すものである。
　本発明のノンアスベスト摩擦材組成物は、剪断強度及び耐クラック性向上の観点から、繊維基材として、有機繊維であるフィブリル化アクリル繊維を必須成分として含有する。フィブリル化アクリル繊維とは、分繊化し、毛羽立ちを有するアクリル繊維である。上記フィブリル化アクリル繊維としては、例えば、Ｓｔｅｒｌｉｎｇ　ｆｉｂｅｒｓ　Ｉｎｃ．製のＣＦＦ　ｆｉｂｅｒなどが挙げられ、商業的に入手できる。なお、本発明において、有機繊維とは、後述する炭素系繊維以外の、有機物を主成分とする繊維状の材料をいい、耐クラック性及び耐摩耗性の向上などのために用いられる。 (Fiber base)
The fiber base material exhibits a reinforcing action such as improvement of mechanical strength in the friction material.
The non-asbestos friction material composition of the present invention contains a fibrillated acrylic fiber, which is an organic fiber, as an essential component as a fiber base material from the viewpoint of improving shear strength and crack resistance. A fibrillated acrylic fiber is an acrylic fiber that is split into fibers and has fluff. Examples of the fibrillated acrylic fiber include Sterling fibers Inc. CFF fiber manufactured by the manufacturer can be mentioned and is commercially available. In addition, in this invention, organic fiber means the fibrous material which has organic substance as a main component other than the carbonaceous fiber mentioned later, and is used for the improvement of crack resistance, abrasion resistance, etc.
　フィブリル化アクリル繊維の濾水度は、２００～３１５ｍｌであることが好ましく、２２０～３１０ｍｌであることがより好ましく、２５０～３００ｍｌであることがさらに好ましい。ここでいう濾水度とはＴＡＰＰＩＴ－２２７に従って測定されるＣＳＦ（Ｃａｎａｄｉａｎ　Ｓｔａｎｄａｒｄ　Ｆｒｅｅｎｅｓｓ）値のことである。フィブリル化アクリル繊維の濾水度を２００～３１５ｍｌの範囲とすることで、摩擦材においてより優れた剪断強度、耐クラック性、及び耐摩耗性が発現する。 The freeness of the fibrillated acrylic fiber is preferably 200 to 315 ml, more preferably 220 to 310 ml, and further preferably 250 to 300 ml. The freeness herein means a CSF (Canadian Standard Freeness) value measured according to TAPPIT-227. By setting the freeness of the fibrillated acrylic fiber in the range of 200 to 315 ml, the friction material exhibits better shear strength, crack resistance, and wear resistance.
　フィブリル化アクリル繊維の平均繊維長は、３～１２ｍｍであることが好ましく、５～１０ｍｍであることがより好ましい。フィブリル化アクリル繊維の平均繊維長を３～１２ｍｍの範囲とすることで、摩擦材においてより優れた剪断強度、耐クラック性、及び耐摩耗性が発現する。
　ここで、平均繊維長とは、該当する全ての繊維の長さの平均値を示した数平均繊維長のことをいう。例えば２００μｍの平均繊維長とは、繊維基材を無作為に５０個選択し、光学顕微鏡で繊維長を測定し、その平均値が２００μｍであることを示す。 The average fiber length of the fibrillated acrylic fiber is preferably 3 to 12 mm, and more preferably 5 to 10 mm. By setting the average fiber length of the fibrillated acrylic fiber in the range of 3 to 12 mm, the friction material exhibits more excellent shear strength, crack resistance, and wear resistance.
Here, the average fiber length refers to a number average fiber length indicating an average value of the lengths of all corresponding fibers. For example, the average fiber length of 200 μm means that 50 fiber substrates are selected at random, the fiber length is measured with an optical microscope, and the average value is 200 μm.
　本発明のノンアスベスト摩擦材組成物中の上記フィブリル化アクリル繊維の含有量は、２～８質量％であることが好ましく、２～７質量％であることがより好ましく、３～７質量％であることが更に好ましい。フィブリル化アクリル繊維の含有量を２質量％以上とすることで優れた剪断強度、耐クラック性、耐摩耗性が発現し、８質量％以下とすることで摩擦材組成物中のフィブリル化アクリル繊維と他の材料の偏在による剪断強度、耐クラック性の悪化をより抑制することができる。 The content of the fibrillated acrylic fiber in the non-asbestos friction material composition of the present invention is preferably 2 to 8% by mass, more preferably 2 to 7% by mass, and 3 to 7% by mass. More preferably it is. When the content of the fibrillated acrylic fiber is 2% by mass or more, excellent shear strength, crack resistance, and wear resistance are exhibited, and when the content is 8% by mass or less, the fibrillated acrylic fiber in the friction material composition And deterioration of shear strength and crack resistance due to uneven distribution of other materials can be further suppressed.
