FRICTION MATERIAL

Abstract

To provide a low-cost friction material which is able to secure the required braking performance, the fading resistance, the wear resistance, and the adhesive strength between the friction material and the back plate while satisfying laws and regulations relating to the required amount of the content of the copper component contained therein. The friction material for the disc brake pad which is manufactured by forming a non-asbestos-organic (NAO) friction material composition that includes no copper component, in which the friction material composition includes no titanate but includes (a) 8-15 volume % of an inorganic friction modifier having the average particle diameter of 0.5-20 m and the Mohs hardness of 5-8 relative to a total amount of the friction material composition, (b) 1-3 volume % of a porous inorganic friction modifier having a micro porous structure relative to the total amount of the friction material composition, and (c) 5-10 volume % of a carbonaceous lubricant, where the carbonaceous lubricant includes 2-4 volume % of coke relative to the total amount of the friction material composition, the average particle diameter of the coke is 300-800 m while the content of the inorganic friction modifier (a), (b), and the carbonaceous lubricant (c) satisfies the following formula: 1.0((a)+(b))/(c)2.5.

Claims

1. A friction material for a disc brake pad, which is manufactured by forming a non-asbestos-organic friction material composition including no copper component, wherein said friction material composition includes no titanate, but includes (a) 8-15 volume % of an inorganic friction modifier having an average particle diameter of 0.5-20 m and the Mohs hardness of 5-8 relative to a total amount of the friction material composition, (b) 1-3 volume % of a porous inorganic friction modifier having a micro porous structure relative to the total amount of the friction material composition, and (c) 5-10 volume % of a carbonaceous lubricant, where said carbonaceous lubricant includes 2-4 volume % of coke relative to the total amount of the friction material composition, and an average particle diameter of coke is 300-800 m while the content of the inorganic friction modifier (a), (b), and the carbonaceous lubricant (c) satisfies a following formula: 1.0((a)+(b))/(c)2.5.

2. The friction material according to claim 1, wherein the porous inorganic friction modifier having the micro porous structure is zeolite.

Description

EMBODIMENTS OF THE INVENTION

[0019] According to this invention, in order to improve the braking performance, 8-15 volume % of an inorganic friction modifier relative to a total amount of a friction material composition having the average particle diameter of 0.5-20 m and the Mohs hardness of 5-8 is added therein.

[0020] The friction material to which 8-15 volume % of the inorganic friction modifier, relative to the total amount of the friction material composition, having the average particle diameter of 0.5-20 m and Mohs hardness of 5-8, is added, when the friction material frictionally contacts to the disc rotor as the contacting member in the braking action, the inorganic friction modifier moderately grinds the sliding surface of the disc rotor, thereby causing the transfer of the grinded powder of the cast iron on the friction surface of the friction material.

[0021] A further braking action causes an adhesive friction between the cast iron component transferred onto the friction surface of the friction material and the sliding surface of the disc rotor, thereby obtaining the friction material that enables to secure the sufficient friction coefficient and effective braking performance.

[0022] The inorganic friction modifier with the Mohs hardness of 5-8 may be one material or any combination of the two or more materials selected from such as a magnesium oxide, a -alumina, a triiron tetroxide, a zirconium silicate, and a zirconium oxide.

[0023] Also, the Mohs hardness used as the standard in this invention is an old Mohs hardness represented by (1) talc, (2) gypsum, (3) calcite, (4) fluorite, (5) apatite, (6) orthoclaes, (7) quartz, (8) topaz, (9) corundum, and (10) diamond.

[0024] Also, this invention, as an average particle diameter, uses a particle diameter (D50) measured by a laser diffraction method.

[0025] Furthermore, a decrease of the fading resistance caused due to elimination of the titanate from the friction material is suppressed by adding 1-3 volume % of the porous inorganic friction modifier having the micro porous structure relative to the total amount of the friction material composition.

[0026] The porous inorganic friction modifier having the micro porous structure may be one material or two materials selected from such as a zeolite and a micro porous alumina; However, it is preferable to use the zeolite alone as the porous inorganic friction modifier.

[0027] As described above, in order to obtain the sufficient braking performance without decreasing the fading resistance, the relatively small inorganic friction modifier with the average particle diameter of 0.5-20 m and the porous inorganic friction modifier having the micro porous structure are utilized in this invention.

