Automobile disc brake pad and method of manufacturing the same

Abstract

The application provides a preparation method of an automobile disc type friction piece, and comprises the following steps: S1, selecting a suitable skeleton material and treating the surface of the skeleton material; S2, wetting the surface of the skeleton material with an adhesive, then spraying and drying a friction aid, and repeating the wetting, spraying and drying for multiple times to obtain a coated body; S3, mixing the coated body and other raw materials according to a proportion to obtain plastic pressure material, and hot-pressing the plastic pressure material to obtain the automobile disc type friction piece. By coating a large amount of friction-reducing aid on the surface of the metal fiber, the metal fiber contact area is targetedly reduced in friction, and the loss of the mating material is effectively avoided. Meanwhile, the metal fiber is coated with light fillers and fibers on the periphery to form a light shell, which reduces the high-frequency noise generated when the metal fiber rubs against the mating material. The prepared automobile disc type friction piece can effectively reduce the wear of the disc type piece, stabilize the friction coefficient, protect the mating material and reduce the noise frequency.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile brake pad manufacturing, in particular to an automobile disc friction plate and a preparation method thereof. BACKGROUND

[0002] With the improvement of people's living standards, the comfort requirement in the automobile braking process is higher and higher, but the traditional semi-metallic disc plate has stable friction coefficient and braking performance under high temperature conditions, but it is easy to hurt the opposite material, and rust bonding occurs in a humid environment. However, the ceramic brake pad has higher braking comfort performance, but the cost is higher, and high-temperature ablation occurs under extreme high temperature.

[0003] Therefore, it is necessary to design an automobile friction plate to improve the injury to the opposite material to overcome the above problems. SUMMARY

[0004] The present application aims to overcome the defects of the prior art and provides an automobile disc friction plate and a preparation method thereof. The dispersively distributed friction-reducing additives and light fillers in the conventional friction material are attached to the surface of the metal fiber by multiple atomization spraying and adhesion, which improves the injury of the metal fiber to the opposite material, prevents high-frequency noise, and increases the designability of the structure of the friction plate to a certain extent.

[0005] The present application is implemented as follows:

[0006] The present application provides a preparation method of an automobile disc friction plate, comprising the following steps:

[0007] S1, selecting a suitable skeleton material and treating the surface of the skeleton material;

[0008] S2, wetting the surface of the skeleton material with an adhesive, then spraying and drying the friction aid, and repeating the wetting, spraying and drying multiple times to obtain a coated body;

[0009] S3, mixing the coated body and the remaining raw materials according to the proportion to obtain plastic pressure material, and hot pressing the plastic pressure material to form an automobile disc friction plate;

[0010] The automobile disc friction plate comprises the following components in mass percentage: phenolic resin 3-8%, synthetic graphite 5-15%, molybdenum disulfide 1-3%, antimony sulfide 0-4%, coated body 25-45%, potassium titanate whisker 5-10%, a alumina 2-10%, filler 5-40%, and calcined petroleum coke 8-20%.

[0011] The skeleton material is generally metal fiber, a large amount of friction-reducing additives is coated on the surface of the metal fiber, the metal fiber contact area is targetedly reduced, and the loss of the counter material is effectively avoided; meanwhile, the metal fiber is coated with light fillers and fibers outside, a light shell is formed, and high-frequency noise generated when the metal fiber rubs against the counter material is reduced.

[0012] Further, the skeleton material is steel fiber or copper fiber, the length of the steel fiber is 5-15mm, and the length of the copper fiber is 5.5-10mm.

[0013] Further, the surface treatment in step S1 is specifically acid pickling by using 1-5% dilute hydrochloric acid and 1-5% dilute nitric acid, and the acid pickling time is 0.2-1h.

[0014] Further, the adhesive is liquid phenolic resin, which is uniformly atomized and sprayed on the skeleton material after surface treatment, and the spraying amount is 1-10% of the weight of the skeleton material.

[0015] Further, the friction aid is two or more of molybdenum disulfide, antimony disulfide, carbon fiber, ceramic fiber, light calcium silicate and light calcium carbonate.

[0016] Further, the hot pressing forming process condition in step S3 is that the forming pressure is 35±2Mpa, the forming temperature is 165±5℃, and the pressure holding time is 9min.

[0017] The application also provides an automobile disc friction plate prepared by the above method, which comprises the following components in percentage by mass: phenolic resin 3-8%, synthetic graphite 5-15%, molybdenum disulfide 1-3%, antimony sulfide 0-4%, coated body 25-45%, potassium titanate whisker 5-10%, a-alumina 2-10%, filler 5-40% and calcined petroleum coke 8-20%.