　本発明のノンアスベスト摩擦材組成物には、更に、上述のフィブリル化アクリル繊維以外の繊維基材を合わせて用いることができる。フィブリル化アクリル繊維以外の繊維基材としては、通常、繊維基材として用いられる、無機繊維、金属繊維、フィブリル化アクリル繊維以外の有機繊維、炭素系繊維等が挙げられ、これらを単独で又は２種以上を組み合わせて用いることができる。 In the non-asbestos friction material composition of the present invention, a fiber substrate other than the above-described fibrillated acrylic fiber can be further used. Examples of the fiber base other than the fibrillated acrylic fiber include inorganic fibers, metal fibers, organic fibers other than the fibrillated acrylic fiber, and carbon-based fibers that are usually used as the fiber base. A combination of more than one species can be used.
　上記無機繊維としては、セラミック繊維、生分解性セラミック繊維、鉱物繊維、ガラス繊維、チタン酸カリウム繊維、シリケート繊維、ウォラストナイト等が挙げられ、これらは単独で又は２種以上を組み合わせて用いることができる。
　なお、環境負荷物質低減の観点からは、これら無機繊維のうち、人体に経口吸引されやすい、チタン酸カリウム繊維やセラミック繊維を含有しないことが好ましく、ＳｉＯ2、Ａｌ2Ｏ3、ＣａＯ、ＭｇＯ、ＦｅＯ、Ｎａ2Ｏなどを任意の組み合わせで含有した生分解性セラミック繊維や生分解性鉱物繊維が好ましい。 Examples of the inorganic fiber include ceramic fiber, biodegradable ceramic fiber, mineral fiber, glass fiber, potassium titanate fiber, silicate fiber, and wollastonite, and these may be used alone or in combination of two or more. Can do.
From the viewpoint of reducing environmental load substances, among these inorganic fibers, it is preferable not to contain potassium titanate fibers or ceramic fibers that are easily orally sucked into the human body, and SiO 2 , Al 2 O 3 , CaO, MgO, FeO, Na 2 O biodegradable ceramic fibers and biodegradable mineral fibers containing such in any combination are preferred.
　ここでいう鉱物繊維とは、スラグウール等の高炉スラグ、バサルトファイバー等の玄武岩、その他の天然岩石等を主成分として溶融紡糸した人造無機繊維であり、Ａｌ元素を含む天然鉱物であることがより好ましい。具体的には、ＳｉＯ2、Ａｌ2Ｏ3、ＣａＯ、ＭｇＯ、ＦｅＯ、Ｎａ2Ｏ等が含まれるもの、又はこれら化合物が単独で又は２種以上含有されるものを用いることができ、より好ましくはこれらのうちＡｌ元素を含むものを、鉱物繊維として用いることができる。摩擦材組成物中に含まれる鉱物繊維全体の平均繊維長が大きくなるほど摩擦材組成物中の各成分との接着強度が低下する傾向があるため、鉱物繊維全体の平均繊維長は５００μｍ以下が好ましい。より好ましくは、１００～４００μｍである。
　本発明で用いられる鉱物繊維は、人体有害性の観点で生体溶解性であることが好ましい。ここでいう生体溶解性の鉱物繊維とは、人体内に取り込まれた場合でも短時間で一部分解され体外に排出される特徴を有する鉱物繊維である。具体的には、化学組成がアルカリ酸化物、アルカリ土類酸化物総量（ナトリウム、カリウム、カルシウム、マグネシウム、バリウムの酸化物の総量）が１８質量％以上で、且つ呼吸による短期バイオ永続試験で、２０μｍ以上の繊維の質量半減期が４０日以内又は腹膜内試験で過度の発癌性の証拠がないか又は長期呼吸試験で関連の病原性や腫瘍発生がないことを満たす繊維を示す（ＥＵ指令９７／６９／ＥＣのＮｏｔａ Ｑ（発癌性適用除外））。このような生体分解性鉱物繊維としては、ＳｉＯ2－Ａｌ2Ｏ3－ＣａＯ－ＭｇＯ－ＦｅＯ－Ｎａ2Ｏ系繊維等が挙げられ、ＳｉＯ2、Ａｌ2Ｏ3、ＣａＯ、ＭｇＯ、ＦｅＯ、Ｎａ2Ｏ等を任意の組み合わせで含有した繊維が挙げられる。市販品としてはＬＡＰＩＮＵＳ ＦＩＢＲＥＳ　Ｂ．Ｖ製のＲｏｘｕｌシリーズなどが挙げられる。「Ｒｏｘｕｌ」は、ＳｉＯ2、Ａｌ2Ｏ3、ＣａＯ、ＭｇＯ、ＦｅＯ、Ｎａ2Ｏ等が含まれる。 The mineral fiber here is a man-made inorganic fiber that is melt-spun mainly composed of blast furnace slag such as slag wool, basalt such as basalt fiber, and other natural rocks, and is more preferably a natural mineral containing Al element. preferable. Specifically, those containing SiO 2 , Al 2 O 3 , CaO, MgO, FeO, Na 2 O, etc., or those containing one or more of these compounds can be used, more preferably. Among them, those containing Al element can be used as mineral fibers. Since the adhesive strength with each component in the friction material composition tends to decrease as the average fiber length of the entire mineral fiber contained in the friction material composition increases, the average fiber length of the entire mineral fiber is preferably 500 μm or less. . More preferably, it is 100 to 400 μm.