[0028] As these materials have large specific surface area, they require a large amount of binder so as to bind these materials.

[0029] The binder contributes to the improvement of the adhesive strength between the friction material and the back plate; however, if large amount of raw materials with large specific surface areas are used in the friction material, the amount of the binder may become insufficient to secure necessary adhesive strength between the friction material and the back plate, thereby tending to reduce the adhesive strength therebetween.

[0030] Accordingly, in this invention, 2-4 volume % of the coke with the average particle diameter of 300-800 m in a portion of the carbonaceous lubricant relative to the total amount of the friction material composition is added.

[0031] The coke with relatively large diameter has the small specific surface area, and adding an appropriate amount of the same controls the consumption of the binder to bind the raw materials together and suppress the reduction of the adhesive strength between the friction material and the back plate.

[0032] In addition, so as to balance the braking performance, the fading resistance, and the wear resistance, 5-10 volume % of the total amount of the above-described coke and the carbonaceous lubricant other than the above-described coke relative to the total amount of the friction material composition are added, while the friction material composition includes (a) 8-15 volume % of an inorganic friction modifier having an average particle diameter of 0.5-20 m and the Mohs hardness of 5-8 relative to the total amount of the friction material composition, (b) 1-3 volume % of a porous inorganic friction modifier having a micro porous structure relative to the total amount of the friction material composition, and (c) the carbonaceous lubricant, in which the carbonaceous lubricant (c) satisfies the formula of 1.0((a)+(b))/(c)2.5.

[0033] The carbonaceous lubricant other than the above-described coke may be such as natural graphite, artificial graphite, and expanded graphite, and one or any combination of two or more of these materials may be used.

[0034] The friction material of this invention includes the friction material composition having the above-described inorganic friction modifier with the average diameter of 0.5-20 m and Mohs hardness of 5-8, the porous inorganic friction modifier having the micro porous structure, the carbonaceous lubricant, as well as components that are usually used for the friction material such as the binder, the fiber base, the lubricant, the inorganic friction modifier, the organic friction modifier, the pH modifier, and the filler.

[0035] The binder may be one material or any combination of the two or more materials, which may be conventionally used for the friction material, selected from such as the straight phenolic resin, the resin obtained by modifying the phenolic resin with various elastomers such as cashew oil, silicone oil, and acrylic rubber, the aralkyl modified phenolic resin obtained by reacting the phenols with aralkyl ethers and aldehydes, and the thermosetting resin dispersing such as various elastomers and fluoropolymer in the phenolic resin. The content of the binder is preferably 10-20 volume % relative to the total amount of the friction material composition but more preferably 12-15 volume % relative to the total amount of the friction material composition.

[0036] The fiber base may be one organic fiber or any combination of the two or more organic fibers, which may be conventionally used for the friction material, selected from such as the aramid fiber, the cellulosic fiber, the poly-p-phenylenebenzobisoxazole (PBO) fiber, and the acrylic fiber. The content of the fiber base is preferably 3-10 volume % relative to the total amount of the friction material composition but more preferably 4-8 volume % of the total amount of the friction material composition.

[0037] In addition to the above-described carbonaceous lubricant, the lubricant may be one metal sulfide type lubricant or any combination of two or more metal sulfide type lubricant selected from such as the molybdenum disulfide, the zinc sulfide, the tin sulfide, and composite metal sulfide. The metal sulfide type lubricant is preferably 0-3 volume % relative to the total amount of the friction material composition but more preferably 1-2 volume % relative to the total amount of the friction material composition.

[0038] The inorganic friction modifier may be one material or any combination of two or more materials selected from the particulate inorganic friction modifiers such as the talc, the mica, the vermiculite, and the dolomite plaster and the fibrous inorganic modifier such as the wollastonite, the sepiolite, the basalt fiber, the grass fiber, the biosoluble artificial mineral fiber, rock wool other than the above-described inorganic friction modifier having the average particle diameter of 0.5-20 m and Mohs hardness of 5-8 and the porous inorganic friction modifier having the micro porous structure.

