WO2023189976A1 - Friction material - Google Patents

Friction material Download PDF

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Publication number
WO2023189976A1
WO2023189976A1 PCT/JP2023/011333 JP2023011333W WO2023189976A1 WO 2023189976 A1 WO2023189976 A1 WO 2023189976A1 JP 2023011333 W JP2023011333 W JP 2023011333W WO 2023189976 A1 WO2023189976 A1 WO 2023189976A1
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Prior art keywords
friction
friction material
mass
coke
fibers
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PCT/JP2023/011333
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French (fr)
Japanese (ja)
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佑亮 大西
素行 宮道
博司 山本
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曙ブレーキ工業株式会社
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Publication of WO2023189976A1 publication Critical patent/WO2023189976A1/en

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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • 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—Composition of linings ; Methods of manufacturing

Definitions

  • the present invention relates to a friction material used for brake pads, brake linings, clutch facings, etc. of automobiles, railway vehicles, industrial machines, etc.
  • Raw steel materials in which the percentage of steel fibers is below a certain level, are widely used as friction materials with well-balanced friction properties, especially in Europe, where a high friction coefficient is required during high-speed braking.
  • cast iron which is a component of the disc rotor.
  • DTV Disc Thickness Variation
  • Patent Document 1 states that 2 to 5 steel fibers containing no copper as an element in a friction material composition or having a copper content of 0.5% by mass or less and a fiber length of 2500 ⁇ m or less are used.
  • a friction material composition is described which contains as essential components a titanate having a tunnel crystal structure and a titanate having a layered crystal structure as titanates.
  • Patent Document 2 discloses that the composition does not contain any copper and copper compounds or alloys, but contains 1 to 10 volumes of copper and/or organic fibers together with inorganic and/or organic fibers in the fibrous base material, calculated from the total volume of the composition.
  • An asbestos-free organic friction material containing % stainless steel fibers is described.
  • Patent Document 2 an attempt is made to improve the effectiveness and stability of high-speed effectiveness by using 1 to 10% by volume of stainless steel fibers. Since strong adhesion friction occurs, no improvement in judder properties can be expected.
  • An object of the present invention is to provide a friction material that has stable and high effectiveness and has good judder characteristics.
  • the present inventors have found that the above problem can be solved by using coated steel fibers and controlling the amounts of steel fibers and coke within a specific range. That is, the present invention is as follows. [1] A friction material containing a friction modifier, a fiber base material, and a binder, The friction modifier contains 2 to 10% by mass of coke, A friction material containing 2 to 15% by mass of steel fibers coated with metal sulfide as the fiber base material. [2] The friction material according to [1], wherein the metal sulfide contains at least one of iron sulfide and tin sulfide.
  • the adhesive friction properties of steel fibers are effectively controlled by using coated steel fibers and greatly limiting the amounts of steel fibers and coke from conventional raw steel material formulations. becomes possible. As a result, a friction material having good judder characteristics and effectiveness stability is obtained.
  • the friction material of the present invention contains a friction modifier, a fiber base material, and a binder.
  • the fiber base material is used to reinforce the friction material.
  • the friction material of the present invention contains steel fibers coated with metal sulfide (hereinafter also referred to as "coated steel fibers") as a fiber base material.
  • Metal sulfides function as solid lubricants. This makes it possible to achieve both adhesive friction properties and lubricity compared to ordinary uncoated steel fibers.
  • metal sulfides include iron sulfide, tin sulfide, copper sulfide, bismuth sulfide, zinc sulfide, tungsten sulfide, manganese sulfide, molybdenum disulfide, antimony trisulfide, etc., and these may be used alone or in combination of two or more. Can be used in combination.
  • the metal sulfide preferably contains at least one of iron sulfide and tin sulfide from the viewpoint of lubricity and environmental impact.
  • the content of the coated steel fibers in the friction material is 2 to 15% by mass, preferably 3 to 12% by mass, and more preferably 3 to 10% by mass. Within this range, the adhesion friction properties of the steel fibers can be effectively controlled, and a friction material having good judder properties and effectiveness stability can be obtained.
  • coated steel fiber for example, those described in Japanese Patent Application Publication No. 2019-501303, commercially available products manufactured by Tribotecc, etc. can be used.
  • fiber base material other fiber base materials can be used in addition to the above-mentioned coated steel fibers.
  • fiber base materials various commonly used organic fibers, inorganic fibers, and metal fibers are used, but it is preferable not to use copper fibers or bronze fibers containing a copper component.
  • organic fibers include aromatic polyamide (aramid) fibers and flame-resistant acrylic fibers
  • inorganic fibers include ceramic fibers, biosoluble inorganic fibers, glass fibers, carbon fibers, rock wool, etc.
  • metal fibers include uncoated steel fibers. Each of these may be used alone or in combination of two or more. Further, the content of other fiber base materials in the friction material is preferably 3 to 30% by mass, more preferably 5 to 20% by mass.
  • Friction modifiers are used to impart desired friction properties such as wear resistance, heat resistance, and fade resistance to friction materials.
  • the friction material of the present invention contains 2 to 10% by mass of coke as a friction modifier.
  • the content of coke in the friction material is preferably 2 to 8% by mass, more preferably 2 to 7% by mass.
  • the coke used preferably has an average particle diameter of 200 to 1000 ⁇ m. If the average particle diameter is 200 ⁇ m or more, wear resistance is improved in a high temperature range, and if it is 1000 ⁇ m or less, segregation is less likely to occur and cracking can be suppressed.
  • Coal coke which is made from high-quality coal, is expensive and difficult to use, but petroleum coke has less variation in quality, is inexpensive, and can be easily obtained, so petroleum coke is preferred. is preferred.
  • the friction material of the present invention further contains graphite as a friction modifier.
  • graphite in addition to coke, appropriate lubricity can be imparted, suppressing the aggressiveness of the abrasive to the mating material, and ensuring a good friction coefficient.
