Friction material composition, friction material and production method thereof

Abstract

A friction material composition containing an alkali metal salt as a friction adjusting material. The alkali metal salt is spherical and porous. The alkali metal salt has an average particle diameter of 20 m to 240 m. A friction material is produced by using the friction material composition.

Claims

1. A friction material composition comprising: a binder in an amount of 5 mass % to 20 mass %; a fiber base material in an amount of 5 mass % to 40 mass %; an organic filler in an amount of 1 mass % to 15 mass %; an alkali metal salt in an amount 5 mass % to 30 mass %; an inorganic filler other than the alkali metal salt in an amount of 1 mass % to 60 mass %; an abrasive in an amount of 5 mass % to 20 mass %; and a lubricant in an amount of 1 mass % to 20 mass %, wherein the alkali metal salt is spherical and porous and has an average particle diameter of 20 m to 240 m, wherein each particle of the alkali metal salt comprises a sintered body in which a plurality of particles in a range of 100 nm or more to 500 nm or less in both a long axis direction and a short axis direction are fused.

2. The friction material composition according to claim 1, wherein the alkali metal salt is potassium titanate.

3. The friction material composition according to claim 1, wherein the average particle diameter of the alkali metal salt is from 90 m to 240 m.

4. The friction material composition according to claim 1, which does not contain a fiber base material containing a copper, a metal powder containing a copper, a fiber base material containing a copper alloy or a metal powder containing a copper alloy.

5. A method for producing a friction material, comprising: pressure-forming the friction material composition as described in claim 1, thereby obtaining a preformed body, adding the preformed body to a thermoforming mold and subjecting it to heat compression forming, thereby obtaining a heat compression-formed body, and heat-treating the heat compression-formed body.

6. A friction material obtained by the method as described in claim 5.

7. The friction material composition according to claim 2, wherein the average particle diameter of the alkali metal salt is from 90 m to 240 m.

8. The friction material composition according to claim 2, which does not contain a fiber base material containing a copper, a metal powder containing a copper, a fiber base material containing a copper alloy or a metal powder containing a copper alloy.

9. The friction material composition according to claim 1, wherein the content of an inorganic filler other than the alkali metal salt is 1 mass % to 35 mass %.

10. The friction material composition according to claim 1, wherein the content of an inorganic filler other than the alkali metal salt is 1 mass % to 23 mass %.

11. The friction material composition according to claim 1, wherein the content of an inorganic filler other than the alkali metal salt is 1 mass % to 22 mass %.

12. The friction material composition according to claim 1, wherein the content of the lubricant is 13 mass % to 20 mass %.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is an SEM image showing an alkali metal salt (potassium titanate) constituting the friction material composition in an aspect of the present invention.

(2) FIG. 2 is an enlarged SEM image showing the surface state of the alkali metal salt of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

(3) In consideration of the above-described objects, the present inventors had made many intensive studies to further improve the friction material composition and the properties, in particular, noise characteristics in a moisture-absorbed state, of a friction material using the friction material composition. An attention was focused on the property and state of wear debris attached to the surface of the friction material. Then, it had been found that in the case of a friction material producing loud creep noise, the particle diameter of the wear debris is small, the moisture absorption amount is large, and the wear debris contains a large amount of titanium (Ti) or barium (Ba), derived from the friction adjusting material.

(4) Taking notice of this point, the present inventors have produced a friction material while changing the kind or content of the constituents of the friction material composition and repeatedly performed an experiment for evaluating the properties thereof. As a result, it has been found that when a spherical and porous alkali metal salt having an average particle diameter of 20 m to 240 m is added, the noise characteristics in a moisture-absorbed state can be improved without impairing the properties such as fade resistance. An aspect of the present invention has been accomplished based on this finding.

(5) 1. Friction Material Composition

(6) The friction material composition in an aspect of the present invention includes a fiber base material, a friction adjusting material and a binder, similarly to conventional techniques. In particular, the friction material composition in an aspect of the present invention includes, as the friction adjusting material, a spherical and porous alkali metal salt having an average particle diameter of 20 m to 240 m.

