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JP2642076B2 - Manufacturing method of friction material assembly - Google Patents
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JP2642076B2 - Manufacturing method of friction material assembly - Google Patents

Manufacturing method of friction material assembly

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Publication number
JP2642076B2
JP2642076B2 JP4183995A JP4183995A JP2642076B2 JP 2642076 B2 JP2642076 B2 JP 2642076B2 JP 4183995 A JP4183995 A JP 4183995A JP 4183995 A JP4183995 A JP 4183995A JP 2642076 B2 JP2642076 B2 JP 2642076B2
Authority
JP
Japan
Prior art keywords
friction material
back metal
adhesive
pad
organic film
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
JP4183995A
Other languages
Japanese (ja)
Other versions
JPH07269618A (en
Inventor
光彦 中川
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sumitomo Electric Industries Ltd
Original Assignee
Sumitomo Electric Industries Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sumitomo Electric Industries Ltd filed Critical Sumitomo Electric Industries Ltd
Priority to JP4183995A priority Critical patent/JP2642076B2/en
Publication of JPH07269618A publication Critical patent/JPH07269618A/en
Application granted granted Critical
Publication of JP2642076B2 publication Critical patent/JP2642076B2/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Description

【発明の詳細な説明】DETAILED DESCRIPTION OF THE INVENTION

【0001】[0001]

【産業上の利用分野】この発明は、摩擦材アッセンブリ
ーに関し、特に、乗用車などに用いられるブレーキに使
用される摩擦材アッセンブリーの製造方法に関する。
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a friction material assembly, and more particularly to a method of manufacturing a friction material assembly used for a brake used in a passenger car or the like.

【0002】[0002]

【従来の技術】摩擦材アッセンブリーの代表としてディ
スクブレーキやパッドをとりあげて以下に説明する。
2. Description of the Related Art Disc brakes and pads will be described below as representatives of a friction material assembly.

【0003】従来、一般的に知られているディスクパッ
ドは、裏金上に摩擦材であるパッドを接合して構成さ
れ、回転するディスクをパッドで押圧し、その摩擦力に
よってディスクの回転を静止し自動車の走行を停止する
ものであり、この場合、ディスクパッドは強大な剪断力
と摩擦熱を受けるばかりでなく、さらに直接外気にさら
されているため風雨やNaCl,CaCl2 などの融雪
剤の影響を直接受けることから機械的強度および腐食条
件において非常に厳しい環境下に置かれる。
Conventionally, a generally known disk pad is formed by joining a pad which is a friction material on a backing metal, pressing a rotating disk with the pad and stopping the rotation of the disk by the frictional force. In this case, the driving of the automobile is stopped. In this case, the disk pad is not only subjected to a strong shearing force and frictional heat, but also exposed directly to the outside air, so that it is affected by wind and rain and a snow melting agent such as NaCl and CaCl 2. Is subjected to a very severe environment in mechanical strength and corrosive conditions.

【0004】一方、ディスクブレーキは安全上万一の故
障も許されないものであり、ディスクパッドにおいて特
にパッドと裏金の接着面は絶対破断することのない接着
強度を有する必要がある。
[0004] On the other hand, a disc brake is one in which a failure is not tolerated for safety reasons, and in particular, the bonding surface between the pad and the back metal of the disk pad needs to have an adhesive strength that never breaks.

【0005】このため、従来は裏金の表面にショットに
より凹凸部を形成しパッドとの接着力を機械的に強化し
ている。しかし、この方法はブレーキが新しいうちは有
効であるが、長期間使用した場合、寒冷地などにおいて
塩分を含んだ道路を走行した場合などは裏金のボス孔部
に錆が発生し、これが次第にパッドと裏金の接着面にま
で拡がりパッドと裏金の剥離や接着力の低下により自動
車走行時における制動不具合を引起し、ついに事故を発
生する危険があった。
For this reason, conventionally, an uneven portion is formed by shots on the surface of the back metal to mechanically strengthen the adhesive force with the pad. However, this method is effective as long as the brake is new.However, if the brake is used for a long period of time, or when traveling on a salty road in a cold area, rust will be generated in the boss hole of the backing metal, There is a danger that a brake failure may occur when the vehicle is running due to the peeling of the pad and the back metal and a decrease in the adhesive strength, and finally an accident may occur.

