Friction member and method for manufacturing a friction member

Abstract

To provide a friction member having a high coefficient of friction and a friction material made from a thermoplastic resin composition, and a method for manufacturing the friction member. [Solution] A method for manufacturing a friction member comprising at least a friction material and a backing plate supporting the friction material, comprising the step of melt-molding a resin composition at a temperature above the softening flow temperature of a thermoplastic resin (A) to form the friction material and the backing plate in the same molding cycle, wherein the resin composition is a blend of a thermoplastic resin (A) having a melt viscosity (V6) of 30 Pa·s or less and a flow softening temperature of 130°C or higher, and an inorganic filler (B) as essential components, and the amount of the thermoplastic resin (A) blended is 50 parts by mass or less per 100 parts by mass of the resin composition, and a friction member.

Claims

1. A method for manufacturing a friction member comprising at least a friction material and a backing plate that supports the friction material, The process involves melt-molding a resin composition at a temperature above the softening flow temperature of a thermoplastic resin (A) to form the friction material and the backing plate in the same molding cycle. The resin composition comprises a thermoplastic resin (A) having a melt viscosity (V6) of 30 Pa·s or less and a fluid softening temperature of 130°C or higher, and an inorganic filler (B) as essential components. A method for manufacturing a friction member, characterized in that the amount of the thermoplastic resin (A) blended is 50 parts by mass or less per 100 parts by mass of the resin composition. (However, the melt viscosity (V6) is the melt viscosity obtained by holding the thermoplastic resin (A) for 6 minutes at a temperature of softening flow temperature + 20°C using a flow tester, with a load of 1.96 MPa, and using an orifice with an orifice length-to-orifice diameter ratio of 10 / 1.)

2. A method for manufacturing a friction member comprising at least a friction material and a backing plate that supports the friction material, The process involves forming a friction material by melt-molding a resin composition at a temperature above the softening flow temperature of thermoplastic resin (A) in a mold into which the backing plate has been inserted. The resin composition comprises a thermoplastic resin (A) having a melt viscosity (V6) of 30 Pa·s or less and a fluid softening temperature of 130°C or higher, and an inorganic filler (B) as essential components, and A method for manufacturing a friction member, characterized in that the amount of the thermoplastic resin (A) blended is 50 parts by mass or less per 100 parts by mass of the resin composition.

3. The method for manufacturing a friction member according to claim 1 or 2, wherein the thermoplastic resin (A) is at least one selected from the group consisting of polybutylene terephthalate, polyamide-6T, polyamide-9T, polyamide-10T, polyamide MXD6, and polyarylene sulfide resin.

4. The method for manufacturing a friction member according to claim 1 or 2, wherein the resin composition is further enriched with a solid lubricant (C).

5. The method for manufacturing a friction member according to claim 1 or 2, wherein the resin composition is further enriched with an organic filler (D).

6. The method for manufacturing a friction member according to claim 2, wherein the backing plate is at least one selected from the group consisting of a resin member, a metal member, and a ceramic member.

7. A friction member comprising at least a friction material and a backing plate that supports the friction material, The friction material and the backing plate are formed by melt-molding a resin composition at a temperature above the softening flow temperature of thermoplastic resin (A). The resin composition comprises a thermoplastic resin (A) having a melt viscosity (V6) of 30 Pa·s or less and a fluid softening temperature of 130°C or higher, and an inorganic filler (B) as essential components, and A friction member characterized in that the amount of the thermoplastic resin (A) blended is 50 parts by mass or less per 100 parts by mass of the resin composition.

8. A friction member comprising at least a friction material and a backing plate that supports the friction material, The friction material is formed by melt-molding a resin composition at a temperature above the softening flow temperature of a thermoplastic resin (A), The backing plate is at least one selected from the group consisting of metal members and ceramic members. The resin composition comprises a thermoplastic resin (A) having a melt viscosity (V6) of 30 Pa·s or less and a fluid softening temperature of 130°C or higher, and an inorganic filler (B) as essential components, and A friction member characterized in that the amount of the thermoplastic resin (A) blended is 50 parts by mass or less per 100 parts by mass of the resin composition.

9. The friction member according to claim 6 or 7, wherein the thermoplastic resin (A) is at least one selected from the group consisting of polybutylene terephthalate, polyamide-6T, polyamide-9T, polyamide-10T, polyamide MXD6, and polyarylene sulfide resin.

10. The friction member according to claim 6 or 7, wherein the resin composition is further compounded with a solid lubricant (C).

11. The friction member according to claim 6 or 7, wherein the resin composition is further enriched with an organic filler (D).

12. A method of using the friction member described in claim 6 or 7 as a braking component.

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