(7) The friction material composition in an aspect of the present invention is obtained by uniformly mixing respective components. At this time, the mixing method is not particularly limited, and a conventional technique such as Eirich mixer, Loedige mixer and pressure kneader may be utilized.

(8) (1) Fiber Base Material

(9) The fiber base material is not particularly limited as long as it does not contain asbestos, and a conventional fiber base material may be used. Specifically, an organic fiber, an inorganic fiber, and a non-ferrous metal fiber can be used. As the organic fiber, examples thereof include an aromatic polyamide (aramid) fiber, a flame-resistant acrylic fiber, etc. As the inorganic fiber, examples thereof include a ceramic fiber such as potassium titanate fiber and alumina fiber, a bio-soluble inorganic fiber, a glass fiber, a carbon fiber, a rock wool, etc. As the non-ferrous metal fiber, examples thereof include an aluminum fiber, a zinc fiber, etc.

(10) Among these fiber base materials, a bio-soluble inorganic fiber may be suitably used because of its little effect on human body. Examples of such a bio-soluble inorganic fiber include a bio-soluble ceramic fiber such as SiO.sub.2CaOMgO-based fiber, SiO.sub.2CaOMgOAl.sub.2O.sub.3-based fiber and SiO.sub.2MgOSrO-based fiber, a bio-soluble rock wool, etc. The above-described fiber base materials may also be used in combination of two or more thereof.

(11) The content of the fiber base material is preferably from 5 mass % to 40 mass %, more preferably from 5 mass % to 25 mass %.

(12) (2) Friction Adjusting Material

(13) As the friction adjusting material, an inorganic filler such as alkali metal salt, vermiculite and mica, an organic filler, an abrasive, a lubricant, etc. may be used.

(14) a) Organic Filler

(15) As the organic filler, various rubber powders (e.g., rubber dust, tire powder), cashew dust, melamine dust, etc. may be used individually or in combination of two or more thereof.

(16) The content of the organic filler is preferably from 1 mass % to 15 mass %, more preferably from 4 mass % to 15 mass %.

(17) b) Inorganic Filler

(18) b-1) Alkali Metal Salt

(19) The friction material composition in an aspect of the present invention includes, as the friction adjusting material, a spherical and porous alkali metal salt having an average particle diameter of 20 m to 240 m. Thanks to this configuration, the noise characteristics can be improved without impairing the fade resistance.

(20) [Formulation]

(21) As the alkali metal salt, examples thereof include a titanic acid alkali metal salt such as potassium titanate, sodium titanate and potassium lithium titanate. Among these, potassium titanate is preferably used because of its small elution amount as an alkali metal ion, and a potassium titanate represented by formula: K.sub.2Ti.sub.nO.sub.2n+1 (wherein n is an integer of 2 to 8) is more preferably used.

(22) [Shape and Structure]

(23) In the friction material composition in an aspect of the present invention, an alkali metal salt being spherical and porous as shown in SEM images of FIGS. 1 and 2 must be used. The spherical as used in the present invention encompasses not only a so-called true spherical shape but also an elliptic spherical shape. In addition, the porous means that pluralities of pores are present in the sintered body surface, and these pores may be in a continuous structure or an independent structure. In the SEM image of FIG. 2, the dark gray or black portion corresponds to a pore part of the porous body. Such a shape or structure of the alkali metal salt can be confirmed by the observation using a scanning electron microscope (SEM).

(24) In the technique described in JP-A-10-139894, as with an aspect of the present invention, a spherical and porous alkali metal salt (potassium hexatitanate) is used as the friction adjusting material. However, the alkali metal salt in this document is produced by firing a granulated powder and is composed of a secondary particle resulting from aggregation of fibrous primary particles each having a length of the m order in the long axis direction. Therefore, the strength of the alkali metal salt itself is low and since the particle wears while loosening the aggregation of primary particles during braking, the wear debris is considered to become very fine.