  • the total content of coke and graphite in the friction material is preferably 1 to 12% by mass, more preferably 5 to 12% by mass, from the viewpoint of ensuring both a friction coefficient and wear resistance.
  • Graphite that is commonly used for friction materials can be used, and may be either natural graphite or artificial graphite. Further, the average particle diameter of graphite is preferably 10 to 1000 ⁇ m, more preferably 200 to 800 ⁇ m from the viewpoint of wear resistance.
  • the average particle diameter can be determined by the value of the particle diameter equivalent to 50% cumulative percentage on a volume basis (D50) measured by a laser diffraction particle size distribution analyzer. Moreover, the average particle diameter can also be measured by a sieving method.
  • friction modifier other friction modifiers other than those mentioned above can be used, such as inorganic fillers, organic fillers, abrasives, solid lubricants, metal powders, and the like.
  • Inorganic fillers include titanates such as potassium titanate, lithium titanate, lithium potassium titanate, sodium titanate, calcium titanate, magnesium titanate, magnesium potassium titanate, barium sulfate, calcium carbonate, and calcium hydroxide. , vermiculite, mica, and other inorganic materials. Each of these may be used alone or in combination of two or more. Further, the content of the inorganic filler in the friction material is preferably 1 to 50% by mass, more preferably 10 to 50% by mass based on the entire friction material.
  • organic filler examples include various rubber powders (raw rubber powder, tire powder, etc.), cashew dust, melamine dust, and the like. Each of these may be used alone or in combination of two or more. Further, the content of the organic filler in the friction material is preferably 1 to 20% by mass, more preferably 1 to 10% by mass based on the entire friction material.
  • abrasive material examples include alumina, silica, magnesium oxide, zirconium oxide, zirconium silicate, chromium oxide, triiron tetraoxide (Fe 3 O 4 ), chromite, and the like. Each of these may be used alone or in combination of two or more. Further, the content of the abrasive in the friction material is preferably 1 to 30% by mass, more preferably 5 to 25% by mass based on the entire friction material.
  • solid lubricants examples include antimony trisulfide, molybdenum disulfide, tin sulfide, polytetrafluoroethylene (PTFE), and the like. Each of these may be used alone or in combination of two or more. Further, the content of the solid lubricant in the friction material is preferably 1 to 30% by mass, more preferably 5 to 25% by mass based on the entire friction material.
  • the metal powder examples include metal powders such as aluminum, tin, and zinc. Each of these may be used alone or in combination of two or more. Further, the content of metal powder in the friction material is preferably 1 to 10% by mass, more preferably 1 to 5% by mass based on the entire friction material.
  • the content of the friction modifier in the friction material is preferably 50 to 90% by mass, more preferably 60 to 90% by mass, based on the entire friction material, from the viewpoint of sufficiently imparting the desired friction characteristics to the friction material.
  • binders As the binder contained in the friction material according to the present invention, various commonly used binders can be used. Specifically, thermosetting resins such as straight phenol resins, various modified phenol resins such as elastomers, melamine resins, epoxy resins, and polyimide resins are mentioned. Examples of the elastomer-modified phenol resin include acrylic rubber-modified phenol resin, silicone rubber-modified phenol resin, and nitrile rubber (NBR)-modified phenol resin. Note that these binders can be used alone or in combination of two or more. Further, the content of the binder in the friction material is preferably 1 to 20% by mass, more preferably 3 to 15% by mass based on the entire friction material.
  • the friction material of the present invention does not contain a copper component.
  • "contains no copper component” means that it does not contain a copper component as an active component for exerting functions such as wear resistance.For example, if a friction material contains a small amount of copper component This does not mean that it does not contain copper components as impurities.
  • the copper component mixed as an impurity etc. is 0.5% by mass or less.
  • a specific embodiment of the method for manufacturing the friction material according to the present invention can be carried out by a known manufacturing process.
  • the above components are blended, and the blend is preformed, thermoformed, Friction materials can be produced through processes such as heating and polishing.
  • the general steps in manufacturing brake pads with friction material are shown below.
  • thermoforming step in which the preformed body and the pressure plate coated with adhesive are fixed together by applying a predetermined temperature and pressure (molding temperature: 130-180°C, molding pressure: 30-80 MPa) , molding time 2-10 minutes), (e) After-curing (150-300°C, 1-5 hours) and finally applying finishing treatments such as polishing, surface baking, and painting.
  • Examples 1 to 8, Comparative Examples 1 to 13 The raw materials having the friction material composition shown in Table 3 or Table 4 described later are mixed in a mixer for 5 minutes, the mixed stirring material is put into a mold, and preforming and heating and pressure molding are performed to produce a friction material. did.
  • the following steel fibers coated with metal sulfide were used.
  • Preforming was carried out by applying a pressure of 20 MPa for 10 seconds.
  • thermoformed product was subjected to heating and pressure molding at a pressure of 35 MPa and a molding temperature of 150° C. for 6 minutes to create a thermoformed product.
  • the thermoformed bodies were subjected to after-curing at a temperature of 250° C. for 3 hours, processed to a predetermined thickness, polished, and painted to produce each friction material.
  • Judder test evaluation criteria The measured DTV was judged based on the following criteria. ⁇ : 0 or more, less than 5.0 ⁇ m ⁇ : 5.0 or more, less than 10.0 ⁇ m ⁇ : 10.0 or more, less than 20.0 ⁇ m ⁇ : 20.0 ⁇ m or more
  • High-speed fade test evaluation criteria The measured minimum instantaneous friction coefficient was judged based on the following criteria. ⁇ : 0.17 or more ⁇ : 0.16 or more ⁇ : 0.15 or more ⁇ : Less than 0.15 or does not stop due to upper limit of hydraulic pressure

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)

Abstract

The present invention pertains to a friction material which contains a friction adjusting material, a fiber base material, and a binding material, and in which 2-10 mass% of coke is contained as the friction adjusting material, and 2-15 mass% of steel fibers coated with a metal sulfide is contained as the fiber base material.