【0006】そこで、裏金とパッドとの間に錆を防止す
る方法として、たとえば、特公昭57−45939号公
報,特開昭51−24533号公報,特開昭59−14
4836号公報に開示されている方法がある。以下、順
に説明する。
Therefore, as a method for preventing rust between the back metal and the pad, for example, Japanese Patent Publication No. 57-45939, Japanese Patent Application Laid-Open No. 51-24533, and Japanese Patent Application Laid-Open No.
No. 4836 discloses a method. Hereinafter, description will be made in order.

【0007】特公昭57−45939号公報には、裏金
の表面に、厚みが0.1〜5.0μmの四三酸化鉄層を
形成することが開示されている。しかし、この方法で
は、ディスクパッドに要求される信頼性を満足させるほ
どの顕著な防錆効果を得ることができないという欠点が
あった。
[0007] JP-B-57-45939 discloses that a triiron tetroxide layer having a thickness of 0.1 to 5.0 µm is formed on the surface of a back metal. However, this method has a drawback that it is not possible to obtain a remarkable rust prevention effect that satisfies the reliability required for the disk pad.

【0008】特開昭51−24533号公報には、裏金
にガス軟窒化処理を施して裏金の防錆力を向上させるこ
とが開示されている。しかし、この方法では、工程が複
雑になり、さらに、コストおよび防錆の点で著しい効果
が得られない欠点がある。
Japanese Patent Application Laid-Open No. 51-24533 discloses that the back metal is subjected to a gas nitrocarburizing treatment to improve the rust prevention of the back metal. However, this method has the drawback that the process becomes complicated, and that no remarkable effects can be obtained in terms of cost and rust prevention.

【0009】特開昭59−144836号公報には、裏
金の表面に、粒子径が5μmのZn粒子を5重量%含有
するクロム酸処理液を塗布することにより防錆力の向上
を図ることが開示されている。しかし、このクロム酸処
理液は、安全・衛生・公害上の見地から取扱い上困難を
伴なうとともに、コスト的にも高価となる欠点がある。
Japanese Unexamined Patent Publication (Kokai) No. 59-144,836 discloses that a chromic acid treatment liquid containing 5% by weight of Zn particles having a particle diameter of 5 μm is applied to the surface of a back metal to improve rust prevention. It has been disclosed. However, this chromic acid treatment liquid has drawbacks that it is difficult to handle from the viewpoint of safety, hygiene and pollution, and that it is expensive.

【0010】[0010]

【発明が解決しようとする課題】上述のように、裏金と
パッドとの間に発生する錆を防止するために種々の方法
が提案されている。しかし、どの方法もディスクパッド
に要求される信頼性に耐え得るほどの防錆効果を得るこ
とは困難であり、また、たとえ得たとしても安全・衛生
・公害上の問題やコスト面での問題があった。また、従
来のディスクパッドは、裏金と摩擦材とが接着剤を介し
て一体形成される。接着剤は摩擦材の成形時の熱や圧力
で延伸され、かつ摩擦材にも吸収されるので実質的に厚
みを特定できない。たとえ接着剤の厚みを大きくしたと
しても、その接着剤が硬化するまでは流動性を持つため
同様である。したがって、従来のディスクパッドでは接
着剤に防錆効果を期待するのは困難であった。
As described above, various methods have been proposed to prevent rust generated between the back metal and the pad. However, it is difficult to obtain a rust-preventive effect that can withstand the reliability required of the disc pad by any of the methods, and even if it is obtained, there is a problem in terms of safety, health, pollution, and cost. was there. Further, in the conventional disk pad, the back metal and the friction material are integrally formed via an adhesive. Since the adhesive is stretched by heat and pressure during molding of the friction material and is absorbed by the friction material, the thickness cannot be substantially specified. Even if the thickness of the adhesive is increased, the same applies because the adhesive has fluidity until it is cured. Therefore, it has been difficult to expect the adhesive to have a rust-preventive effect with the conventional disk pad.