(25) On the other hand, in an aspect of the present invention, an alkali metal salt produced, for example, by firing a milled mixture obtained by mechanochemical milling of a titanium source and an alkali metal source to prepare a titanate, and subjecting this titanate to acid treatment and firing, may be used. Such an alkali metal salt includes a sintered body in which a plurality of particles each having a dimension of the 100 nm order, preferably from 100 nm to 500 nm, in both the long axis direction and the short axis direction has been fused. Therefore, the strength is high compared with the alkali metal salt as described in JP-A-10-139894, and the wear debris can have a large particle diameter. In other words, the alkali metal salt in an aspect of the present invention greatly differs in this point from the alkali metal salt as described in JP-A-10-139894.

(26) [Average Particle Diameter]

(27) As described above, in order to improve the noise characteristics in a moisture-absorbed state, use of an alkali metal salt having an average particle diameter of 20 m to 240 m is effective. However, in the case of using an alkali metal salt having an average particle diameter of 20 m or more, the fade resistance may be deteriorated due to reduction in the porosity of the friction material and, in particular, this tendency is conspicuous in a copper-free friction material containing no copper which has an excellent thermal conductivity.

(28) The present inventors have made many intensive studies on this point and found that when a spherical and porous alkali metal salt is used, even if the average particle diameter thereof is 20 m or more, the porosity of the friction material can be ensured and reduction in the fade resistance can be suppressed.

(29) Specifically, in the friction material in an aspect of the present invention, an alkali metal salt having an average particle diameter of 20 m to 240 m, preferably from 90 m to 240 m, must be used. If the average particle diameter of the alkali metal salt is less than 20 m, the wear debris becomes too fine, and the noise characteristics in a moisture-absorbed state cannot be improved. On the other hand, according to the studies by the present inventors, it is confirmed that when the average particle diameter of the alkali metal salt is about 240 m, the porosity of the friction material is not greatly reduced and the fade resistance can be sufficiently ensured.

(30) The average particle diameter as used in an aspect of the present invention means the median diameter (D50), and the average particle diameter can be measured, for example, by a laser diffraction particle size distribution analyzer.

(31) [Content]

(32) The content of the alkali metal salt is, in total, preferably from 5 mass % to 30 mass %, more preferably from 10 mass % to 28 mass %, still more preferably from 15 mass % to 28 mass %. If the content of the alkali metal salt is less than 5 mass %, the above-described effects may not be obtained. On the other hand, if the content of the alkali metal salt exceeds 30 mass %, the content of other constituents decreases, and the properties such as strength and durability may be significantly reduced.

(33) b-2) Other Inorganic Fillers

(34) As the inorganic filler (other inorganic fillers) other than the alkali metal salt, a mineral powder such as vermiculite and mica, or a metal powder such as aluminum, tin and zinc, may be used. A powder including an alkali metal salt or alkaline earth metal salt having an average particle diameter of less than 20 m may also be used. Furthermore, two or more thereof may be used in combination.

(35) The content of the other inorganic filler is preferably from 1 mass % to 60 mass %, more preferably from 1 mass % to 50 mass %.

(36) c) Abrasive

(37) As the abrasive, alumina, silica, magnesia, zirconia, zirconium silicate, chromium oxide, triiron tetraoxide (Fe.sub.3O.sub.4), etc. may be used individually or in combination of two or more thereof.

(38) The content of the abrasive is preferably from 5 mass % to 20 mass %, more preferably from 10 mass % to 20 mass %.

(39) d) Lubricant

(40) As the lubricant, graphite, molybdenum disulfide, tin sulfide, polytetrafluoroethylene (PTFE), etc. may be used individually or in combination of two or more thereof.

(41) The content of the lubricant is, in total, preferably from 1 mass % to 20 mass %, more preferably from 3 mass % to 15 mass %.