Description

摩擦材Friction material
　本発明は、自動車、鉄道車両、産業機械等のブレーキパッド、ブレーキライニング、クラッチフェーシング等に用いられる摩擦材に関する。 The present invention relates to a friction material used for brake pads, brake linings, clutch facings, etc. of automobiles, railway vehicles, industrial machines, etc.
　スチール繊維の割合が一定以下であるロースチール材は、摩擦特性のバランスが良好な摩擦材として、特に高速制動時の摩擦係数の確保が要求される欧州で広く用いられている。ここで、ロースチール材に含まれるスチール繊維と相手材であるディスクロータの成分である鋳鉄との凝着摩擦の制御が重要になる。しかし、アウトバーンや山岳・市街地間走行で想定されるフェードと通常制動を繰り返すようなモードにおいて、その凝着摩擦の制御が困難になり、ＤＴＶ（Ｄｉｓｃ　Ｔｈｉｃｋｎｅｓｓ　Ｖａｒｉａｔｉｏｎ：ディスク肉厚変動）が大きく成長し、ジャダーが発生する。これは、フェード時にディスクロータ摺動面に形成される摩擦材由来の移着被膜が、通常制動時の凝着摩擦を阻害し、ディスクロータ摺動面の凝着摩耗が均一に促進されなくなることが原因であると考えられる。 Raw steel materials, in which the percentage of steel fibers is below a certain level, are widely used as friction materials with well-balanced friction properties, especially in Europe, where a high friction coefficient is required during high-speed braking. Here, it is important to control the adhesion friction between the steel fibers contained in the raw steel material and the other material, cast iron, which is a component of the disc rotor. However, in modes where fade and normal braking are repeated, which is expected when driving on the autobahn or between mountains and urban areas, it becomes difficult to control the adhesive friction, and DTV (Disc Thickness Variation) grows significantly. , judder occurs. This is because the transfer film derived from the friction material that is formed on the sliding surface of the disc rotor during fade inhibits adhesive friction during normal braking, and adhesive wear on the sliding surface of the disc rotor is not promoted uniformly. This is thought to be the cause.
　対策として、スチール繊維を減量すれば、ジャダーは改善に向かうが、スチール繊維は存在するため根本的な解決にはならない。また、スチール繊維を減量すると、通常制動時や高速高温時において効きが低下するおそれがある。 As a countermeasure, reducing the amount of steel fibers will improve the judder, but since steel fibers still exist, this will not be a fundamental solution. Furthermore, if the steel fiber is reduced in amount, there is a risk that the effectiveness will decrease during normal braking and at high speeds and high temperatures.
　ここで、特許文献１には、摩擦材組成物中に元素としての銅を含まない、または銅の含有量が０．５質量％以下であり、繊維長が２５００μｍ以下のスチール繊維を２～５質量％含有し、チタン酸塩としてトンネル構造の結晶構造のチタン酸塩および層状構造の結晶構造のチタン酸塩を必須成分とする摩擦材組成物が記載されている。 Here, Patent Document 1 states that 2 to 5 steel fibers containing no copper as an element in a friction material composition or having a copper content of 0.5% by mass or less and a fiber length of 2500 μm or less are used. A friction material composition is described which contains as essential components a titanate having a tunnel crystal structure and a titanate having a layered crystal structure as titanates.
　特許文献２には、組成物は銅及び銅化合物、又は合金を全く含まないが、線維性基材中に、無機及び／又は有機繊維と共に、組成物の合計体積から計算して１～１０体積％のステンレススチール繊維を含むアスベストフリーの有機摩擦材料が記載されている。 Patent Document 2 discloses that the composition does not contain any copper and copper compounds or alloys, but contains 1 to 10 volumes of copper and/or organic fibers together with inorganic and/or organic fibers in the fibrous base material, calculated from the total volume of the composition. An asbestos-free organic friction material containing % stainless steel fibers is described.
日本国特開２０１６－１２１２４３号公報Japanese Patent Application Publication No. 2016-121243 日本国特表２０１５－５３０５３２号公報Japan Special Table No. 2015-530532
　特許文献１に記載の摩擦材では、チタン酸塩と少量のスチール繊維の添加により高温制動時の振動を抑制させているが、これは高温時に移着被膜を効果的に生成することで制動を安定させる手法であり、フェードと通常制動を繰り返すような走行モードの対策とはならない。 In the friction material described in Patent Document 1, vibrations during high-temperature braking are suppressed by adding titanate and a small amount of steel fiber, but this suppresses braking by effectively forming a transfer film at high temperatures. This is a stabilizing method and is not a countermeasure for driving modes that repeat fade and normal braking.
　また特許文献２では、１～１０体積％のステンレス繊維を使用することで、高速効力の効き安定性の向上を試みているが、ステンレス繊維は、ディスクロータの成分である鋳鉄との同種金属間の強い凝着摩擦を発生させるため、ジャダー特性の改善は期待できない。 Furthermore, in Patent Document 2, an attempt is made to improve the effectiveness and stability of high-speed effectiveness by using 1 to 10% by volume of stainless steel fibers. Since strong adhesion friction occurs, no improvement in judder properties can be expected.
　本発明は、安定した高い効きを有し、ジャダー特性が良好な摩擦材を提供することを目的とする。 An object of the present invention is to provide a friction material that has stable and high effectiveness and has good judder characteristics.
