JP3682139B2 - Friction member and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a friction member used for a brake or the like of a vehicle, and particularly relates to a member having improved rust resistance.
[0002]
[Prior art]
A friction member used as a brake shoe for a drum brake or a disc pad for a disc brake in a vehicle has a configuration in which a lining material is attached to one side of a back plate. However, simply attaching it to one side of the back plate is not perfect for safety, so one or more binding holes that penetrate the back plate are opened and the lining material is attached to one side of the back plate. The lining material is entered into the binding hole, and the inner wall of the binding hole is adhered to the lining material to improve the bonding force.
[0003]
FIG. 5 shows an example of a conventional friction member and shows a back plate used for a disk pad of a disk brake. The back plate 1 shown in FIG. 1 is formed by punching a steel plate for automobiles or a structural steel plate for machinery with a press machine into a predetermined shape, and simultaneously penetrating two binding holes 2 and 2. .
[0004]
The back plate 1 is subjected to a degreasing process for removing oil on the surface after punching by a press machine, and the surface is finished by sandblasting or the like, and a thermosetting adhesive is applied to increase the bonding strength with the lining material.
[0005]
On the other hand, the lining material is manufactured from a material in which a fiber material, a filler, and a binder are mixed. As the fiber material, organic fibers such as cellulose pulp and aramid, metal fibers such as chip-shaped metal pieces or steel wool, and inorganic fibers such as rock wool are used. The filler is used for the purpose of increasing the amount or for providing a lubrication characteristic so as to obtain a stable friction. For example, barium sulfate, calcium carbonate, graphite or the like is used. The binding material binds the fiber material and the filler, and a thermosetting resin such as phenol resin or rubber is used.
[0006]
The lining material after the mixing of the raw materials is weighed to a predetermined weight, put into a mold (not shown), pressurized, and formed into a temporary molded product called “unpressed”. In the preliminary molding, in principle, the molding is performed only by pressurization and is not heated, but depending on the case, it may be heated to a temperature at which the binder does not react.
[0007]
FIG. 6 is a view showing a temporarily formed lining material. The temporary molded product 3 has the same shape as the finished product, but the density is coarse, and the thickness T is the thickness t of the finished product that is pressure-bonded to the back plate 1 and compressed to a predetermined density (see FIG. It is almost twice that of 8). The temporary molded product 3 is formed with raised portions 4 and 4 corresponding to the binding holes 2. Although the base portion 4 of the raised portion 4 is widened, the diameter d1 of the tip portion is smaller than the diameter D (FIG. 5) of the binding hole 2 so that it can easily enter the binding hole 2.
[0008]
When the back plate 1 and the lining material temporary molding 3 are thus formed, they are sent to the press shown in FIG. The press machine has an upper die 5, a frame die 6, and a plunger 7. The frame mold 6 is fixed, and the upper mold 5 and the plunger 7 are configured to be movable in the vertical direction. The upper die 5 has two protrusions 8 corresponding to the binding holes 2. The protrusion 8 has a low cylindrical shape, and its diameter d2 is considerably smaller than the diameter D of the binding hole 2.
[0009]
As shown in FIG. 7, the temporary molded product 3 is placed on the plunger 7, and the back plate 1 is placed on the frame mold 6. The frame mold 6 has a positioning pin (not shown), whereby the back plate 1 is positioned. Thereafter, the plunger 7 rises and the raised portions 4 and 4 enter from below the binding holes 2 and 2, and at the same time the upper mold 5 descends and the protrusions 8 and 8 enter from above the binding holes 2 and 2. The back plate 1 and the temporary molded product 3 are overlapped, and pressurization / heating is performed.
[0010]
FIG. 8 is a diagram showing a state where the press working has been completed. As shown in the figure, the temporary molded article 3 of the lining material reacts when heated, the binding material reacts, is pressurized and increases in density, and its thickness is reduced by about half from T to t. It becomes a lining material 9 having a density and is adhered to the back plate 1. Furthermore, the raised portions 4 and 4 that have entered the binding hole 2 are pressed from the top by the protrusions 8, spread in the binding hole 2, and are in close contact with the inner wall. Thus, the lining material 9 is bonded to both the lower surface of the back plate 1 and the inner surface of the binding hole 2 to obtain a strong bonding force.
FIG. 9 is a view showing the friction member 10 formed as described above.
[0011]
[Problems to be solved by the invention]
In the above prior art, the diameter d2 of the protrusions 8 of the upper mold 5 must be considerably smaller than the diameter D of the binding hole 2. This is because the accuracy of alignment between the positions of the protrusions 8 and 8 and the position of the binding hole 2 cannot be increased, and the protrusion 8 cannot enter the binding hole 2 when the diameter d2 of the protrusion 8 is brought close to D. This is because the protrusions 8 are galling around the periphery of the binding hole 2 and are difficult to separate after molding.
[0012]
In FIG. 8, the lining material 9 in the binding hole 2 is softened by pressurization / heating with a press and becomes a semi-fluid state. The portion of the raised portion 4 that is in contact with the protrusion 8 spreads along the top surface of the protrusion 8, but when reaching the end of the protrusion 8, the subsequent elongation deteriorates, and between the inner wall of the binding hole 2. As shown in FIG. 9, the gap 11 is easily formed.