[0039] The content of the inorganic friction material in the total amount of the above-described inorganic friction modifier having the average particle diameter of 0.5-20 m and Mohs hardness of 5-8 together and the above-described porous inorganic friction modifier having the micro porous structure is preferably 18-30 volume % relative to the total amount of the friction material composition but more preferably 20-25 volume % relative to the total amount of the friction material composition.

[0040] The organic friction modifier may be one material or any combination of two or more materials selected from the organic friction modifiers that may be conventionally used for the friction material such as the cashew dust, the vulcanized powders of the tire tread rubber and the unvulcanized rubber powders or the vulcanized rubber powders such as the nitrile rubber, the acrylic rubber, the silicone rubber, and the butyl rubber.

[0041] The content of the organic friction modifier is preferably 10-25 volume % relative to the total amount of the friction material composition but more preferably 15-20 volume % relative to the total amount of the friction material composition.

[0042] The pH adjuster may be a conventionally used pH adjuster for the friction material such as the calcium hydroxide.

[0043] The pH adjuster is preferably 4-8 volume % relative to the total amount of the friction material composition but more preferably 5-7 volume % relative to the total amount of the friction material composition.

[0044] The filler such as the barium sulfate and the calcium carbonate as the remaining portion of the friction material composition.

[0045] The friction material of this invention used for the disc brake is manufactured through a mixing step to obtain a raw friction material mixture by uniformly mixing the predetermined amount of the friction material composition using a mixer, a heat press forming step to obtain a molded product by heat press forming the raw friction material mixture positioned in the heat forming die superposed on the separately pre-cleaned, surface treated, and adhesive applied back plate, a heat treatment step of heating the molded product to complete the cure reaction of the binder thereon, a coating step of applying the coating thereon, a baking step of baking the coating thereon, and a grinding step of forming the friction surface by a rotary grinding wheel.

[0046] After the heat press forming step, instead of above described separated heat treatment step, coating step and baking step, the heat treatment process combining above mentioned three steps and the girding step after that step may be adopted to manufacture the friction material.

[0047] As necessary, prior to the heat press forming step, the granulation step of granulating the raw friction material mixture, the kneading step of kneading the raw friction material mixture, and the pre-forming step of forming an unfinished preformed article by positioning the raw friction material mixture, the granulated raw friction material mixture obtained through the granulation step or the kneaded raw friction material mixture obtained through the kneading step into the pre-forming die, are performed. In addition, after the heat press forming step, the scorching step may be performed.

Embodiments

[0048] In the following sections, the embodiments and the comparative examples are disclosed to concretely explain this invention; however, this invention is not limited to the following embodiments.

The Manufacturing Method of the Friction Material of Embodiments 1-10/Comparative Examples 1-9

[0049] Each friction material composition shown in TABLE 1 and TABLE 2 is mixed for 5 minutes by the Loedige mixer and is pressed in the forming die under 30 MPa for 10 seconds to form the pre-forming article. This unfinished pre-forming article is superposed on the pre-cleaned, surface treated, adhesive coated steel back plate to form for 10 minutes in the heat press forming die at the forming temperature of 150 centigrade under the forming pressure of 40 MPa, to heat treatment (post-curing) for 5 hours at 200 centigrade, and to grind to form the friction surface for the disc brake pad of the passenger car (Embodiments 1-10 and Comparative Examples 1-9).