　本発明者らは、被覆スチール繊維を使用し、スチール繊維とコークスの量を特定範囲とすることで上記課題を解決できることを見出した。
　すなわち本発明は以下のとおりのものである。
〔１〕摩擦調整材、繊維基材及び結合材を含有する摩擦材であって、
　前記摩擦調整材として、コークスを２～１０質量％含有し、
　前記繊維基材として、金属硫化物で被覆されているスチール繊維を２～１５質量％含有する摩擦材。
〔２〕前記金属硫化物が硫化鉄及び硫化錫の少なくとも一方を含有する、〔１〕に記載の摩擦材。
〔３〕前記摩擦調整材として黒鉛をさらに含有し、
　前記コークスと前記黒鉛の合計含有量が１～１２質量％である、〔１〕又は〔２〕に記載の摩擦材。
〔４〕銅成分を含有しない、〔１〕～〔３〕のいずれかに記載の摩擦材。 The present inventors have found that the above problem can be solved by using coated steel fibers and controlling the amounts of steel fibers and coke within a specific range.
That is, the present invention is as follows.
[1] A friction material containing a friction modifier, a fiber base material, and a binder,
The friction modifier contains 2 to 10% by mass of coke,
A friction material containing 2 to 15% by mass of steel fibers coated with metal sulfide as the fiber base material.
[2] The friction material according to [1], wherein the metal sulfide contains at least one of iron sulfide and tin sulfide.
[3] Further containing graphite as the friction modifier,
The friction material according to [1] or [2], wherein the total content of the coke and the graphite is 1 to 12% by mass.
[4] The friction material according to any one of [1] to [3], which does not contain a copper component.
　本発明によれば、被覆スチール繊維を使用し、スチール繊維とコークスの量を従来のロースチール材の配合から大きく量を制限することで、スチール繊維の凝着摩擦特性を効果的に制御することが可能になる。その結果、良好なジャダー特性と効き安定性を有する摩擦材が得られる。 According to the present invention, the adhesive friction properties of steel fibers are effectively controlled by using coated steel fibers and greatly limiting the amounts of steel fibers and coke from conventional raw steel material formulations. becomes possible. As a result, a friction material having good judder characteristics and effectiveness stability is obtained.
　以下、本発明について詳述するが、これらは望ましい実施態様の一例を示すものであり、これらの内容に特定されるものではない。 The present invention will be described in detail below, but these are examples of preferred embodiments and are not limited to these details.
　本発明の摩擦材は、摩擦調整材、繊維基材、結合材を含有する。 The friction material of the present invention contains a friction modifier, a fiber base material, and a binder.
＜繊維基材＞
　繊維基材は、摩擦材を補強するために用いられる。
　本発明の摩擦材は、繊維基材として、金属硫化物で被覆されているスチール繊維（以下「被覆スチール繊維」とも記載する。）を含有する。金属硫化物は、固体潤滑材として機能する。これにより、被覆されていない通常のスチール繊維よりも凝着摩擦特性と潤滑性を両立させることが可能である。 <Fiber base material>
The fiber base material is used to reinforce the friction material.
The friction material of the present invention contains steel fibers coated with metal sulfide (hereinafter also referred to as "coated steel fibers") as a fiber base material. Metal sulfides function as solid lubricants. This makes it possible to achieve both adhesive friction properties and lubricity compared to ordinary uncoated steel fibers.
　金属硫化物としては、硫化鉄、硫化錫、硫化銅、硫化ビスマス、硫化亜鉛、硫化タングステン、硫化マンガン、二硫化モリブデン、三硫化アンチモン等が挙げられ、これらの１種を単独又は２種以上を組み合わせて用いることができる。金属硫化物としては潤滑性や環境負荷の観点から硫化鉄および硫化錫の少なくとも一方を含むことがより好ましい。 Examples of metal sulfides include iron sulfide, tin sulfide, copper sulfide, bismuth sulfide, zinc sulfide, tungsten sulfide, manganese sulfide, molybdenum disulfide, antimony trisulfide, etc., and these may be used alone or in combination of two or more. Can be used in combination. The metal sulfide preferably contains at least one of iron sulfide and tin sulfide from the viewpoint of lubricity and environmental impact.
　摩擦材における被覆スチール繊維の含有量は、２～１５質量％、好ましくは３～１２質量％、より好ましくは３～１０質量％である。かかる範囲であることで、スチール繊維の凝着摩擦特性を効果的に制御でき、良好なジャダー特性と効き安定性を有する摩擦材が得られる。 The content of the coated steel fibers in the friction material is 2 to 15% by mass, preferably 3 to 12% by mass, and more preferably 3 to 10% by mass. Within this range, the adhesion friction properties of the steel fibers can be effectively controlled, and a friction material having good judder properties and effectiveness stability can be obtained.
　被覆スチール繊維としては、例えば、日本国特表２０１９－５０１３０３号公報に記載されるものや、Ｔｒｉｂｏｔｅｃｃ社製等の市販品を使用できる。 As the coated steel fiber, for example, those described in Japanese Patent Application Publication No. 2019-501303, commercially available products manufactured by Tribotecc, etc. can be used.
　繊維基材としては、上記の被覆スチール繊維以外に、他の繊維基材を使用できる。他の繊維基材としては、通常用いられる種々の有機繊維、無機繊維、金属繊維が使用されるが、銅成分を含む銅繊維や青銅繊維は使用しないことが好ましい。 As the fiber base material, other fiber base materials can be used in addition to the above-mentioned coated steel fibers. As other fiber base materials, various commonly used organic fibers, inorganic fibers, and metal fibers are used, but it is preferable not to use copper fibers or bronze fibers containing a copper component.
　有機繊維としては、例えば芳香族ポリアミド（アラミド）繊維、耐炎性アクリル繊維が挙げられ、無機繊維としては、例えばセラミック繊維、生体溶解性無機繊維、ガラス繊維、カーボン繊維、ロックウール等が挙げられ、また、金属繊維としては、例えば被覆されていないスチール繊維が挙げられる。これらは各々単独、または２種以上組み合わせて用いられる。
　また、摩擦材における他の繊維基材の含有量は、好ましくは３～３０質量％、より好ましくは５～２０質量％である。 Examples of organic fibers include aromatic polyamide (aramid) fibers and flame-resistant acrylic fibers; examples of inorganic fibers include ceramic fibers, biosoluble inorganic fibers, glass fibers, carbon fibers, rock wool, etc. Furthermore, examples of metal fibers include uncoated steel fibers. Each of these may be used alone or in combination of two or more.