When such a gap is formed, when this friction member is used in a vehicle or the like, moisture enters the gap, rust is generated, and the bonding force decreases from that portion.
[0013]
Therefore, conventionally, the binding material of the back plate was previously filled with a line material with a coarse density so that the gap 11 was not formed. For this reason, the number of processing steps for the friction member is increased, resulting in an increase in cost. Further, even if the hole filling is performed in this way, the problem that the protrusion 8 and the binding hole 2 are galled and difficult to be separated after molding cannot be solved.
[0014]
The present invention has been conceived from the above facts, and an object of the present invention is to provide a friction member in which the gap 11 is not formed and the mold can be easily detached after molding, and a manufacturing method thereof.
[0015]
[Means for Solving the Problems]
In order to achieve the above object, the friction member manufacturing method of the present invention is configured such that a lining material is stacked on a back plate having one or more binding holes, and the press machine is placed between an upper die or a lower die and a plunger. In a method for manufacturing a friction member that is pressed and heated between two layers and allows the lining material to enter the binding hole and adhere to the back plate, the binding is performed on the upper die or the lower die of the press facing the back plate. A chevron protrusion having a diameter larger than the hole and a height lower than the thickness of the back plate is formed, and when the lining material is compressed and fixed, the chevron protrusion enters the binding hole from the tip, and the chevron protrusion A skirt part forms a concave plastic deformation part in the peripheral part of a binding hole, and it is characterized by sticking the above-mentioned lining material with the above-mentioned binding hole inner wall.
[0016]
In addition, the lining material is preliminarily molded, or the lining material is preliminarily formed with a raised portion corresponding to the binding hole, or the lining material is preliminarily formed in the binding hole of the back plate. May be filled with a coarse density.
[0017]
The friction member according to the present invention includes a back plate having one or more binding holes, and a lining material fixed to one surface of the back plate and filled in the binding holes. In the present invention, a concave plastic deformation portion is formed in the peripheral portion of the binding hole on the side where the lining material is not fixed.
[0018]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 is a view showing a main part of a press machine for manufacturing the friction member of the present invention. The frame mold 6 and the plunger 7 are the same as the conventional one, but the shape of the protrusion 12 of the upper mold 5 is different. The conventional protrusion 8 has a short (low) cylindrical shape, but the protrusion 12 of the present invention has a mountain shape. The chevron is generally a shape that has a narrow top and expands toward the bottom, and includes various shapes such as a cone, a paraboloid, or a polygonal pyramid as well as a spherical surface as illustrated. The diameter d3 of the skirt of the chevron 12 is about 1 to 10 mm larger than the diameter D of the binding hole 2, and the height h of the chevron 12 is about 0.2 to 0.8 times the thickness H of the back plate 1. It is. The back plate 1 and the temporary molding 3 of the lining material have the same configuration as before.
[0019]
The temporary molding 3 of the lining material is placed on the plunger 7 and the back plate 1 is placed on the frame mold 6. The back plate 1 is positioned by a pin or the like (not shown) as described in the conventional example.
[0020]
Thereafter, the plunger 7 is raised, and at the same time, the upper die 5 is lowered, and the back plate 1 and the temporary molded product 3 are overlapped to be pressurized and heated. The raised portion 4 enters from below the binding hole 2, and the chevron 12 causes the tip to enter from above the binding hole 2.
[0021]
Since the ridge diameter d3 of the chevron 12 is larger than the diameter D of the binding hole 2, even if there is a slight shift in the relative position between the upper mold 5 and the back plate 1, the tip portion can be easily bonded. 2 and the chevron 12 can block the upper surface of the binding hole 2. When the chevron 12 is further lowered by the pressing force of the press, the upper die 5 is made of tool steel having a very high hardness, and the back plate 1 is made of a considerably softer automotive steel plate or mechanical structural steel plate. Plastic deformation is performed so that the peripheral portion of the hole 2 is chamfered. The raised portion 4 entering from below the binding hole 2 is in a semi-molten state by pressurization and heating, and spreads along the top surface of the chevron 12, but the chevron 12 extends over the entire surface of the binding hole 2. Since it is closed, it can be completely adhered to the inner wall of the binding hole 2. Since the protrusions are chevron shaped, the protrusions are not squeezed into the binding hole during pressing, and the mold can be easily detached.
[0022]
FIG. 2 is a view showing the configuration of the friction member 15 formed in this way. The peripheral portion of the binding hole 2 is plastically deformed to form a concave plastic deformation portion 14, and a convex plastic deformation portion 14 ′ corresponding thereto is formed below the binding hole 2. Further, the lining material packed inside the binding hole 2 has a concave surface formed by the top surface of the chevron 12, and one continuous concave corresponding to the top surface of the chevron 12 together with the plastic deformation portion 14. Form a curved surface.
[0023]
With such a configuration, the lining material 9 and the inner wall of the binding hole 2 are more closely contacted than before, and a gap cannot be formed. Therefore, moisture does not enter and rust generation can be prevented. In addition, since the close contact is good, it is possible to omit the hole filling step that has been conventionally performed, and to reduce the cost.