(42) (3) Binder

(43) As the binder, various binders which are usually employed can be used. Specific examples thereof include a thermosetting resin, e.g., a straight phenol resin, various phenol resins modified with elastomer or the like, a melamine resin, an epoxy resin and a polyimide resin. Among these, an elastomer-modified phenol resin is preferably used from the standpoint of imparting flexibility to the friction material, reducing counterpart material attack, and improving noise characteristics. Examples of the elastomer-modified phenol resin include an acrylic rubber-modified phenol resin, a silicone rubber-modified phenol resin, an NBR rubber-modified phenol resin, etc., and an acrylic rubber-modified phenol resin and a silicone rubber-modified phenol resin are preferably used. These binders may be used individually or in combination of two or more thereof.

(44) The content of the binder is preferably from 5 mass % to 20 mass %, more preferably from 5 mass % to 15 mass %.

(45) (4) Copper

(46) The friction material composition in an aspect of the present invention includes the above-described components but is preferably free of a fiber base material or metal powder, which contains copper or a copper alloy. More specifically, the copper content in the friction material composition is preferably 0.5 mass % or less. The friction material formed of such a copper-free friction material composition can reduce the load on the environment or human body, because the amount of copper contained in the wear debris produced during braking is also very small.

(47) 2. Friction Material

(48) (1) Production Method of Friction Material

(49) As for the production method of the friction material in an aspect of the present invention, the friction material can be obtained in the same manner as in conventional techniques except for using the above-described friction material composition. Specifically, the production method of a friction material in an aspect of the present invention includes:

(50) a) a preforming step of pressure-forming the above-described friction material composition, thereby obtaining a preformed body,

(51) b) a heat compression forming step of adding the preformed body to a thermoforming mold and performing heat compression forming, thereby obtaining a heat compression-formed body, and

(52) c) a heat treatment step of heat-treating the heat compression-formed body. The conditions, etc. in each step are the same as in conventional techniques, and therefore, description thereof is omitted here.

(53) (2) Friction Material

(54) The friction material in an aspect of the present invention is obtained by the production method above and can be suitably used as a disc brake pad or a drum brake lining.

(55) The friction material in an aspect of the present invention contains, as described above, an alkali metal salt having an average particle diameter of 20 m to 240 m, but since this alkali metal salt is spherical and porous, the porosity of the friction material can be sufficiently ensured. Specifically, the porosity of the friction material can be controlled to a range of preferably from 10% to 25%, more preferably from 15 to 25%, so that the friction material in an aspect of the present invention can be assured of fade resistance comparable to that of conventional friction materials. The porosity of the friction material can be measured by a mercury porosimeter.

EXAMPLES

(56) An aspect of the present invention is described in greater detail below by referring to Examples and Comparative Examples.

Examples 1 to 6 and Comparative Examples 1 to 5

(57) a) Production of Friction Material

(58) The raw material powders shown in Table 1 were prepared, and these raw material powders were uniformly mixed in the ratio shown in Table 2 to obtain a friction material composition. This friction material composition was added to a forming mold, followed by subjecting it to pressure-forming at room temperature and 15 MPa for 1 second, thereby obtaining a preformed body. This preformed body was set in a thermoforming mold and after overlaying thereon a metal plate (pressure plate) previously coated with an adhesive, heat compression forming was performed at 150 C. and 40 MPa for 5 minutes, thereby obtaining a heat compression-formed body. This heat compression-formed body was heat-treated at 250 C. for 3 hours, then cooled to room temperature, grinded into predetermined shape and thickness, and painted, whereby a friction material (friction pad) was produced. Out of inorganic fillers a to f, inorganic fillers a to c used in Examples 1 to 6 falls within the scope of the alkali metal salt in an aspect of the present invention.