Further, the content of other fiber base materials in the friction material is preferably 3 to 30% by mass, more preferably 5 to 20% by mass.
＜摩擦調整材＞
　摩擦調整材は、耐摩耗性、耐熱性、耐フェード性等の所望の摩擦特性を摩擦材に付与するために用いられる。 <Friction adjustment material>
Friction modifiers are used to impart desired friction properties such as wear resistance, heat resistance, and fade resistance to friction materials.
　本発明の摩擦材は、摩擦調整材としてコークスを２～１０質量％含有する。上記特定量の被覆スチール繊維と特定量のコークスを含むことで、良好なジャダー特性と効き安定性を有する摩擦材が得られる。摩擦材におけるコークスの含有量は好ましくは２～８質量％、より好ましくは２～７質量％である。 The friction material of the present invention contains 2 to 10% by mass of coke as a friction modifier. By containing the specified amount of coated steel fibers and the specified amount of coke, a friction material having good judder characteristics and effectiveness stability can be obtained. The content of coke in the friction material is preferably 2 to 8% by mass, more preferably 2 to 7% by mass.
　コークスとしては、好ましくは平均粒子径２００～１０００μｍのものを用いる。平均粒子径が２００μｍ以上であれば高温域で耐摩耗性が改善され、また１０００μｍ以下であれば偏析を起こしにくく、クラックの発生を抑制することができる。 The coke used preferably has an average particle diameter of 200 to 1000 μm. If the average particle diameter is 200 μm or more, wear resistance is improved in a high temperature range, and if it is 1000 μm or less, segregation is less likely to occur and cracking can be suppressed.
　コークスの種類には石炭コークスと石油コークスがあり、いずれも使用することができる。良質の石炭を原料とする石炭コークスは高価であるために使用しにくいが、石油コークスは品質にばらつきが少なく、価格も低廉であり、容易に入手することができるので、石油コークスを使用することが好ましい。 There are two types of coke: coal coke and petroleum coke, both of which can be used. Coal coke, which is made from high-quality coal, is expensive and difficult to use, but petroleum coke has less variation in quality, is inexpensive, and can be easily obtained, so petroleum coke is preferred. is preferred.
　本発明の摩擦材は、摩擦調整材として黒鉛をさらに含有することが好ましい。コークス
に加え黒鉛を併用することで、適度な潤滑性を付与することができ、研削材の相手材攻撃性を抑制し、摩擦係数を確保することができる。
　摩擦材におけるコークスと黒鉛の合計含有量は、摩擦係数の確保と耐摩耗性の両立の観点から、好ましくは１～１２質量％であり、より好ましくは５～１２質量％である。
　また、コークスと黒鉛の比率は、摩擦係数の確保と耐摩耗性の両立の観点から、好ましくはコークス：黒鉛（質量比）＝３：１～１：３である。 It is preferable that the friction material of the present invention further contains graphite as a friction modifier. By using graphite in addition to coke, appropriate lubricity can be imparted, suppressing the aggressiveness of the abrasive to the mating material, and ensuring a good friction coefficient.
The total content of coke and graphite in the friction material is preferably 1 to 12% by mass, more preferably 5 to 12% by mass, from the viewpoint of ensuring both a friction coefficient and wear resistance.
Further, the ratio of coke to graphite is preferably coke:graphite (mass ratio) = 3:1 to 1:3 from the viewpoint of ensuring both a friction coefficient and wear resistance.
　黒鉛は、摩擦材に通常用いられるものを使用することができ、天然黒鉛又は人造黒鉛のいずれでもよい。
　また黒鉛の平均粒子径は、耐摩耗性の観点から好ましくは１０～１０００μｍであり、より好ましくは２００～８００μｍである。 Graphite that is commonly used for friction materials can be used, and may be either natural graphite or artificial graphite.
Further, the average particle diameter of graphite is preferably 10 to 1000 μm, more preferably 200 to 800 μm from the viewpoint of wear resistance.
　なお、平均粒子径は、レーザー回折式粒度分布測定装置によって測定した体積基準の累積百分率５０％相当粒子径（Ｄ５０）の値により求めることができる。また、平均粒子径は、ふるい分け法によって測定することもできる。 Note that the average particle diameter can be determined by the value of the particle diameter equivalent to 50% cumulative percentage on a volume basis (D50) measured by a laser diffraction particle size distribution analyzer. Moreover, the average particle diameter can also be measured by a sieving method.
　摩擦調整材としては、上記以外に他の摩擦調整材を使用でき、例えば無機充填材、有機充填材、研削材、固体潤滑材、金属粉末等が挙げられる。 As the friction modifier, other friction modifiers other than those mentioned above can be used, such as inorganic fillers, organic fillers, abrasives, solid lubricants, metal powders, and the like.
　無機充填材としては、チタン酸カリウム、チタン酸リチウム、チタン酸リチウムカリウム、チタン酸ナトリウム、チタン酸カルシウム、チタン酸マグネシウム、チタン酸マグネシウムカリウム等のチタン酸塩、硫酸バリウム、炭酸カルシウム、水酸化カルシウム、バーミキュライト、マイカ等の無機材料等が挙げられる。これらは各々単独で、または２種以上組み合わせて用いられる。
　また、摩擦材における無機充填材の含有量は、摩擦材全体中、好ましくは１～５０質量％、より好ましくは１０～５０質量％である。 Inorganic fillers include titanates such as potassium titanate, lithium titanate, lithium potassium titanate, sodium titanate, calcium titanate, magnesium titanate, magnesium potassium titanate, barium sulfate, calcium carbonate, and calcium hydroxide. , vermiculite, mica, and other inorganic materials. Each of these may be used alone or in combination of two or more.