The mineral fiber used in the present invention is preferably biosoluble from the viewpoint of human harm. The term “biosoluble mineral fiber” as used herein refers to a mineral fiber having a characteristic that even if it is taken into the human body, it is partially decomposed and discharged outside the body in a short time. Specifically, the chemical composition is alkali oxide, alkaline earth oxide total amount (total amount of sodium, potassium, calcium, magnesium, barium oxide) is 18% by mass or more, and in a short-term biopermanent test by respiration, A fiber that has a mass half-life of 20 μm or more within 40 days or no evidence of excessive carcinogenicity in an intraperitoneal test or that has no associated pathogenicity or tumor development in a long-term respiratory test (EU Directive 97 / 69 / EC Nota Q (carcinogenic exclusion)). Examples of such biodegradable mineral fibers include SiO 2 —Al 2 O 3 —CaO—MgO—FeO—Na 2 O fibers, and the like, including SiO 2 , Al 2 O 3 , CaO, MgO, FeO, Na. the 2 O and the like include fibers containing any combination. As a commercial product, LAPINUS FIBRES B. For example, V Roxul series. “Roxul” includes SiO 2 , Al 2 O 3 , CaO, MgO, FeO, Na 2 O and the like.
　上記金属繊維としては、耐クラック性及び耐摩耗性の向上のため、銅又は銅合金の繊維を用いることができる。銅又は銅合金の繊維としては、銅繊維、黄銅繊維、青銅繊維等が挙げられ、これらを単独で又は２種以上を組み合わせて用いることができる。
　ただし、銅又は銅合金の繊維を含有させる場合、環境への負荷を考慮すると、本発明のノンアスベスト摩擦材組成物中の銅全体の含有量が、銅元素として０．５質量％以下の範囲となることを要する。 As the metal fibers, copper or copper alloy fibers can be used to improve crack resistance and wear resistance. Examples of the copper or copper alloy fibers include copper fibers, brass fibers, bronze fibers, and the like, and these can be used alone or in combination of two or more.
However, when the fiber of copper or copper alloy is included, the content of the entire copper in the non-asbestos friction material composition of the present invention is in the range of 0.5% by mass or less as the copper element, considering the environmental load. It is necessary to become.
　また、上記金属繊維として、摩擦係数向上、耐クラック性の観点から銅及び銅合金以外の金属繊維を用いてもよい。銅及び銅合金以外の金属繊維としては、例えば、アルミニウム、鉄、亜鉛、錫、チタン、ニッケル、マグネシウム、シリコン等の金属単体又は合金形態の繊維や、鋳鉄繊維などの金属を主成分とする繊維が挙げられ、これらを単独で又は２種以上を組み合わせて用いることができる。
　耐摩耗性の観点から、本発明のノンアスベスト摩擦材組成物中の銅及び銅合金以外の金属の含有量は、０．５質量％以下となる範囲であることを要する。耐摩耗性向上の観点からは、銅及び銅合金以外の金属繊維を含有しないこと（含有量０質量％）が好ましい。 Moreover, you may use metal fibers other than copper and a copper alloy from a viewpoint of a friction coefficient improvement and crack resistance as said metal fiber. Examples of metal fibers other than copper and copper alloys include fibers in the form of simple metals or alloys such as aluminum, iron, zinc, tin, titanium, nickel, magnesium, and silicon, and fibers mainly composed of metals such as cast iron fibers. These can be used alone or in combination of two or more.