[0024]
FIG. 3 shows a second embodiment of the present invention. In this embodiment, a lining material 3 ′ having a coarse density similar to that of the temporary molded product 3 is preliminarily packed in the binding hole 2 of the back plate 1. The raised portion 16 of the temporary molded product 3 may be lower than the raised portion 4 of the embodiment of FIG. 1 or may not form the raised portion at all. The subsequent pressurizing / heating process is the same as in the embodiment of FIG. In this embodiment, the hole filling operation remains, but since the chevron 12 is used, the protrusion does not bite into the binding hole, and it is not difficult to remove the mold after molding.
In the case of this embodiment, it is possible to change the composition of the lining material 3 ′ packed in the binding hole 2 and the lining material of the temporary molded product 3.
[0025]
FIG. 4 is a diagram showing a third embodiment of the present invention. This embodiment has a configuration in which the top and bottom of the embodiment of FIG. 1 are inverted. That is, the back plate 1 is mounted on the lower mold 17, the frame mold 18 is mounted thereon, and the powdered lining material is put into a space 20 formed below the plunger 19. In this case, the chevron 12 is formed on the lower mold 17 that directly faces the back plate 1.
In the above embodiments, the back plate is made of a steel plate for automobiles or a structural steel plate for machinery, but it goes without saying that a back plate made of aluminum (including an aluminum alloy) or plastic can be used.
[0026]
【The invention's effect】
As described above, according to the present invention, in the method for manufacturing a friction member, a chevron having a diameter larger than the binding hole is formed on the upper die or the lower die of the press facing the back plate, and the lining material is compressed. When fixing, the chevron protrusion enters the binding hole from the tip thereof, and the bottom part of the chevron protrusion forms a concave plastic deformation part in the periphery of the binding hole, and the lining material is Since it is in close contact with the inner wall of the binding hole, the adhesion between the binding hole and the lining material is improved, a gap is not formed, and the problem of generation of rust due to intrusion of moisture does not occur. In addition, since the conventional hole filling process can be omitted, the cost is reduced. Even when the hole filling operation is performed, the mold can be easily detached.
[Brief description of the drawings]
FIG. 1 is a longitudinal sectional view for explaining a method of manufacturing a friction member according to the present invention.
2A and 2B are views of a friction member according to the present invention, in which FIG. 2A is a top view and FIG. 2B is a sectional view taken along line II-II in FIG.
FIG. 3 is a view of a second embodiment of the method for manufacturing a friction member according to the present invention, showing a cross section of a back plate and a side surface of a temporary molded product.
FIG. 4 is a longitudinal sectional view showing a third embodiment of the method for producing a friction member according to the present invention.
5A and 5B are views of a back plate, in which FIG. 5A is a top view and FIG. 5B is a cross-sectional view taken along line VV in FIG.
6A and 6B are diagrams of a lining material temporary molded product, in which FIG. 6A is a top view and FIG. 6B is a side view.
FIG. 7 is a longitudinal sectional view for explaining a conventional method of manufacturing a friction member.
FIG. 8 is a view for explaining a conventional method of manufacturing a friction member, and is a longitudinal sectional view showing a state where pressurization / heating processing is completed.
9A and 9B are views of a conventional friction member, in which FIG. 9A is a top view and FIG. 9B is a cross-sectional view taken along line IX-IX in FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Back plate 2 Binding hole 3 Temporary molding 5 (liner member) Upper mold | type 17 Lower mold | type 7,19 Plunger 9 Lining member 12 Angle projection 14 Plastic deformation part 15 Friction member

Claims (5)

A lining material is stacked on a back plate with one or more binding holes drilled, and is pressed and heated between the upper or lower mold of the press and the plunger, and the lining material enters the binding hole. In the manufacturing method of the friction member that adheres to the back plate while letting
In the upper mold or the lower mold of the press facing the back plate, a chevron projection having a diameter larger than the binding hole and lower than the thickness of the back plate is formed, and when the lining material is compressed and fixed, The chevron protrudes from the tip of the chevron into the binding hole, and the skirt of the chevron forms a concave plastic deformation part at the periphery of the binding hole so that the lining material is in close contact with the inner wall of the binding hole. The manufacturing method of the friction member characterized by these. The method for manufacturing a friction member according to claim 1, wherein the lining material is preliminarily formed. 3. The method for manufacturing a friction member according to claim 2, wherein a raised portion corresponding to the binding hole is formed in the temporarily formed lining material. The method for manufacturing a friction member according to any one of claims 1 to 3, wherein the binding hole of the back plate is previously filled with a lining material at a rough density. A friction member having a back plate in which one or more binding holes are formed, and a lining material fixed to one side of the back plate and filled in the binding holes. A concave plastic deformation portion is formed in the peripheral portion where the lining material is not fixed, and the lining material that has entered the binding hole is in close contact with the inner wall of the binding hole, and the surface of the lining material is the plastic deformation portion. And a continuous concave curved surface .

Images