Further, the content of the inorganic filler in the friction material is preferably 1 to 50% by mass, more preferably 10 to 50% by mass based on the entire friction material.
　有機充填材としては、各種ゴム粉末（生ゴム粉末、タイヤ粉末等）、カシューダスト、メラミンダスト等が挙げられる。これらは各々単独、または２種以上組み合わせて用いられる。
　また、摩擦材における有機充填材の含有量は、摩擦材全体中、好ましくは１～２０質量％、より好ましくは１～１０質量％である。 Examples of the organic filler include various rubber powders (raw rubber powder, tire powder, etc.), cashew dust, melamine dust, and the like. Each of these may be used alone or in combination of two or more.
Further, the content of the organic filler in the friction material is preferably 1 to 20% by mass, more preferably 1 to 10% by mass based on the entire friction material.
　研削材としては、アルミナ、シリカ、酸化マグネシウム、酸化ジルコニウム、ケイ酸ジルコニウム、酸化クロム、四三酸化鉄（Ｆｅ３Ｏ４）、クロマイト等が挙げられる。これらは各々単独、または２種以上組み合わせて用いられる。
　また、摩擦材における研削材の含有量は、摩擦材全体中、好ましくは１～３０質量％、より好ましくは５～２５質量％である。 Examples of the abrasive material include alumina, silica, magnesium oxide, zirconium oxide, zirconium silicate, chromium oxide, triiron tetraoxide (Fe 3 O 4 ), chromite, and the like. Each of these may be used alone or in combination of two or more.
Further, the content of the abrasive in the friction material is preferably 1 to 30% by mass, more preferably 5 to 25% by mass based on the entire friction material.
　固体潤滑材としては、三硫化アンチモン、二硫化モリブデン、硫化錫、ポリテトラフルオロエチレン（ＰＴＦＥ）等が挙げられる。これらは各々単独、または２種以上組み合わせて用いられる。
　また、摩擦材における固体潤滑材の含有量は、摩擦材全体中、好ましくは１～３０質量％、より好ましくは５～２５質量％である。 Examples of solid lubricants include antimony trisulfide, molybdenum disulfide, tin sulfide, polytetrafluoroethylene (PTFE), and the like. Each of these may be used alone or in combination of two or more.
Further, the content of the solid lubricant in the friction material is preferably 1 to 30% by mass, more preferably 5 to 25% by mass based on the entire friction material.
　金属粉末としては、例えば、アルミニウム、錫、亜鉛等の金属粉末が挙げられる。これらは各々単独、または２種以上組み合わせて用いられる。
　また、摩擦材における金属粉末の含有量は、摩擦材全体中、好ましくは１～１０質量％、より好ましくは１～５質量％である。 Examples of the metal powder include metal powders such as aluminum, tin, and zinc. Each of these may be used alone or in combination of two or more.
Further, the content of metal powder in the friction material is preferably 1 to 10% by mass, more preferably 1 to 5% by mass based on the entire friction material.
　摩擦材における摩擦調整材の含有量は、上記所望の摩擦特性を摩擦材に十分付与する観点から、摩擦材全体中、好ましくは５０～９０質量％、より好ましくは６０～９０質量％である。 The content of the friction modifier in the friction material is preferably 50 to 90% by mass, more preferably 60 to 90% by mass, based on the entire friction material, from the viewpoint of sufficiently imparting the desired friction characteristics to the friction material.
＜結合材＞
　本発明に係る摩擦材に含まれる結合材としては、通常用いられる種々の結合材を用いることができる。具体的には、ストレートフェノール樹脂、エラストマー等による各種変性フェノール樹脂、メラミン樹脂、エポキシ樹脂、ポリイミド樹脂等の熱硬化性樹脂が挙げられる。エラストマー変性フェノール樹脂としては、アクリルゴム変性フェノール樹脂やシリコーンゴム変性フェノール樹脂、ニトリルゴム（ＮＢＲ）変性フェノール樹脂等が挙げられる。なお、これらの結合材は単独または２種以上組み合わせて用いることができる。
　また、摩擦材における結合材の含有量は、摩擦材全体中、好ましくは１～２０質量％、より好ましくは３～１５質量％である。 <Binding material>
As the binder contained in the friction material according to the present invention, various commonly used binders can be used. Specifically, thermosetting resins such as straight phenol resins, various modified phenol resins such as elastomers, melamine resins, epoxy resins, and polyimide resins are mentioned. Examples of the elastomer-modified phenol resin include acrylic rubber-modified phenol resin, silicone rubber-modified phenol resin, and nitrile rubber (NBR)-modified phenol resin. Note that these binders can be used alone or in combination of two or more.
Further, the content of the binder in the friction material is preferably 1 to 20% by mass, more preferably 3 to 15% by mass based on the entire friction material.
　本発明の摩擦材は銅成分を含有しないことが好ましい。なお、「銅成分を含有しない」とは、銅成分を、耐摩耗性などの機能を発現させるための有効成分としては含有しないという意味であり、例えば、摩擦材中に不可避的にわずかに含まれる不純物等としての銅成分をも含まないことまでを意味するものではない。なお、環境負荷の観点から不純物等として混入する銅成分は０．５質量％以下であることが好ましい。 It is preferable that the friction material of the present invention does not contain a copper component. Note that "contains no copper component" means that it does not contain a copper component as an active component for exerting functions such as wear resistance.For example, if a friction material contains a small amount of copper component This does not mean that it does not contain copper components as impurities. In addition, from the viewpoint of environmental load, it is preferable that the copper component mixed as an impurity etc. is 0.5% by mass or less.