From the viewpoint of wear resistance, the content of metals other than copper and copper alloy in the non-asbestos friction material composition of the present invention is required to be in a range of 0.5% by mass or less. From the viewpoint of improving wear resistance, it is preferable not to contain metal fibers other than copper and copper alloys (content 0 mass%).
　上記フィブリル化アクリル繊維以外の有機繊維としては、アラミド繊維、セルロース繊維、フェノール樹脂繊維（架橋構造を有する）等が挙げられ、これらは単独で又は２種以上を組み合わせて用いることができる。 Examples of organic fibers other than the fibrillated acrylic fibers include aramid fibers, cellulose fibers, phenol resin fibers (having a crosslinked structure), and the like, and these can be used alone or in combination of two or more.
　上記炭素系繊維としては、耐炎化繊維、ピッチ系炭素繊維、ポリアクリロニトリル（ＰＡＮ）系炭素繊維、活性炭繊維等が挙げられ、これらは単独で又は２種以上を組み合わせて用いることができる。 Examples of the carbon-based fibers include flame-resistant fibers, pitch-based carbon fibers, polyacrylonitrile (PAN) -based carbon fibers, activated carbon fibers, and the like, and these can be used alone or in combination of two or more.
　本発明のノンアスベスト摩擦材組成物中の上記繊維基材の含有量は、フィブリル化アクリル繊維を含め、５～４０質量％であることが好ましく、５～３０質量％であることがより好ましく、１０～３０質量％であることが更に好ましい。繊維基材の含有量を５～４０質量％の範囲とすることで、摩擦材としての適正な気孔率が得られるため、弾性率が高くなることによる鳴きなどの音振性能悪化が避けられる。また適正な材料強度及び耐摩耗性が得られ、更に成形性も向上させることができる。 The content of the fiber substrate in the non-asbestos friction material composition of the present invention is preferably 5 to 40% by mass, more preferably 5 to 30% by mass, including fibrillated acrylic fibers. More preferably, it is 10 to 30% by mass. By setting the content of the fiber base in the range of 5 to 40% by mass, an appropriate porosity as a friction material can be obtained, so that deterioration in sound vibration performance such as squeal due to an increase in elastic modulus can be avoided. Moreover, appropriate material strength and wear resistance can be obtained, and the moldability can be further improved.
（その他の材料）
　また、本発明のノンアスベスト摩擦材組成物には、前記の結合材、有機充填材、無機充填材、及び繊維基材以外に、必要に応じてその他の材料を配合することができる。
　例えば、耐摩耗性の向上のために、ポリテトラフルオロエチレン（ＰＴＦＥ）などのフッ素系ポリマーなどの有機添加剤を配合することができる。 (Other materials)
Moreover, in the non-asbestos friction material composition of the present invention, in addition to the binder, the organic filler, the inorganic filler, and the fiber substrate, other materials can be blended as necessary.
For example, an organic additive such as a fluorine-based polymer such as polytetrafluoroethylene (PTFE) can be blended for improving wear resistance.
［摩擦材及び摩擦部材］
　また、本発明は、上述のノンアスベスト摩擦材組成物を用いた摩擦材及び摩擦部材を提供する。
　本発明のノンアスベスト摩擦材組成物は、これを成形することにより、自動車などのディスクブレーキパッドやブレーキライニングなどの摩擦材として使用することができる。本発明の摩擦材は良好な摩擦係数、耐クラック性及び耐摩耗性を示すため、制動時に負荷の大きいディスクブレーキパッドの摩擦材に好適である。
　さらに、上記摩擦材を用いることにより、該摩擦材が摩擦面となるように形成した摩擦部材を得ることができる。該摩擦材を用いて形成することができる本発明の摩擦部材としては、例えば、下記の構成などが挙げられる。 [Friction material and friction member]
The present invention also provides a friction material and a friction member using the above-described non-asbestos friction material composition.