【0011】この発明は、上記のような課題を解決する
ためになされたもので、ディスクパッドに要求される信
頼性に耐え得る防錆性を備えたディスクパッドの製造方
法を提供することを目的とする。
SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and has as its object to provide a method for manufacturing a disk pad having rustproofness that can withstand the reliability required for the disk pad. And

【0012】[0012]

【課題を解決するための手段】この発明における摩擦材
アッセンブリーの製造方法では、裏金の摩擦材に対する
接着面部分に粉体塗装により熱硬化性有機物を膜状に塗
布した後、硬化処理を施すことによって裏金の接着面部
分に熱硬化性有機物の皮膜を形成する。そしてその熱硬
化性有機物の皮膜が形成された裏金の接着面部分に対し
て摩擦材を熱および圧力のうちの少なくとも一方を施し
て接着剤により接着することによって摩擦材と裏金とを
一体的に形成する。
According to a method of manufacturing a friction material assembly according to the present invention, a thermosetting organic material is applied in a film shape to a surface of an adhesive surface of a back metal to a friction material by powder coating and then subjected to a curing treatment. As a result, a thermosetting organic film is formed on the bonding surface of the back metal. Then, the friction material and the back metal are integrally formed by applying at least one of heat and pressure to the friction material on the bonding surface portion of the back metal on which the thermosetting organic material film is formed and bonding the friction material with the adhesive. Form.

【0013】[0013]

【作用】この発明に係る摩擦材アッセンブリーの製造方
法では、裏金の摩擦材に対する接着面部分に硬化処理が
施された熱硬化性有機物の皮膜が形成された後、裏金の
接着面部分に対して摩擦材を熱および圧力のうちの少な
くとも一方を施して接着剤により接着することによって
摩擦材と裏金とが一体的に形成されるので、裏金に形成
された熱硬化性有機物の皮膜が一体成形時の熱や圧力に
影響されない。
In the method of manufacturing a friction material assembly according to the present invention, after a thermosetting organic material film that has been subjected to a hardening treatment is formed on a bonding surface portion of the back metal to the friction material, the bonding surface portion of the back metal is formed on the bonding surface portion. The friction material and the back metal are integrally formed by applying at least one of heat and pressure to the friction material with an adhesive, so that the thermosetting organic film formed on the back metal is integrally formed. It is not affected by heat or pressure.

【0014】[0014]

【実施例】図1は、本発明の一実施例を示したディスク
パッドの断面構造図である。図1を参照して、ディスク
パッドは、鉄系材料であるSAPHからなる裏金1と、
裏金1の表面に形成された防錆のための硬化ずみの有機
皮膜2と、有機皮膜2上にフェノール樹脂性の接着剤層
3を介して形成された、スチールファイバ30重量%,
ガラスファイバ10重量%,アラミド繊維10重量%,
フェノール樹脂20重量%,硫酸バリウム10重量%,
銅粉10重量%,フリクションダスト10重量%からな
る摩擦母材4とを含む。なお、裏金1には、摩擦母材4
との嵌合のためのボス孔5が設けられている。
FIG. 1 is a sectional structural view of a disk pad showing an embodiment of the present invention. Referring to FIG. 1, a disk pad includes a back metal 1 made of an iron-based material, SAPH,
A hardened organic film 2 for rust prevention formed on the surface of the backing metal 1 and a 30% by weight of steel fiber formed on the organic film 2 with a phenolic resin adhesive layer 3 interposed therebetween.
Glass fiber 10% by weight, aramid fiber 10% by weight,
Phenolic resin 20% by weight, barium sulfate 10% by weight,
A friction base material 4 composed of 10% by weight of copper powder and 10% by weight of friction dust. The back metal 1 has a friction base material 4
A boss hole 5 is provided for fitting with the boss.