　本発明に係る摩擦材の製造方法の具体的な態様としては、公知の製造工程により行うことができ、例えば、上記各成分を配合し、その配合物を通常の製法に従って予備成形、熱成形、加熱、研摩等の工程を経て摩擦材を作製することができる。
　摩擦材を備えたブレーキパッドの製造における一般的な工程を以下に示す。
（ａ）板金プレスによりプレッシャプレートを所定の形状に成形する工程、
（ｂ）上記プレッシャプレートに脱脂処理、化成処理及びプライマー処理を施し、接着剤を塗布する工程、
（ｃ）繊維基材、摩擦調整材、及び結合材等の原料を配合し、撹拌により十分に均質化して、常温にて所定の圧力で成形して予備成形体を作製する工程、
（ｄ）上記予備成形体と接着剤が塗布されたプレッシャプレートとを、所定の温度及び圧力を加えて両部材を一体に固着する熱成形工程（成形温度１３０～１８０℃、成形圧力３０～８０ＭＰａ、成形時間２～１０分間）、
（ｅ）アフターキュア（１５０～３００℃、１～５時間）を行って、最終的に研摩、表面焼き、及び塗装等の仕上げ処理を施す工程。 A specific embodiment of the method for manufacturing the friction material according to the present invention can be carried out by a known manufacturing process. For example, the above components are blended, and the blend is preformed, thermoformed, Friction materials can be produced through processes such as heating and polishing.
The general steps in manufacturing brake pads with friction material are shown below.
(a) a step of forming the pressure plate into a predetermined shape using a sheet metal press;
(b) a step of subjecting the pressure plate to degreasing treatment, chemical conversion treatment, and primer treatment, and applying adhesive;
(c) a step of blending raw materials such as a fiber base material, a friction modifier, and a binder, sufficiently homogenizing them by stirring, and molding them at a predetermined pressure at room temperature to produce a preformed body;
(d) A thermoforming step in which the preformed body and the pressure plate coated with adhesive are fixed together by applying a predetermined temperature and pressure (molding temperature: 130-180°C, molding pressure: 30-80 MPa) , molding time 2-10 minutes),
(e) After-curing (150-300°C, 1-5 hours) and finally applying finishing treatments such as polishing, surface baking, and painting.
　以下、実施例により本発明を具体的に説明する。ただし、本発明はこれらの実施例のみに限定されるものではない。 Hereinafter, the present invention will be specifically explained with reference to Examples. However, the present invention is not limited only to these examples.
（実施例１～８、比較例１～１３）
　後述する表３または表４に示す摩擦材配合組成の原材料をミキサーにて５分間混合し、混合された攪拌材料を金型に投入し、予備成形及び加熱加圧成形を実施し摩擦材を作製した。
　なお金属硫化物で被覆されているスチール繊維として下記のものを使用した。
・硫化鉄コーティング（スチール）繊維：Ｔｒｉｂｏｔｅｃｃ社製、商品名：ＳＦ１５０
・硫化錫コーティング（スチール）繊維：Ｔｒｉｂｏｔｅｃｃ社製、商品名：ＳＦ１００
　予備成形は圧力２０ＭＰａにて１０秒間加圧することによって実施した。
　この予備成形体を圧力３５ＭＰａ、成形温度１５０℃にて６分間加熱加圧成形を行い、熱成形体を作成した。
　熱成形体に対し温度２５０℃にて３時間のアフターキュアを実施し、所定の厚さに加工、研摩、塗装を実施して、各摩擦材を作製した。 (Examples 1 to 8, Comparative Examples 1 to 13)
The raw materials having the friction material composition shown in Table 3 or Table 4 described later are mixed in a mixer for 5 minutes, the mixed stirring material is put into a mold, and preforming and heating and pressure molding are performed to produce a friction material. did.
The following steel fibers coated with metal sulfide were used.
・Iron sulfide coating (steel) fiber: manufactured by Tribotecc, product name: SF150
・Tin sulfide coating (steel) fiber: manufactured by Tribotecc, product name: SF100
Preforming was carried out by applying a pressure of 20 MPa for 10 seconds.
This preform was subjected to heating and pressure molding at a pressure of 35 MPa and a molding temperature of 150° C. for 6 minutes to create a thermoformed product.
The thermoformed bodies were subjected to after-curing at a temperature of 250° C. for 3 hours, processed to a predetermined thickness, polished, and painted to produce each friction material.
＜摩擦材の評価試験＞
　上記作製した実施例および比較例の摩擦材について、ジャダー試験、効き特性試験、フェード試験を行った。 <Friction material evaluation test>
A judder test, an effectiveness characteristic test, and a fade test were conducted on the friction materials of Examples and Comparative Examples produced above.
（１）ジャダー試験
　各摩擦材を使用し、下記表１の試験条件に基づきＮｏ．２～Ｎｏ．３を３０サイクル繰り返してフルサイズのダイナモメータを用いて実施した後、ＤＴＶ（Ｄｉｓｃ　Ｔｈｉｃｋｎｅｓｓ　Ｖａｒｉａｔｉｏｎ：ディスク肉厚変動）を測定した。 (1) Judder test Using each friction material, No. 2~No. 3 was repeated for 30 cycles using a full-size dynamometer, and then DTV (Disc Thickness Variation) was measured.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　ジャダー試験評価基準：測定したＤＴＶを、下記判断基準に基づき判定した。
　◎：０以上、５．０μｍ未満
　○：５．０以上、１０．０μｍ未満
　△：１０．０以上、２０．０μｍ未満
　×：２０．０μｍ以上 Judder test evaluation criteria: The measured DTV was judged based on the following criteria.
◎: 0 or more, less than 5.0 μm ○: 5.0 or more, less than 10.0 μm △: 10.0 or more, less than 20.0 μm ×: 20.0 μm or more
（２）一般性能試験
　各摩擦材を使用し、ＪＡＳＯ　Ｃ４０６「乗用車ブレーキ装置ダイナモメータ試験方法」に準拠した一般性能試験をフルサイズのダイナモメータを用いて実施した。第２効力試験の初速度５０ｋｍ／ｈ、１００ｋｍ／ｈにおける平均摩擦係数を測定した。。
　一般性能試験評価基準：測定した平均摩擦係数を下記判断基準に基づき判断した。
　◎：０．４３以上０．４７未満、
　○：０．４０以上０．４３未満　または、０．４７以上０．５０未満
　×：上記以外 (2) General performance test Using each friction material, a general performance test was conducted using a full-size dynamometer in accordance with JASO C406 "Passenger car brake system dynamometer test method." The average friction coefficient was measured at an initial speed of 50 km/h and 100 km/h in the second effectiveness test. .