[0018] The application has the following beneficial effects:

[0019] 1. The metal fiber is wrapped by spraying the aid, the structure form of the metal fiber is improved, the first layer of the friction-reducing material provides targeted lubrication effect, the product wear is reduced, the disc damage feature of the semi-metallic friction plate is greatly relieved, and the thermal welding effect of the metal fiber is also weakened.

[0020] 2. The combination strength of the steel fiber and the base material is improved by the coating of the inorganic fiber material, meanwhile, a damping space is provided around the steel fiber, and the high-frequency noise generated by the friction of the steel fiber and the disc is reduced. BRIEF DESCRIPTION OF DRAWINGS

[0021] In order to make the technical solutions in the embodiments of the present application or the prior art clearer, the accompanying drawings needed in the embodiments or prior art description will be briefly introduced. Obviously, the accompanying drawings in the following description only represent some of the embodiments of the present application, and all other embodiments obtained by a person of ordinary skill in the art without any creative effort based on the embodiments in the present application shall fall within the protection scope of the present application.

[0022] Figure 1 The disc surface state diagram of the disc brake pad prepared in Example 1 and Example 2 and the conventional product after the bench test completed by the AKmaster program in the present application. DETAILED DESCRIPTION

[0023] The technical solutions in the embodiments of the present application will be described clearly and completely in the following with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments only represent some of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without any creative effort shall fall within the protection scope of the present application.

[0024] Example 1

[0025] The automobile disc brake pad in the present embodiment comprises components of phenolic resin 5%, synthetic graphite 11%, molybdenum disulfide 3%, coating body 32.20%, potassium titanate whisker 6%, a-alumina 4%, calcined petroleum coke 11%, and filler 27.80% by mass percentage; wherein the coating body comprises steel fiber 28%, molybdenum disulfide 1.4%, acrylic pulp 0.4%, and light calcium silicate 2.4%.

[0026] The preparation process is as follows:

[0027] 1. Low-carbon steel fiber with a fiber length of 5-15 mm is selected, and the surface of the steel fiber is pickled with 1-5% concentrated hydrochloric acid and 1-5% or so dilute nitric acid, the pickling time is 0.4 h, and the steel fiber is immediately rinsed in a buffer solution and clean water after pickling, and is immediately dried by warm air;

[0028] 2. The liquid resin is atomized and uniformly sprayed on the surface of the steel fiber by using an atomizing nozzle, the polymerization degree of the liquid phenolic resin is between 30-300, the spraying amount is between 1%-10% of the weight of the steel fiber, then the first layer of friction aid molybdenum disulfide and light calcium silicate is sprayed, and after drying, the liquid resin is continuously sprayed, and the second layer of friction aid acrylic pulp is sprayed. After the spraying is completed, separation is carried out on a high-frequency vibration machine or in a double-motion mixer, and a separating agent barium sulfate can be added during the separation, and finally a granular coating body is obtained;

[0029] 3. The wrapped body particles and other formula components are mixed using a plowshare mixer at a speed of 1500 r / min, and plasticized material is obtained after mixing for 5 min; the plasticized material is put into a hot-pressing mold, the forming pressure is 35±2 Mpa, the forming temperature is 165±5℃, and the pressure holding time is 9 min.

[0030] Example 2

[0031] The automobile disc friction plate of the embodiment comprises components of phenolic resin 4%, synthetic graphite 8%, molybdenum disulfide 4%, wrapped body 29.79%, potassium titanate whisker 7%, a-alumina 4%, calcined petroleum coke 9%, and filler 34.21% by mass percentage; wherein the wrapped body comprises steel fiber 25%, molybdenum disulfide 0.7%, antimony sulfide 1%, aramid pulp 0.49%, light calcium silicate 1%, and light calcium carbonate 1.6%.

[0032] The preparation process is as follows:

[0033] 1. Low-carbon steel fibers with a fiber length of 5-15 mm are selected, and the surface of the steel fibers is pickled with 1-5% concentrated hydrochloric acid and 1-5% dilute nitric acid, the pickling time is 1 h, and the steel fibers are immediately rinsed in a buffer solution, clean water, and immediately dried by warm air after pickling;

[0034] 2. The surface of the steel fibers is uniformly sprayed with liquid resin using an atomizing nozzle, the degree of polymerization of the liquid phenolic resin is between 30-300, the spraying amount is between 1%-10% of the weight of the steel fibers, and then the first layer of friction aids, molybdenum disulfide, antimony sulfide, light calcium silicate, and light calcium carbonate, are sprayed, and after drying, the liquid resin is continuously sprayed, and the second layer of friction aids, aramid pulp, is sprayed. After the spraying is completed, separation is performed on a high-frequency vibration machine or in a double-motion mixer, and a separating agent, barium sulfate, can be added during the separation, and finally, the wrapped body in the form of particles is obtained;

[0035] 3. The wrapped body particles and other formula components are mixed using a plowshare mixer at a speed of 1500 r / min, and plasticized material is obtained after mixing for 5 min; the plasticized material is put into a hot-pressing mold, the forming pressure is 35±2 Mpa, the forming temperature is 165±5℃, and the pressure holding time is 9 min.

