JPH11325140A - Friction material for rotor made of aluminum alloy composite material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sufficiently high friction coefficient for a rotor made of an aluminum alloy composite material by containing metallic compound particles identical to a reinforcement. SOLUTION: A friction material is prepared by dispersing metallic compound particles identical to the reinforcement of the aluminum alloy composite material of a rotor in an organic binding material. A disk pad for a disk brake is formed to have a specified shape by plate pressing, and subjected to a defatting or primer treatment, a back plate coated with adhesive, a fiber material such as a heat resistant organic fiber, an inorganic fiber, a metallic fiber or the like, an inorganic/organic filler, and a powder raw material such as friction adjusting agents, a thermosetting resin binder or the like are blended, a stirred material sufficiently made uniform by stirring is molded by a specified pressure at a normal temperature, and then a premolded body is produced. In a thermomolding process, thermomolding is carried out by specified temperature and pressure to integrally fix both members, post-curing is executed and finishing treatment is carried out. Thus, a largest friction coefficient is provided.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a friction material used for a disc brake used for automobiles, railway vehicles and various industrial machines, and more particularly to an organic friction material used for a disc brake using a rotor made of an aluminum alloy composite material. The present invention relates to a friction material capable of obtaining a large friction coefficient.

[0002]

2. Description of the Related Art Conventionally, cast iron rotors have been used for disc brakes used in automobiles, railway vehicles, and various industrial machines. Cast iron rotors are also excellent in friction performance, but have the disadvantage of being heavy, and aluminum rotors have been developed to solve this problem. For the purpose of improving the mechanical strength of the rotor, alumina (Al) having a particle size of 5 to 100 μm is contained in an aluminum alloy matrix.
₂ O ₃ ), silicon nitride (Si ₃ N ₄ ), silicon carbide (Si
There is a rotor material (JP-A-2-25538) composed of a particle dispersion strengthened aluminum alloy in which reinforcing particles such as C) are dispersed by 1 to 7% by weight. Moreover, Si4.0-
12.0%, Cu 2.0-6.0%, the balance being Al
Al in the aluminum alloy consisting of unavoidable impurities
_A rotor material in which ceramic particles such as ₂ O ₃ and SiC are dispersed (JP-A-4-173936) has been proposed.

[0003] Since such an aluminum alloy rotor material is manufactured as a cast material in which reinforcing particles are added to a molten aluminum alloy, uniform dispersion of the reinforcing particles in an aluminum alloy matrix is difficult. The wettability between the particles and the aluminum alloy is not always good, and sufficient characteristics such as abrasion resistance may not be obtained. Therefore, in order to increase the heat resistance, the alloy contains Si2 to 10%, Ni, An aluminum alloy powder compact containing one or more of Cu, Fe, Zn, Mn, Ti, Zr, and Cr in a total amount of 2% or less, and the balance being Al and unavoidable impurities. In the matrix,
An aluminum alloy composite for a disc brake having a thermal conductivity of 180 W / mK or more, in which one or two of SiC and AlN particles having an average particle diameter of 1 to 15 μm are dispersed in a total amount of 3 to 15% (Japanese Patent Laid-Open No. No. 9-184037). In addition, in order to improve mechanical strength, metal compound particles are further increased as a reinforcing material (for example, 5 to 40).
wt%) have been developed.

[0004]

The aluminum alloy rotor material has been improved as described above. However, when this aluminum alloy composite rotor material is used in combination with a conventional organic friction material, cast iron is used. There is a problem that the friction coefficient is significantly reduced as compared with the combination of the rotor and the organic friction material. SUMMARY OF THE INVENTION An object of the present invention is to obtain a combination of a rotor made of an aluminum alloy composite material and a conventional organic friction material so that a sufficiently high friction coefficient can be obtained.

[0005]

The present invention has solved the above-mentioned problems by the following means. (1) An organic friction material for a disc brake using a rotor made of an aluminum alloy composite material containing metal compound particles as a reinforcing material, wherein the friction material contains the same metal compound particles as the reinforcing material. (2) The friction material according to (1), wherein the metal compound particles contained in the friction material are alumina particles. (3) The friction material according to (1), wherein the metal compound particles contained in the friction material are silicon carbide particles.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION The friction material of the present invention is obtained by dispersing the same metal compound particles as the reinforcing material of the aluminum alloy composite material of the rotor in a base material containing the organic binder.
In the production of disc pads for disc brakes,
As shown in FIG. 1, the back metal is formed into a predetermined shape by a sheet metal press, subjected to a degreasing process and a primer process, and is coated with an adhesive, a heat-resistant organic fiber or an inorganic fiber,
Compounding fiber materials such as metal fibers and powder raw materials such as inorganic and organic fillers, friction modifiers and thermosetting resin binders,
The agitated product sufficiently homogenized by agitation is molded (preformed) at normal temperature and at a predetermined pressure to prepare a preformed body.
Next, this preformed body is thermoformed at a predetermined temperature and pressure in a thermoforming step to fix both members together, perform after-curing, and finally perform a finishing treatment.

Examples of the above-mentioned heat-resistant organic fibers include aromatic polyamide fibers and flame-resistant acrylic fibers. Examples of the inorganic fibers include ceramic fibers such as potassium titanate fibers and alumina fibers, glass fibers, carbon fibers, and rock fibers. Wool and the like can be mentioned, and examples of the metal fiber include a copper fiber and a steel fiber. Examples of the inorganic filler include metal particles such as copper, aluminum, and zinc, scaly inorganic substances such as balm curite and mica, and particles such as barium sulfate and calcium carbonate.Examples of the organic filler include synthetic rubber and Cashew resin and the like. Examples of the thermosetting resin binder include a phenol resin (including various modified phenol resins such as a straight phenol resin and a rubber), a melamine resin, and a polyimide resin.