By molding the non-asbestos friction material composition of the present invention, it can be used as a friction material for disc brake pads and brake linings for automobiles. Since the friction material of the present invention exhibits a good coefficient of friction, crack resistance and wear resistance, it is suitable as a friction material for a disk brake pad having a large load during braking.
Furthermore, by using the friction material, a friction member formed so that the friction material becomes a friction surface can be obtained. Examples of the friction member of the present invention that can be formed using the friction material include the following configurations.
（１）摩擦材のみの構成。
（２）裏金と、該裏金の上に摩擦面となる本発明のノンアスベスト摩擦材組成物からなる摩擦材とを有する構成。
（３）上記（２）の構成において、裏金と摩擦材との間に、裏金の接着効果を高めるための表面改質を目的としたプライマー層、及び、裏金と摩擦材との接着を目的とした接着層をさらに介在させた構成。
　上記裏金は、摩擦部材の機械的強度の向上のために、通常、摩擦部材に用いるものである。材質としては、金属又は繊維強化プラスチック等を用いることができ、例えば、鉄、ステンレス、無機繊維強化プラスチック、炭素繊維強化プラスチック等が挙げられる。プライマー層及び接着層としては、通常、ブレーキシューなどの摩擦部材に用いられるものであればよい。 (1) Configuration of friction material only.
(2) The structure which has a back metal and the friction material which consists of a non-asbestos friction material composition of this invention used as a friction surface on this back metal.
(3) In the configuration of (2) above, between the back metal and the friction material, a primer layer for the purpose of surface modification for enhancing the adhesion effect of the back metal, and for the purpose of bonding the back metal and the friction material A configuration in which an adhesive layer is further interposed.
The back metal is usually used for a friction member in order to improve the mechanical strength of the friction member. As the material, metal or fiber reinforced plastic can be used, and examples thereof include iron, stainless steel, inorganic fiber reinforced plastic, and carbon fiber reinforced plastic. The primer layer and the adhesive layer may be those used for friction members such as brake shoes.
　本発明の摩擦材は、一般に使用されている方法を用いて製造することができ、本発明のノンアスベスト摩擦材組成物を成形して、好ましくは加熱加圧成形して製造される。
　具体的には、本発明のノンアスベスト摩擦材組成物を、レディーゲミキサー、加圧ニーダー、アイリッヒミキサー等の混合機を用いて均一に混合し、この混合物を成形金型にて予備成形し、得られた予備成形物を成形温度１３０～１６０℃、成形圧力２０～５０ＭＰａの条件で２～１０分間で成形し、得られた成形物を１５０～２５０℃で２～１０時間熱処理する。必要に応じて塗装、スコーチ処理、研磨処理を行うことによって摩擦材を製造することができる。 The friction material of the present invention can be produced by a generally used method, and is produced by molding the non-asbestos friction material composition of the present invention, preferably by hot pressing.
Specifically, the non-asbestos friction material composition of the present invention is uniformly mixed using a mixer such as a Readyge mixer, a pressure kneader, or an Eirich mixer, and this mixture is preformed in a molding die. The obtained preform is molded in a molding temperature of 130 to 160 ° C. and a molding pressure of 20 to 50 MPa for 2 to 10 minutes, and the resulting molded product is heat-treated at 150 to 250 ° C. for 2 to 10 hours. A friction material can be manufactured by performing coating, scorch treatment, and polishing treatment as necessary.
　本発明のノンアスベスト摩擦材組成物を成形してなる摩擦材は、摩擦係数、耐クラック性及び耐摩耗性に優れるため、ディスクブレーキパッドやブレーキライニングなどの摩擦部材の「上張り材」として有用であり、さらに摩擦材として高い耐クラック性を有するため、摩擦部材の「下張り材」として成形して用いることもできる。
　なお、「上張り材」とは、摩擦部材の摩擦面となる摩擦材であり、「下張り材」とは、摩擦部材の摩擦面となる摩擦材と裏金との間に介在する、摩擦材と裏金との接着部付近の剪断強度、耐クラック性向上を目的とした層のことである。 The friction material formed by molding the non-asbestos friction material composition of the present invention is excellent as a coefficient of friction, crack resistance and wear resistance, and thus is useful as a “upper material” for friction members such as disc brake pads and brake linings. Furthermore, since it has high crack resistance as a friction material, it can be molded and used as a “underlay material” of a friction member.
The “upper material” is a friction material that becomes the friction surface of the friction member, and the “underlay material” is a friction material that is interposed between the friction material that becomes the friction surface of the friction member and the back metal. It is a layer for the purpose of improving the shear strength and crack resistance in the vicinity of the adhesion part with the back metal.