[0036] The compositions of the products prepared in Examples 1 and 2 and conventional products are compared, and Klaus tests and brake noise tests are respectively performed, and the results are shown in Table 1:

[0037] Table 1

[0038]

[0039]

[0040] Wherein, uop1 and uop2 represent the friction coefficient of the material, and pad1 and pad2 represent the wear of the product, and it can be seen from the data that the quality wear pad1 and pad2 of the embodiment 1 and the embodiment 2 added with the cladding body are obviously smaller than the wear of the conventional product, and the uop1 and uop2 are more stable.

[0041] In addition, the bench test is completed by the AKmaster program for the embodiment 1, the embodiment 2 and the conventional product respectively, and the disc surface effect is as shown in Figure 1 Figure 1 Wherein Figure 1 (a) is the disc surface state diagram of the product of the embodiment 1, (b) is the disc surface state diagram of the product of the embodiment 2, and (c) is the disc surface state diagram of the conventional product, and it can be seen from the test result that the wear of the friction material product added with the cladding body is lower on the klaus test machine, and the friction coefficient is more stable. From the bench data, it can be seen that the high decibel noise occurrence proportion of the embodiment 1 and the embodiment 2 added with the cladding body is obviously reduced, and the smoothness of the brake disc surface is obviously better. The above conclusion is drawn that the addition of the cladding body can effectively reduce the wear of the disc type sheet, stabilize the friction coefficient, protect the mating material and reduce the noise occurrence frequency.

[0042] In conclusion, the present application coats a large amount of friction-reducing additives on the surface of the metal fiber, and the metal fiber contact area is reduced in friction, the loss of the mating material is effectively avoided, and at the same time, the light filler and the fiber are coated on the periphery of the metal fiber, a light shell is formed, and the high-frequency noise generated when the metal fiber rubs with the mating material is reduced.

[0043] The above only describes the preferred embodiments of the present application, and does not limit the present application, and any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A method of manufacturing a disc brake pad for an automotive vehicle, characterized in that, It comprises the following steps: S1, selecting a suitable skeleton material, treating the surface of the skeleton material; the skeleton material is metal fiber; S2, wetting the surface of the skeleton material with an adhesive, then spraying and drying a rubbing aid, repeating the wetting, spraying and drying several times to obtain a coated body; the adhesive is liquid phenolic resin, which is uniformly atomized and sprayed on the surface treated skeleton material, the spraying amount is 1-10% of the weight of the skeleton material; the rubbing aid is two or more of molybdenum disulfide, carbon fiber, ceramic fiber, light calcium silicate and light calcium carbonate; S3, mixing the coated body and the remaining raw materials according to the proportion to obtain plastic pressure material, and hot pressing the plastic pressure material to obtain automobile disc friction plate; The automobile disc friction plate comprises the following components in mass percentage: phenolic resin 3-8%, synthetic graphite 5-15%, molybdenum disulfide 1-3%, antimony sulfide 0-4%, coated body 25-45%, potassium titanate whisker 5-10%, a alumina 2-10%, filler 5-40%, and calcined petroleum coke 8-20%.

2. The method of manufacturing an automotive disc brake pad according to claim 1, wherein: The skeleton material is steel fiber or copper fiber, the length of steel fiber is 5-15mm, and the length of copper fiber is 5.5-10mm.

3. The method of manufacturing an automotive disc brake pad of claim 1, wherein: The surface treatment in step S1 is specifically: pickling with 1-5% dilute hydrochloric acid and 1-5% dilute nitric acid, pickling time is 0.2-1h.

4. The method of claim 1 wherein: The hot pressing process conditions in step S3 are: forming pressure is 35±2Mpa, forming temperature is 165±5℃, and pressure holding time is 9min.

5. A disc brake pad for automotive vehicles, prepared by the process according to any one of claims 1 to 4, characterized in that, It comprises the following components in mass percentage: phenolic resin 3-8%, synthetic graphite 5-15%, molybdenum disulfide 1-3%, antimony sulfide 0-4%, coated body 25-45%, potassium titanate whisker 5-10%, a alumina 2-10%, filler 5-40%, and calcined petroleum coke 8-20%.

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