(59) TABLE-US-00001 TABLE 1 Sign Name [Property and State] Fiber base Organic fiber a aramid fiber material Inorganic a bio-soluble fiber fiber Metal fiber a copper fiber Friction Organic filler a cashew dust adjusting Inorganic a potassium titanate [spherical/porous, average material filler particle diameter: 90 m] (produced by Otsuka Chemical Co., Ltd., sample name: TERRACESS DPA) b potassium titanate [spherical/porous, average particle diameter: 20 m] (produced by Otsuka Chemical Co., Ltd., sample name: TERRACESS DPA) c potassium titanate [spherical/porous, average particle diameter: 240 m] (produced by Otsuka Chemical Co., Ltd., sample name: TERRACESS DPA) d lithium potassium titanate [scale-like, average particle diameter: 2.5 m] e potassium titanate [amorphous, average particle diameter: 9.5 m] f potassium titanate [plate-like, average particle diameter: 7 m] Other a barium sulfate inorganic b mica filler c calcium hydroxide d zinc Abrasive a zircon-based abrasive b iron oxide Lubricant a graphite/metal sulfide b polytetrafluoroethylene Binder a phenol resin

(60) TABLE-US-00002 TABLE 2 Fiber Base Material Friction Adjusting Material Organic Inorganic Metal Organic Inorganic Filler (alkali Other Inorganic Fiber Fiber Fiber Filler metal salt) Filler Abrasive Lubricant Binder a a a a a b c d e f a b c d a b a b a Example 1 4 3 0 4 25 0 0 0 0 0 18 1 3 1 13 7 12 1 8 Example 2 4 3 0 4 0 25 0 0 0 0 18 1 3 1 13 7 12 1 8 Example 3 4 3 0 4 0 0 25 0 0 0 18 1 3 1 13 7 12 1 8 Example 4 4 3 0 4 13 0 0 0 0 0 30 1 3 1 13 7 12 1 8 Example 5 4 3 0 4 6 0 0 0 0 0 37 1 3 1 13 7 12 1 8 Example 6 4 3 0 4 13 0 0 13 0 0 17 1 3 1 13 7 12 1 8 Comparative 4 3 5 4 0 0 0 0 0 25 13 1 3 1 13 7 12 1 8 Example 1 Comparative 4 3 0 4 0 0 0 17 8 0 18 1 3 1 13 7 12 1 8 Example 2 Comparative 4 3 0 4 0 0 0 25 0 0 18 1 3 1 13 7 12 1 8 Example 3 Comparative 4 3 0 4 0 0 0 0 25 0 18 1 3 1 13 7 12 1 8 Example 4 Comparative 4 3 0 4 0 0 0 0 0 25 18 1 3 1 13 7 12 1 8 Example 5
b) Evaluation of Friction Material (Friction Pad)
[Static/Dynamic Reduction Test]

(61) The friction pad was subjected to frictional contact by using a full-size dynamometer in an environment having a temperature of 30 C. and a humidity of 80% under the conditions of a braking initial speed of 40 km/h, a braking deceleration rate of 1.96 m/s.sup.2, an initial brake temperature of friction material of 70 C. or less, and a number of braking of 5,200 times, and then left standing in an environment having a temperature of 25 C. and a humidity of 100% for 15 hours. Subsequently, a static/dynamic reduction test was performed under the conditions of a liquid pressure of 2 MPa, a pressure reduction rate of 0.5 MPa/s, a creep torque of 200 Nm, and a number of braking of 5 times, and the static/dynamic reduction was evaluated by the torque drop amount.

(62) [Noise Characteristics]

(63) The friction pad after the static/dynamic reduction test was mounted on a vehicle having an FC150-made disc brake rotor, followed by subjecting to burnishing frictional contact under the conditions of a braking initial speed of 40 km/h, a braking deceleration rate of 1.96 m/s.sup.2, an initial brake temperature of friction material of 70 C. or less, and a number of braking of 130 times, and then, it was left standing in an environment having a temperature of 20 C. and a humidity of 95% for 15 hours. Subsequently, a sensory evaluation was performed by the loudness of creep noise at the time of releasing the brake under a liquid pressure of 2 MPa. Specifically, a 5-grade evaluation was performed, where 1 was assigned when creep noise was not heard at all and 5 was assigned when clearly heard.