　以下、本発明のノンアスベスト摩擦材組成物、摩擦材及び摩擦部材について、実施例及び比較例を用いて更に詳細に説明するが、本発明は何らこれらに制限されるものではない。 Hereinafter, the non-asbestos friction material composition, the friction material, and the friction member of the present invention will be described in more detail using Examples and Comparative Examples, but the present invention is not limited to these.
［実施例１～５及び比較例１～５］
（ディスクブレーキパッドの作製）
　表１に示す配合比率に従って材料を配合し、実施例１～５及び比較例１～５の摩擦材組成物を得た。この摩擦材組成物をレディーゲミキサー（（株）マツボー製、商品名：レディーゲミキサーＭ２０）で混合し、この混合物を成形プレス（王子機械工業（株）製）で予備成形した。得られた予備成形物を成形温度１４５℃、成形圧力３０ＭＰａの条件で５分間、成形プレス（三起精工（株）製）を用いて鉄製の裏金（日立オートモティブシステムズ（株）製）と共に加熱加圧成形した。得られた成形品を２００℃で４．５時間熱処理し、ロータリー研磨機を用いて研磨し、５００℃のスコーチ処理を行って、実施例１～５及び比較例１～５のディスクブレーキパッドを得た。なお、実施例及び比較例では、裏金の厚さ６ｍｍ、摩擦材の厚さ１１ｍｍ、摩擦材投影面積５２ｃｍ2のディスクブレーキパッドを作製した。 [Examples 1 to 5 and Comparative Examples 1 to 5]
(Production of disc brake pad)
The materials were blended according to the blending ratio shown in Table 1, and the friction material compositions of Examples 1 to 5 and Comparative Examples 1 to 5 were obtained. The friction material composition was mixed with a Readyge mixer (manufactured by Matsubo Co., Ltd., trade name: Ladyge mixer M20), and the mixture was preformed with a molding press (Oji Machinery Co., Ltd.). The obtained preform was heated together with an iron backing (manufactured by Hitachi Automotive Systems) using a molding press (manufactured by Sanki Seiko Co., Ltd.) for 5 minutes at a molding temperature of 145 ° C. and a molding pressure of 30 MPa. Press molded. The obtained molded product was heat-treated at 200 ° C. for 4.5 hours, polished using a rotary polishing machine, and subjected to scorch treatment at 500 ° C., so that the disc brake pads of Examples 1 to 5 and Comparative Examples 1 to 5 were obtained. Obtained. In Examples and Comparative Examples, a disc brake pad having a back metal thickness of 6 mm, a friction material thickness of 11 mm, and a friction material projection area of 52 cm 2 was produced.
（剪断強度の評価）
　剪断強度は、日本工業規格ＪＩＳ　Ｄ４４２２に基づき測定した。 (Evaluation of shear strength)
The shear strength was measured based on Japanese Industrial Standard JIS D4422.
（耐クラック性の評価）
　耐クラック性は、ＪＡＳＯ　Ｃ４２７に示されるブレーキ温度４００℃の制動（初速度５０ｋｍ／ｈ、終速度０ｋｍ／ｈ、減速度０．３Ｇ、制動前ブレーキ温度１００℃）を摩擦材が半分の厚みとなるまで繰り返し、摩擦材側面及び摩擦面のクラックの生成を測定した。クラックの生成は、下記に従い、３段階評点にて評価した。
水準１：クラックの発生無し
水準２：摩擦材の摩擦面又は側面に０．１ｍｍのシックネスゲージが入らない程度のクラックが生成
水準３：摩擦材の摩擦面又は側面に０．１ｍｍのシックネスゲージが入る程度のクラックが生成
　なお、摩擦材の摩擦面及び側面の一方にシックネスゲージが入らない程度のクラックが生成し、他方にシックネスゲージが入る程度のクラックが生成した場合、水準３とする。 (Evaluation of crack resistance)
As for crack resistance, braking with a brake temperature of 400 ° C. shown in JASO C427 (initial speed 50 km / h, final speed 0 km / h, deceleration 0.3 G, brake temperature 100 ° C. before braking) is half the friction material. The generation of cracks on the friction material side surface and the friction surface was measured repeatedly. The generation of cracks was evaluated according to the following three-point score.