Further, as the friction adjusting material, for example, metal oxides such as alumina, silica, magnesia, zirconia, chromium oxide, and quartz can be used. As the solid lubricant, for example, graphite and molybdenum disulfide can be used. . Illustrating these compounding ratios, heat-resistant organic fiber 2
-10% (vol, hereinafter the same), inorganic fiber 0-7%, thermosetting resin binder 15-25%, friction modifier 30-7
0%, preferably about 50%.

In the present invention, a metal compound particle serving as a reinforcing material for an aluminum alloy material is added to and dispersed in a base material of such an organic friction material. The metal compound particles include particles of metal oxides, metal carbides, metal nitrides, etc., for example, alumina (Al ₂ O ₃ ), silicon nitride (Si ₃ N ₄ ), silicon carbide (SiC), aluminum nitride (Al _{xN y} ). And the important point in the present invention is
As the metal compound particles, the same metal compound particles as those used for the aluminum alloy material of the rotor are used. For a rotor made of an aluminum alloy material in which alumina is dispersed as the reinforcing particles, a friction material in which alumina particles are dispersed is used. In this case, the largest coefficient of friction is obtained. For the rotor, for example, even if silicon carbide particles other than alumina particles are used, better results are obtained than when no rotor is used, but the largest coefficient of friction is obtained as when the same alumina particles are used. It will not be done. The metal compound particles have an average particle size of 1
~ 200 µm, preferably 5-150 µm. Various shapes can be used for the particles. The content of the metal compound particles in the friction material is 1
２５25%, preferably 3-20%.

[0010] A mating material in which the organic friction material of the present invention is used.
Particle-dispersed aluminum in rotor as rotor
Various compositions can be used for the alloy material.
Wear. For example, the above-mentioned aluminum alloy matrix
Alumina having a particle size of 5 to 100 μm (Al
_TwoO_Three), Silicon nitride (Si_ThreeN_Four), Silicon carbide (Si
Particle dispersion in which reinforcing particles such as C) are dispersed in 1 to 7 wt%
Reinforced aluminum alloy material (JP-A-2-25538)
Report), Si 4.0-12.0%, Cu 2.0-6.0%
Containing aluminum and the balance of Al and unavoidable impurities
Aluminum alloy_TwoO _Three, Ceramic grains such as SiC
Alloy material in which particles are dispersed (Japanese Unexamined Patent Publication No.
73936) and various known ones.
Can be.

[0011]

EXAMPLES The present invention will be described below in more detail with reference to examples, but the present invention is not limited to these examples.

Example 1 (Production of friction material) As a basic material of a friction material, an organic basic material No. 1 was prepared by mixing the materials shown in Table 1.
1, No. 2 was prepared. In the basic material of the above friction material,
Chromium oxide particles, zirconia particles, silicon carbide particles,
Alumina particles were respectively added, and a disk brake was manufactured according to a conventional manufacturing method. The addition amount is 3vol
%, 10 vol%, and 20 vol%, and as one of comparative examples, a friction material to which these were not added (addition amount 0 v
ol%). In addition, the addition amount is 0 vol% product and 3
vol% product, basic material No. 1 was used. Also one
Basic material No. is included in 0 vol% and 20 vol% products. 2 was used. In the latter case, the amount of added phenolic resin is larger than that of the 3vol% product in order to adjust the physical properties.
The amount of friction modifier was reduced accordingly. The average particle diameter of each of the particles added is 25 μm.

[0013]

[Table 1]

(Friction test) (1) Test rotor As the rotor used for the test, the following two types of rotors having different materials of the aluminum alloy composite material were used. B) Rotor A: Material: 68 wt% aluminum, 30 wt% alumina particles, balance (Ni, Cu, Mn, Fe)
2 wt% b) Rotor B: Material: aluminum 79 wt%, silicon carbide particles 20 wt%, residue (Ni, Cu, Mn, Fe)
1wt%

(2) Test method After the new rotor produced in the above (1) and the friction material are sufficiently rubbed with each other, using a dynamometer, 100 km / h, 0.6 G using a dynamometer in the specification of an automobile standard performance test. , An efficiency test was performed, and a coefficient of friction between the rotor and the friction material was measured. (Test Results) The test results are shown in Tables 2 and 3.

[0016]

[Table 2]

[0017]

[Table 3]

As can be seen from Tables 2 and 3, the friction material to which alumina particles are added has a large friction coefficient in the case of rotor A to which alumina particles are added, whereas the friction material in the case of rotor B to which silicon carbide particles are added. Low coefficient of friction. Also,
The friction material to which the silicon carbide particles are added has a large friction coefficient in the case of the rotor B to which the silicon carbide particles are added, but has a small friction coefficient in the case of the rotor A to which the alumina particles are added. Accordingly, a friction material having the same metal compound particles as the reinforcing agent added to the rotor has a large friction coefficient.

[0019]

The organic friction material of the present invention has a large friction coefficient by adding the same metal compound particles as the reinforcing material added to the rotor. Therefore, even if a rotor for a disc brake is manufactured from a lightweight aluminum alloy composite material, a disc brake having good friction performance can be obtained by using the friction material of the present invention.

[Brief description of the drawings]

FIG. 1 shows a flow sheet of a manufacturing process of a friction material of the present invention.

Claims (3)

[Claims] 1. An organic friction material for a disc brake using a rotor made of an aluminum alloy composite material containing metal compound particles to be a reinforcing material, wherein the friction material contains the same metal compound particles as the reinforcing material. Wood. 2. The friction material according to claim 1, wherein the metal compound particles contained in the friction material are alumina particles. 3. The friction material according to claim 1, wherein the metal compound particles contained in the friction material are silicon carbide particles.