TABLE-US-00001 TABLE 1 Embodiments 1 2 3 4 5 6 7 8 9 10 Binder Straight Phenolic Resin 14.0 14.0 14.0 14.0 14.0 14.0 14.0 14.0 14.0 14.0 Fiber Base Aramid Fiber 5 .0 5 .0 5 .0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 Inorganic Friction Zirconium Silicate Modifier (Average Particle Diameter = 0.3 m) Mohs Hardness = 7.5 Zirconium Silicate (a) 6.0 (Average Particle Diameter = 0.5 m) Mohs Hardness = 7.5 Zirconium Silicate (a) 6.0 6.0 2.5 9.5 5.0 9 .0 6 .0 6 .0 (Average Particle Diameter = 10 m) Mohs Hardness = 7.5 Zirconium Silicate (a) 6.0 (Average Particle Diameter = 20 m) Mohs Hardness = 7.5 Zirconium Silicate (Average Particle Diameter = 30 m) Mohs Hardness = 7.5 Activated Alumina (a) 5.0 5 .0 5 .0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 (Average Particle Diameter = 10 m) Mohs Hardness = 6 Black Iron Oxide (a) 0 .5 0 .5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 (Average Particle Diameter = 1 m) Mohs Hardness = 6.5 Silicon Carbide (Average Particle Diameter = 10 m) Mohs Hardness = 9 Zeolite (b) 2.0 2.0 2.0 1.0 3.0 2.0 2 .0 2 .0 2 .0 Micro Porous Alumina (b) 2.0 Muscovite 6.0 6.0 6 .0 6 .0 6 .0 6.0 6.0 6.0 6.0 6.0 Unbaked Vermiculite 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3 .0 3 .0 3 .0 Carbon Type Artificial Graphite (c) 5.0 5.0 5.0 5.0 5.0 5.0 2.0 6.0 5.0 5.0 Lubricant Petroleum Coke (Average Particle Diameter = 100 m) Petroleum Coke (c) 3.0 (Average Particle Diameter = 300 m) Petroleum Coke (c) 3.0 3.0 3.0 3.0 3.0 3.0 3.0 4 .0 (Average Particle Diameter = 450 m) Petroleum Coke (c) 3 .0 (Average Particle Diameter = 800 m) Petroleum Coke (Average Particle Diameter = 1000 m) Metal Sulfide Type Molybdenum Disulfide 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1 .0 1.0 1.0 Lubricant Organic Friction Cashew Dust 12 .0 12 .0 12 .0 12 .0 12 .0 12.0 12.0 12.0 12.0 12.0 Modifier Tire Tread Rubber 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 Vulcanized Powder pH Adjuster Calcium Hydroxide 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6 .0 6 .0 Remaining Barium Sulfate 25 .5 25 .5 25 .5 25 .5 30 .0 21.0 29.5 20.5 25.5 25.5 Components Total 100 .0 100 .0 100 .0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 (a) Total 11 .5 11 .5 11 .5 11.5 8.0 15.0 10.5 14.5 11.5 11.5 (b) Total 2.0 2.0 2.0 2.0 1.0 3.0 2.0 2 .0 2 .0 2 .0 (c) Total 8.0 8.0 8.0 3.0 3.0 8.0 5.0 10.0 8.0 8.0 ((a) + (b))/(c) 1 .69 1 .69 1.69 1.69 1.13 2.25 2.50 1.65 1.69 1.69

Figure No. 000002

[0050]

TABLE-US-00002 TABLE 2 Comparative Examples 1 2 3 4 5 6 7 8 9 Binder Straight Phenolic Resin 14.0 14.0 14.0 14.0 14.0 14.0 14.0 14.0 14.0 Fiber Base Aramid Fiber 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 Inorganic Friction Zirconium Silicate (Average 6.0 Modifier Particle Diameter = 0.3 m) Mohs Hardness = 7.5 Zirconium Silicate (Average (a) Particle Diameter = 0.5 m) Mohs Hardness = 7.5 Zirconium Silicate (Average (a) 6.0 6.0 1.5 11.0 2.5 9.0 Particle Diameter = 10 m) Mohs Hardness = 7.5 Zirconium Silicate (Average (a) Particle Diameter = 20 m) Mohs Hardness = 7.5 Zirconium Silicate (Average 6.0 Particle Diameter = 30 m) Mohs Hardness = 7.5 Activated Alumina (Average (a) 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 Particle Diameter = 10 m) Mohs Hardness = 6 Black Iron Oxide (Average Particle Diameter = 1 m) (a) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Mohs Hardness = 6.5 Silicon Carbide (Average 6.0 Particle Diameter = 10 m) Mohs Hardness = 9 Zeolite (b) 2.0 2.0 2.0 2.0 2.0 0.5 5.0 2.0 2.0 Micro Porous Alumina (b) Muscovite 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 Unbaked Vermiculite 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 Carbon Type Artificial Graphite (c) 5.0 5.0 5.0 5.0 5.0 4.0 6.0 8.0 Lubricant Petroleum Coke (Average 3.0 Particle Diameter = 100 m) Petroleum Coke (Average (c) Particle Diameter = 300 m) Petroleum Coke (Average (c) 3.0 3.0 3.0 3.0 3.0 3.0 4.0 Particle Diameter = 450 m) Petroleum Coke (Average (c) Particle Diameter = 800 m) Petroleum Coke (Average 3.0 Particle Diameter = 1000 m) Metal Sulfide Molybdenum Disulfide 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 Type Lubricant Organic Friction Cashew Dust 12.0 12.0 12.0 12.0 12.0 12.0 12.0 12.0 12.0 Modifier Tire Tread Rubber 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 Vulcanized Powder pH Adjuster Calcium Hydroxide 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 Remaining Barium Sulfate 25.5 25.5 25.5 25.5 25.5 32.5 16.5 34.0 18.5 Components Total 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 (a) Total 11.5 11.5 5.5 5.5 5.5 7.0 16.5 8.0 14.5 (b) Total 2.0 2.0 2.0 2.0 2.0 0.5 5.0 2.0 2.0 (c) Total 5.0 5.0 8.0 8.0 8.0 7.0 9.0 3.0 12.0 ((a) + (b))/(c) 2.70 2.70 0.94 0.94 0.94 1.07 2.39 3.33 1.38