Level 1: No occurrence of cracks Level 2: Cracks to the extent that a 0.1 mm thickness gauge does not enter the friction surface or side surface of the friction material Level 3: 0.1 mm thickness gauge is generated on the friction surface or side surface of the friction material If a crack that does not contain a thickness gauge is generated on one of the friction surface and the side surface of the friction material and a crack that contains a thickness gauge is generated on the other side, the level 3 is set.
（耐摩耗性の評価）
　耐摩耗性は、自動車技術会規格ＪＡＳＯ　Ｃ４２７に基づき測定し、ブレーキ温度１００℃及び３００℃の制動１０００回相当の摩擦材の摩耗量を評価した。
　上記ＪＡＳＯ　Ｃ４０６、ＪＡＳＯ　Ｃ４２７準拠による摩擦係数、耐摩耗性、耐クラック性の評価は、ダイナモメータ（三起精工（株）製）を用い、イナーシャ７ｋｇｆ・ｍ・ｓ2で評価を行った。また、上記評価は、ベンチレーテッドディスクロータ（材質：ＦＣ１９０、（株）キリウ製）及び、一般的なピンスライド式のコレットタイプのキャリパを用いて実施した。 (Evaluation of wear resistance)
The wear resistance was measured based on the Japan Society of Automotive Engineers standard JASO C427, and the wear amount of the friction material corresponding to 1000 brakings at a brake temperature of 100 ° C and 300 ° C was evaluated.
Evaluation of the friction coefficient, wear resistance, and crack resistance according to the above-mentioned JASO C406 and JASO C427 was performed using a dynamometer (manufactured by Sanki Seiko Co., Ltd.) and an inertia of 7 kgf · m · s 2 . The evaluation was performed using a ventilated disc rotor (material: FC190, manufactured by Kiriu Co., Ltd.) and a general pin slide type collet type caliper.
　評価結果を表１に示す。
　なお、表１における、各構成成分の詳細は以下の通りである。
（結合材）
　フェノール樹脂：日立化成工業（株）製（商品名：ＨＰ４９１ＵＰ）
（有機充填材）
　カシューダスト：東北化工（株）製（商品名：ＦＦ－１０５６、最大粒子径５００μｍ）
（無機充填材）
　硫酸バリウム：堺化学（株）製（商品名：硫酸バリウムＢＡ）
　炭酸カルシウム：竹原化学工業（株）製（商品名：サンライト）
　黒鉛：ＴＩＭＣＡＬ社製（商品名：ＫＳ７５）
　マイカ：イメリス社製（商品名：３２５ＨＫ）
　チタン酸カリウム：（株）クボタ製（商品名：ＴＡＸＡ－ＭＡ、板状チタン酸カリウム）
（有機繊維）
　フィブリル化アクリル繊維：Ｓｔｅｒｌｉｎｇ　ｆｉｂｅｒｓ　Ｉｎｃ．製（商品名：ＣＦＦ　Ｖ１１０－１、平均繊維長５～６ｍｍ、濾水度２６７ｍｌ）
　アラミド繊維：東レ・デュポン（株）製（商品名：１Ｆ５３８）
（金属繊維）
　銅繊維：Ｓｕｎｎｙ　ｍｅｔａｌ社製（商品名：ＳＣＡ－１０７０）
　鉄繊維：ＧＭＴ社製（商品名：＃０）
（無機繊維）
　鉱物繊維：ＬＡＰＩＮＵＳ　ＦＩＢＲＥＳ　Ｂ．Ｖ社製（商品名：ＲＢ２４０Ｒｏｘｕｌ１０００、平均繊維長３００μｍ） The evaluation results are shown in Table 1.
In addition, the detail of each structural component in Table 1 is as follows.