【0015】次に、図1に示したディスクパッドの製造
方法について説明する。まず、裏金1をトリクレンで洗
浄後、ショットブラストで表面に凹凸を与える。裏金1
の表面に有機皮膜2となるエポキシなどの樹脂粉体を静
電吹付け法で粉体塗装する。実験ベースでは裏金を18
0℃に加熱し100メッシュの金網を通して粉体樹脂を
散布して所定の厚みの有機皮膜を得ることができる。そ
の後、180℃で1時間加熱処理して硬化された有機皮
膜2を完成する。有機皮膜2にフェノール樹脂性の接着
剤を塗布し、80℃で30分間乾燥後摩擦母材4と一緒
に160℃の金型内で一体に成形しさらに200℃で1
0時間熱処理しディスクパッドを得る。なお、有機皮膜
2は、フェノール樹脂に限らず、エポキシ,メラミン,
アクリル,熱硬化性樹脂,ゴムフェノール系の粉体であ
ってもよい。これらの有機物に充填剤,着色剤を加える
ことも考えられるが、無添加の方がより好ましい。ま
た、接着剤2は、有機皮膜2と同一材料もしくは類似材
料を使用するのが望ましい。これは、同一材料もしくは
類似材料を使うことにより、有機皮膜2と接着剤との接
合強度が向上されるためである。有機皮膜2の厚みは、
5μm以上であればかなりの防錆硬化が得られ、好まし
くは10μm,より好ましくは15μm以上が望まし
い。
Next, a method of manufacturing the disk pad shown in FIG. 1 will be described. First, the back metal 1 is washed with trichlene, and then the surface is made uneven by shot blasting. Back money 1
A resin powder such as epoxy which becomes the organic film 2 is powder-coated on the surface of the substrate by an electrostatic spraying method. 18 base metal on an experimental basis
By heating to 0 ° C. and spraying the powder resin through a 100 mesh wire netting, an organic film having a predetermined thickness can be obtained. Thereafter, a heat treatment is performed at 180 ° C. for 1 hour to complete the cured organic film 2. A phenolic resin adhesive is applied to the organic film 2, dried at 80 ° C. for 30 minutes, and integrally molded with the friction base material 4 in a mold at 160 ° C.
Heat treatment for 0 hour to obtain a disk pad. The organic film 2 is not limited to phenol resin, but may be epoxy, melamine,
Acrylic, thermosetting resin, or rubber phenol powder may be used. It is conceivable to add a filler and a colorant to these organic substances, but it is more preferable to add no. It is desirable that the same material as the organic film 2 or a similar material be used for the adhesive 2. This is because the bonding strength between the organic film 2 and the adhesive is improved by using the same material or a similar material. The thickness of the organic film 2 is
If it is 5 μm or more, considerable rust-preventive hardening can be obtained, preferably 10 μm, more preferably 15 μm or more.

【0016】以下に示す表1は、本発明のディスクパッ
ドおよび従来のディスクパッドの接合強度および防錆力
についての試験結果を示した表である。
Table 1 shown below is a table showing the results of tests on the bonding strength and rust prevention of the disk pad of the present invention and the conventional disk pad.

【0017】[0017]

【表1】 [Table 1]

【0018】上記表1を参照して、実施例1は、前述し
た本実施例のディスクパッドの製造方法において、有機
皮膜2の膜厚を30μmとしたものであり、実施例2は
6μm、実施例3は11μmとしたものである。比較例
1は、SAPHからなる裏金を軟窒化処理し、その上に
直接フェノール樹脂接着剤を塗布乾燥し、20μmの接
着剤皮膜を形成し、摩擦母材と一体成形したものであ
る。比較例2はSAPHからなる裏金をトリクレンで洗
浄後、その表面上に四三酸化鉄層を4μm形成した後、
比較例1と同様の処理を行なったものである。
Referring to Table 1, Example 1 is different from the above-described method of manufacturing a disk pad in this example in that the thickness of the organic film 2 was 30 μm, and Example 2 was 6 μm. Example 3 is 11 μm. In Comparative Example 1, a back metal made of SAPH was subjected to a soft nitriding treatment, and a phenol resin adhesive was directly applied thereon and dried to form a 20 μm adhesive film, which was integrally formed with a friction base material. In Comparative Example 2, after cleaning the back metal made of SAPH with trichlorene, a triiron tetroxide layer was formed on the surface thereof at 4 μm.
The same processing as in Comparative Example 1 was performed.