Figure No. 000003

[0051] The obtained friction materials were evaluated with respect to the braking performance, the fading resistance, the wear resistance, the adhesive strength between the friction material and the back plate, and the product appearance of the products. The results of the evaluation are shown in TABLE 3 and TABLE 4 while the evaluation standards are shown in TABLE 5 and TABLE 6.

TABLE-US-00003 TABLE 3 Embodiments 1 2 3 4 5 6 7 8 9 10 Evaluation Braking Result Performance Fading Resistance Wear Resistance Adhesive Strength Friction Material Appearance

Figure No. 000004

[0052]

TABLE-US-00004 TABLE 4 Comparative Examples 1 2 3 4 5 6 7 8 9 Evaluation Braking Performance Result Fading Resistance X X X Wear Resistance X X X Adhesive Strength X X Friction Material X Appearance

Figure No. 000005

[0053]

TABLE-US-00005 TABLE 5 Evaluation Items Braking Effectiveness Fading Resistance Wear Resistance Adhesive Strength Evaluation Method JASO C406 JASO C427 JIS D4422 Passenger Car - Braking Device - Automobile Parts - Automobile Parts - Dynamometer Test Procedures Brake Lining and Disc Drum Brake Shoe Brake Pad - Wear Assemblies and Disc Test Procedure on Brake Pad - Shear Inertia Dynamometer Test Procedure (kN/cm2) Second Effectiveness Fist Fade Recovery Wear Test at Test Test Respective Average Friction Minimum Friction Temperature Coefficient Coefficient Wear of Friction Initial Braking Speed: Material 130 km/h Braking Braking Deceleration: Temperature; 100 0.6 G centigrade Brake Cycle: 1000 Cycles (mm) Evaluation 0.35 or more 0.20 or more less than 0.10 0.55 or more Standard 0.30 or more 0.18 or more 0.10 or more 0.50 or more less than 0.35 less than 0.20 less than 0.15 less than 0.55 0.25 or more 0.15 or more 0.15 or more 0.45 or more less than 0.30 less than 0.20 less than 0.20 less than 0.50 X less than 0.25 less than 0.15 0.20 or more less than 0.45

[0054] Figure No. 000006

TABLE-US-00006 TABLE 6 Evaluation Items Product Appearance Evaluation Method Visually Checking the Existence of Wrinkle and Crack on the Friction Material Surface Evaluation No Wrinkle or Crack Standard X Wrinkle or Crack

[0055] Figure No. 000007

INDUSTRIAL APPLICABILITY

[0056] This invention is able to provide the friction material used for the disc brake pad, manufactured by forming the NAO friction material composition, wherein the friction material is able to secure required braking performance, fading resistance, and wear resistance, and the adhesive strength between the friction material and the back plate and the product appearance thereof is good and the cost thereof is low while satisfying laws and regulations relating to the required amount of the content of the copper component contained therein. Therefore, the friction material in this invention is extremely high practical value.