(Binder)
Phenolic resin: manufactured by Hitachi Chemical Co., Ltd. (trade name: HP491UP)
(Organic filler)
Cashew dust: manufactured by Tohoku Kako Co., Ltd. (trade name: FF-1056, maximum particle size 500 μm)
(Inorganic filler)
Barium sulfate: manufactured by Sakai Chemical Co., Ltd. (trade name: barium sulfate BA)
Calcium carbonate: Takehara Chemical Industry Co., Ltd. (trade name: Sunlight)
Graphite: manufactured by TIMCAL (trade name: KS75)
Mica: Made by Imeris (Product name: 325HK)
Potassium titanate: manufactured by Kubota Corporation (trade name: TAXA-MA, plate-like potassium titanate)
(Organic fiber)
Fibrilized acrylic fiber: Sterling fibers Inc. Made (trade name: CFF V110-1, average fiber length 5-6mm, freeness 267ml)
Aramid fiber: Toray DuPont Co., Ltd. (trade name: 1F538)
(Metal fiber)
Copper fiber: Sunny metal (trade name: SCA-1070)
Iron fiber: manufactured by GMT (trade name: # 0)
(Inorganic fiber)
Mineral fiber: LAPINUS FIBRES B. V (Product name: RB240Roxul1000, average fiber length 300 μm)
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　実施例１～５は、銅を多量に含有する比較例１及び比較例５と同水準の剪断強度、耐クラック性、耐摩耗性を示した。また、実施例１～５は、銅を含有せず、銅及び銅合金以外の金属の含有量が０．５質量％以下であり、フィブリル化アクリル繊維のかわりにアラミド繊維を含有する比較例２、及び銅を含有せず、銅及び銅合金以外の金属の含有量が０．５質量％以下であり、有機繊維を含まない比較例３、銅及び銅合金以外の金属として０．５質量％を超える量の鉄繊維を含有する比較例４と比較して剪断強度、耐クラック性、耐摩耗性に優れる。
　更に、フィブリル化アクリル繊維の含有量を２～７質量％の範囲で含有する実施例１～４は、実施例５と比較して更に耐摩耗性に優れる。 Examples 1 to 5 showed the same level of shear strength, crack resistance, and wear resistance as Comparative Examples 1 and 5 containing a large amount of copper. Examples 1 to 5 do not contain copper, the content of metals other than copper and copper alloys is 0.5% by mass or less, and comparative example 2 containing aramid fibers instead of fibrillated acrylic fibers. And the content of metals other than copper and copper alloys is 0.5 mass% or less, and contains 0.5 mass% as a metal other than copper and copper alloys. Compared to Comparative Example 4 containing iron fibers in an amount exceeding 1, the shear strength, crack resistance, and wear resistance are excellent.
Further, Examples 1 to 4 containing a fibrillated acrylic fiber content in the range of 2 to 7% by mass are more excellent in abrasion resistance than Example 5.
　本発明のノンアスベスト摩擦材組成物、これを用いた摩擦材及び摩擦部材は、従来品と比較して制動時に生成する摩耗粉中の銅が少ないことから環境への負荷が少なく、かつ優れた剪断強度、耐クラック性、及び耐摩耗性の発現が可能であり、乗用車用ブレーキパッドなどに好適である。 The non-asbestos friction material composition of the present invention, the friction material using the non-asbestos friction material composition, and the friction member have less impact on the environment because of less copper in the wear powder generated during braking compared to conventional products, and are excellent. It can exhibit shear strength, crack resistance, and wear resistance, and is suitable for brake pads for passenger cars.

Claims (4)

  1. 　結合材、有機充填材、無機充填材、及び繊維基材を含有するノンアスベスト摩擦材組成物であって、該摩擦材組成物中の銅の含有量が銅元素として０．５質量％以下であり、銅及び銅合金以外の金属の含有量が０．５質量％以下であり、かつ、繊維基材としてフィブリル化アクリル繊維を含有するノンアスベスト摩擦材組成物。 A non-asbestos friction material composition containing a binder, an organic filler, an inorganic filler, and a fiber base material, wherein the copper content in the friction material composition is 0.5% by mass or less as a copper element A non-asbestos friction material composition having a metal content other than copper and copper alloy of 0.5% by mass or less and containing fibrillated acrylic fibers as a fiber base material.
  2. 　前記フィブリル化アクリル繊維の含有量が２～８質量％である請求項１に記載のノンアスベスト摩擦材組成物。 The non-asbestos friction material composition according to claim 1, wherein the content of the fibrillated acrylic fiber is 2 to 8% by mass.
  3. 　請求項１又は２に記載のノンアスベスト摩擦材組成物を成形してなる摩擦材。 A friction material formed by molding the non-asbestos friction material composition according to claim 1 or 2.
  4. 　請求項１又は２に記載のノンアスベスト摩擦材組成物を成形してなる摩擦材と裏金とを用いて形成される摩擦部材。 A friction member formed using a friction material obtained by molding the non-asbestos friction material composition according to claim 1 or 2, and a back metal.
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WO2021010003A1 (en) * 2019-07-18 2021-01-21 日清紡ブレーキ株式会社 Friction material composition, friction material, and disk brake pad
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