General performance test evaluation criteria: The measured average coefficient of friction was judged based on the following criteria.
◎: 0.43 or more and less than 0.47,
○: 0.40 or more and less than 0.43 or 0.47 or more and less than 0.50 ×: Other than the above
（３）高速フェード試験
　各摩擦材を使用し、下記表２の試験条件に基づきフルサイズのダイナモメータを用いて実施した。最終制動時の瞬時最低摩擦係数を測定した。なお最終制動時は、終速時温度が７５０℃になるように設定した。 (3) High-speed fade test Each friction material was used and a full-size dynamometer was used to conduct the test based on the test conditions shown in Table 2 below. The instantaneous minimum coefficient of friction during final braking was measured. Note that during final braking, the temperature at final speed was set to 750°C.
Figure JPOXMLDOC01-appb-T000002
Figure JPOXMLDOC01-appb-T000002
　高速フェード試験評価基準：測定した瞬時最低摩擦係数を下記判断基準に基づき判断した。
　◎：０．１７以上
　○：０．１６以上
　△：０．１５以上
　×：０．１５未満もしくは液圧上限により停止せず High-speed fade test evaluation criteria: The measured minimum instantaneous friction coefficient was judged based on the following criteria.
◎: 0.17 or more ○: 0.16 or more △: 0.15 or more ×: Less than 0.15 or does not stop due to upper limit of hydraulic pressure
　得られた評価結果を下記表３および表４に示す。 The obtained evaluation results are shown in Tables 3 and 4 below.
Figure JPOXMLDOC01-appb-T000003
Figure JPOXMLDOC01-appb-T000003
Figure JPOXMLDOC01-appb-T000004
Figure JPOXMLDOC01-appb-T000004
　上記結果より、金属硫化物で被覆されている特定量のスチール繊維と、特定量のコークスとを含有する実施例１～８の摩擦材は、十分な摩擦係数を維持し、比較例の摩擦材よりも、安定した高い効きを有し、またジャダー特性が良好な結果となった。 From the above results, the friction materials of Examples 1 to 8 containing a specific amount of steel fibers coated with metal sulfide and a specific amount of coke maintain sufficient friction coefficients, and the friction materials of Comparative Examples It had more stable and high effectiveness than the previous one, and had better judder characteristics.
　本発明を詳細にまた特定の実施態様を参照して説明したが、本発明の精神と範囲を逸脱することなく様々な変更や修正を加えることができることは当業者にとって明らかである。本出願は２０２２年３月２９日出願の日本特許出願（特願２０２２－０５４１０４）に基づくものであり、その内容はここに参照として取り込まれる。 Although the invention has been described in detail and with reference to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention. This application is based on a Japanese patent application (Japanese Patent Application No. 2022-054104) filed on March 29, 2022, the contents of which are incorporated herein by reference.

Claims (4)

  1. 　摩擦調整材、繊維基材及び結合材を含有する摩擦材であって、
    　前記摩擦調整材として、コークスを２～１０質量％含有し、
    　前記繊維基材として、金属硫化物で被覆されているスチール繊維を２～１５質量％含有する摩擦材。     A friction material containing a friction modifier, a fiber base material, and a binder,
    The friction modifier contains 2 to 10% by mass of coke,
    A friction material containing 2 to 15% by mass of steel fibers coated with metal sulfide as the fiber base material.
  2. 　前記金属硫化物が硫化鉄及び硫化錫の少なくとも一方を含有する、請求項１に記載の摩擦材。 The friction material according to claim 1, wherein the metal sulfide contains at least one of iron sulfide and tin sulfide.
  3. 　前記摩擦調整材として黒鉛をさらに含有し、
    　前記コークスと前記黒鉛の合計含有量が１～１２質量％である、請求項１又は２に記載の摩擦材。     Further containing graphite as the friction modifier,
    The friction material according to claim 1 or 2, wherein the total content of the coke and the graphite is 1 to 12% by mass.
  4. 　銅成分を含有しない、請求項１又は２に記載の摩擦材。 The friction material according to claim 1 or 2, which does not contain a copper component.
PCT/JP2023/011333 2022-03-29 2023-03-22 Friction material WO2023189976A1 (en)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2009132816A (en) * 2007-11-30 2009-06-18 Advics Co Ltd Friction material
JP2015530532A (en) * 2012-08-07 2015-10-15 アイティーティー・イタリア・エス．アール．エル Friction material
JP2016027086A (en) * 2014-05-12 2016-02-18 アイティーティー マニュファクチャリング エンタープライジーズ エルエルシー Friction material
JP2016121243A (en) * 2014-12-24 2016-07-07 日本ブレーキ工業株式会社 Friction material composition, and friction material and friction member using the same
JP2019501303A (en) * 2015-10-20 2019-01-17 トリボテック ゲーエムベーハー Tribological fiber

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2009132816A (en) * 2007-11-30 2009-06-18 Advics Co Ltd Friction material
JP2015530532A (en) * 2012-08-07 2015-10-15 アイティーティー・イタリア・エス．アール．エル Friction material
JP2016027086A (en) * 2014-05-12 2016-02-18 アイティーティー マニュファクチャリング エンタープライジーズ エルエルシー Friction material
JP2016121243A (en) * 2014-12-24 2016-07-07 日本ブレーキ工業株式会社 Friction material composition, and friction material and friction member using the same
JP2019501303A (en) * 2015-10-20 2019-01-17 トリボテック ゲーエムベーハー Tribological fiber

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