【0019】表1において、実施例1ないし3は比較例
1および2に比べて、剪断強度および防錆力の両方で改
善されていることがわかる。実施例1ないし3の防錆力
は、有機皮膜2の膜厚が厚いほど大きいことがわかる。
また、実施例1のディスクパッドを切断して顕微鏡観察
した結果、25μm前後の有機膜が全面に形成されてい
ることが判明した。つまり、有機皮膜は摩擦母材との一
体成形時の熱や圧力にはほとんど影響されていないので
ある。しかし、比較例1,2はともに明確な厚みを持っ
た皮膜は観察できなかった。
In Table 1, it can be seen that Examples 1 to 3 are improved in both the shear strength and the rust preventive power as compared with Comparative Examples 1 and 2. It can be seen that the rust-preventing power of Examples 1 to 3 increases as the thickness of the organic film 2 increases.
Further, as a result of cutting the disk pad of Example 1 and observing it with a microscope, it was found that an organic film of about 25 μm was formed on the entire surface. In other words, the organic film is hardly affected by heat and pressure during integral molding with the friction base material. However, in Comparative Examples 1 and 2, a film having a clear thickness could not be observed.

【0020】[0020]

【発明の効果】以上のように、この発明によれば、裏金
の摩擦材に対する接着面部分に熱硬化性有機物の皮膜を
粉体塗装により膜状に塗布して硬化処理を行なった後、
摩擦材を接着して摩擦材と裏金とを一体的に形成するこ
とにより、裏金に形成された熱硬化性有機物の皮膜が一
体成形時の熱や圧力に影響されないため、ディスクパッ
ドに要求される信頼性に耐え得る防錆力を実現すること
ができる。
As described above, according to the present invention, a thermosetting organic film is applied to the surface of the back metal to be bonded to the friction material by powder coating, and the film is cured.
By forming the friction material and the back metal integrally by bonding the friction material, the film of the thermosetting organic material formed on the back metal is not affected by heat and pressure during the integral molding, which is required for the disc pad. Rust prevention that can withstand reliability can be achieved.

【図面の簡単な説明】[Brief description of the drawings]

【図1】本発明の一実施例を示したディスクパッドの断
面構造図である。
FIG. 1 is a sectional structural view of a disk pad showing an embodiment of the present invention.

【符号の説明】[Explanation of symbols]

1 裏金 2 有機皮膜 3 接着剤層 4 摩擦母材 DESCRIPTION OF SYMBOLS 1 Back metal 2 Organic film 3 Adhesive layer 4 Friction base material

Claims (1)

(57)【特許請求の範囲】(57) [Claims] 【請求項1】 摩擦材と裏金とを含む摩擦材アッセンブ
リーの製造方法であって、 前記裏金の、前記摩擦材に対する接着面部分に、粉体塗
装により熱硬化性有機物を膜状に塗布した後、硬化処理
を施すことによって前記裏金の接着面部分に前記熱硬化
性有機物の皮膜を形成する工程と、 前記熱硬化性有機物の皮膜が形成された裏金の接着面部
分に対して、前記摩擦材を、熱および圧力のうちの少な
くとも一方を施して接着剤により接着することによっ
て、前記摩擦材と前記裏金とを一体的に形成する工程と
を備えた、摩擦材アッセンブリーの製造方法。
1. A method of manufacturing a friction material assembly including a friction material and a back metal, comprising: applying a thermosetting organic material in a film shape to a surface of the back metal bonded to the friction material by powder coating. Forming a film of the thermosetting organic material on the bonding surface portion of the back metal by performing a curing process; and applying the friction material to the bonding surface portion of the back metal on which the thermosetting organic film is formed. Forming the friction material and the back metal integrally by applying at least one of heat and pressure with an adhesive to obtain a friction material assembly.
JP4183995A 1995-03-01 1995-03-01 Manufacturing method of friction material assembly Expired - Fee Related JP2642076B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP4183995A JP2642076B2 (en) 1995-03-01 1995-03-01 Manufacturing method of friction material assembly

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP4183995A JP2642076B2 (en) 1995-03-01 1995-03-01 Manufacturing method of friction material assembly

Publications (2)

Publication Number Publication Date
JPH07269618A JPH07269618A (en) 1995-10-20
JP2642076B2 true JP2642076B2 (en) 1997-08-20

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Country Link
JP (1) JP2642076B2 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5328609B2 (en) * 2009-10-28 2013-10-30 日立オートモティブシステムズ株式会社 Brake pads

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6350568B2 (en) 2016-03-09 2018-07-04 コベルコ建機株式会社 Upper swing body

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6350568B2 (en) 2016-03-09 2018-07-04 コベルコ建機株式会社 Upper swing body

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