(64) [Wear Amount and Surface Roughness of Friction Material]

(65) The wear amount was measured at 4 portions in each of the outer circumference and inner circumference of the friction pad after the evaluation of noise characteristics, by using a digital micrometer ( 1/1000 Digital Micrometer, manufactured by Mitutoyo Corporation), and the average value thereof was calculated, whereby the wear amount was evaluated. In addition, the arithmetic average roughness Ra was measured at 6 portions on the friction pad surface by using a non-contact three-dimensional roughness meter (Profile Scanner PS200, manufactured by Tokyo Seimitsu Co., Ltd.), and the average value thereof was calculated, whereby the surface roughness was evaluated.

(66) [Average Particle Diameter of Wear Debris]

(67) After the evaluation of noise characteristics, the wear debris accumulated on the friction pad surface was collected, and the average particle diameter (D50) thereof was measured by using a particle diameter distribution measuring apparatus (SALD-7100, manufactured by Shimadzu Corporation).

(68) [Moisture Absorption Amount of Wear Debris]

(69) First, 100 mg of the wear debris after the evaluation of noise characteristics was dried at 105 C. for 2 hours and then, the mass w.sub.0 was measured. Next, the wear debris was left standing still in a vessel filled with water and allowed to stand in an environment having a temperature of 25 C. and a humidity of 100% for 15 hours and then, the mass w.sub.1 was measured. From the thus-obtained masses w.sub.0 and w.sub.1, the moisture absorption amount w (=w.sub.1w.sub.0) of the wear debris was calculated.

(70) [Porosity]

(71) The porosity of the friction pad before carrying out each evaluation test was measured by means of a mercury porosimeter (Autopore D19500 Series, manufactured by Shimadzu Corporation).

(72) [Effectiveness and Fade Resistance]

(73) A friction test (in conformity with JASO C 406:2000) was performed by using a full-size dynamometer testing device to evaluate the effectiveness and fade resistance (the average friction coefficient .sub.avg in the second effectiveness test at a braking initial speed of 100 km/h and the minimum friction coefficient .sub.min in the first fade test) of each friction material.

(74) TABLE-US-00003 TABLE 3 Surface Wear Debris Torque Roughness Average Moisture Drop Wear Ra of Particle Absorption Fade Amount Noise Amount Friction Pad Diameter Amount w Porosity Effectiveness Resistance (Nm) Characteristics (mm) (m) (m) (mg/100 mg) (%) .sub.avg .sub.min Example 1 24 2 0.14 1.29 5.1 7.7 20.0 0.46 0.26 Example 2 27 3 0.10 1.10 4.5 8.6 18.0 0.46 0.24 Example 3 24 2 0.16 1.43 5.9 7.0 21.0 0.46 0.26 Example 4 27 3 0.10 1.07 4.3 8.9 16.5 0.45 0.23 Example 5 30 3 0.09 0.90 3.2 9.5 14.2 0.44 0.21 Example 6 30 3 0.09 0.91 2.9 9.2 17.0 0.45 0.23 Comparative 36 5 0.08 0.85 1.4 11.4 15.0 0.44 0.21 Example 1 Comparative 40 5 0.07 0.85 1.5 11.8 18.0 0.46 0.24 Example 2 Comparative 35 4 0.05 0.82 1.1 12.1 20.0 0.45 0.25 Example 3 Comparative 32 4 0.07 0.88 1.6 10.8 14.0 0.45 0.20 Example 4 Comparative 40 5 0.06 0.79 1.3 11.7 15.3 0.44 0.21 Example 5
c) Comprehensive Evaluation

(75) From Tables 1 to 3, it is confirmed that in the case of the frictions materials of Examples 1 to 6, the noise characteristics are good and the torque drop amount is small. In addition, it is confirmed from these Examples that as the average particle diameter of the alkali metal salt in an aspect of the present invention is larger, the wear debris tends to have a larger average particle diameter and a smaller moisture absorption amount. Furthermore, the comparison with the friction materials of Comparative Examples 1 to 5 using an alkali metal salt having an average particle diameter of less than 20 m reveals that the friction materials of Examples 1 to 6 have an equivalent fade resistance. It is understood from these results that according to an aspect of the present invention, the noise characteristics in a moisture-absorbed state can be improved without impairing the fade resistance.

(76) While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention.