JP6765211B2 - How to manufacture disc brake pads - Google Patents

How to manufacture disc brake pads Download PDF

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JP6765211B2
JP6765211B2 JP2016082944A JP2016082944A JP6765211B2 JP 6765211 B2 JP6765211 B2 JP 6765211B2 JP 2016082944 A JP2016082944 A JP 2016082944A JP 2016082944 A JP2016082944 A JP 2016082944A JP 6765211 B2 JP6765211 B2 JP 6765211B2
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JP2017194082A (en
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久 坂本
久 坂本
良尚 高橋
良尚 高橋
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Japan Brake Industrial Co Ltd
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Description

本発明は、自動車や自動二輪車等の制動に用いられるディスクブレーキパッドに関するものであり、特に、繊維基材、結合材、有機充填材および無機充填材を含む摩擦材組成物からなる摩擦材が、直接バックプレートもしくは中間層を介してバックプレート（裏金）に固着されたディスクブレーキパッドに関するものである。 The present invention relates to disc brake pads used for braking automobiles, motorcycles and the like, and in particular, a friction material composed of a friction material composition containing a fiber base material, a binder, an organic filler and an inorganic filler. It relates to a disc brake pad directly fixed to a back plate (back metal) via a back plate or an intermediate layer.

自動車や自動二輪車等の制動に用いられるディスクブレーキパッドは、キャリパ内に収容され、車軸とともに回転するディスクロータの側面を油圧等により挟み込み押さえつけることで摩擦力を発生し、運動エネルギーを熱エネルギーに変換して制動を行う部品であり、図１に示すように、キャリパに取り付けられるバックプレート（裏金）１上に、ディスクロータと摩擦摺動を行う摩擦材２が直接積層された構造、あるいは摩擦材２が接着等をになう中間層３を介して積層された構造となっている。 Disc brake pads used for braking automobiles and motorcycles are housed in calipers, and frictional force is generated by holding down the sides of the disc rotor that rotates with the axle by hydraulic pressure, etc., and converts kinetic energy into thermal energy. As shown in FIG. 1, a structure in which a friction material 2 that performs frictional sliding with a disc rotor is directly laminated on a back plate (back metal) 1 attached to a caliper, or a friction material. The structure is such that 2 is laminated via an intermediate layer 3 for bonding or the like.

ディスクブレーキパッドは、繊維基材、結合材、有機充填材および無機充填材を含む摩擦材組成物を金型の型孔に充填し、充填された摩擦材組成物を押圧して予備成形し、得られた予備成形体をバックプレート１とともに熱圧成形して一体化した後、必要に応じて熱処理をおこなって結合材の硬化を行い、摩擦材２の上端面２ａやチャンファ２ｂの研削加工、スリット２ｃの切削加工等の機械加工を経て製造される（特許文献１等）。中間層３を有するディスクブレーキパッドの場合は、中間層を形成する組成物上に摩擦材組成物を積層して充填し、摩擦材組成物と中間層組成物を予備成形することで製造することができる。なお、中間層３を有するディスクブレーキパッドにおいては、摩擦材２を上張材、中間層３を下張材と称すこともある。 The disc brake pad is preformed by filling a mold hole with a friction material composition containing a fiber base material, a binder, an organic filler and an inorganic filler, and pressing the filled friction material composition. After the obtained preformed body is hot-press molded together with the back plate 1 and integrated, heat treatment is performed as necessary to harden the binder, and the upper end surface 2a of the friction material 2 and the chamfer 2b are ground. Manufactured through machining such as cutting of the slit 2c (Patent Document 1 etc.). In the case of a disc brake pad having an intermediate layer 3, the friction material composition is laminated and filled on the composition forming the intermediate layer, and the friction material composition and the intermediate layer composition are preformed to be produced. Can be done. In the disc brake pad having the intermediate layer 3, the friction material 2 may be referred to as an upholstery material, and the intermediate layer 3 may be referred to as an underlaying material.

特開平９−１３６２５５号公報JP-A-9-136255

ディスクブレーキパッドの製造方法においては、上記のように摩擦材２の上端面２ａが研削加工等により機械加工されて製造されるが、摩擦材は既に熱硬化しているため除去される部分に関しては、再利用できず廃棄するしかなく、廃棄のためのコストが必要となっている。そこで、廃棄量を削減できれば、その分廃棄のためのコストが低減され、安価にディスクブレーキパッドを製造できることとなる。このことから、本発明は、廃棄量を削減できるディスクブレーキパッドの製造方法を提供することを目的とする。 In the disc brake pad manufacturing method, the upper end surface 2a of the friction material 2 is machined by grinding or the like as described above, but the friction material is already heat-cured and is therefore removed. , It cannot be reused and must be discarded, and the cost for disposal is required. Therefore, if the amount of waste can be reduced, the cost for disposal can be reduced accordingly, and the disc brake pad can be manufactured at low cost. From this, it is an object of the present invention to provide a method for manufacturing a disc brake pad capable of reducing the amount of waste.

上記目的を達成するため、本発明者らは、後に機械加工され平坦にされ、摩擦面となる摩擦材上端面に凹凸を形成して、機械加工により摩擦材上端面の凸部のみ除去するようにすれば、摩擦材上端面の凹部の分だけ、廃棄量が削減できると考えた。ただし、単純に予備成形工程と熱圧成形工程において、成形面に凹凸を設けた成形型および熱圧成形型で成形を行うと、成形面に設けた凹部と凸部で圧縮比が異なるため、一様な密度の摩擦材とすることができない。このため本発明者らは、上端面に凹凸を形成しながら比較的一様な密度の摩擦材とする方法について鋭意研究を重ね、本発明を成し遂げた。 In order to achieve the above object, the present inventors so as to form irregularities on the upper end surface of the friction material which is later machined and flattened to be a friction surface, and remove only the convex portion of the upper end surface of the friction material by machining. It was thought that the amount of waste could be reduced by the amount of the recess on the upper end surface of the friction material. However, if molding is simply performed with a molding die having irregularities on the molding surface and a hot pressure molding die in the preforming step and the hot pressure molding step, the compression ratio differs between the concave portion and the convex portion provided on the molding surface. It cannot be a friction material with a uniform density. For this reason, the present inventors have earnestly studied a method of forming a friction material having a relatively uniform density while forming irregularities on the upper end surface, and achieved the present invention.

上記目的を達成する本発明のディスクブレーキパッドの製造方法は、下部金型と、摩擦部材の外周形状を形成する型孔を有する上部金型と、摩擦部材の上端面に形成される凸部を成形する第１成形型と、摩擦部材の上端面に形成される凹部を成形する第２成形型と、からなる金型装置を用いて、下部金型と、上部金型の型孔とにより形成されるキャビティに摩擦部材組成物からなる原材料を充填するとともに、前記摩擦部材の上端面に形成される凹部を成形する第２成形型を下降させて、第２成形型によって形成される凹部の体積分に相当する原材料を予め周囲に流動させ、次いで、摩擦部材の上端面に形成される凸部を成形する第１成形型を降下させるとともに前記第２成形型を降下させて原材料を熱圧成形して予備成形を行い、上端面に凹凸を有する予備成形体を得る予備成形工程と、成形面に前記予備成形体の凹凸の位置に対応する凹凸を有する前記熱圧成形用成形型を用いて熱圧成形して、上端面に凹凸を有する熱圧成形体を得る熱圧成形工程と、前記上端面に凹凸を有する熱圧成形体の上端面を平坦に機械加工する機械加工工程を含むことを特徴とする。 In the method for manufacturing a disc brake pad of the present invention that achieves the above object, a lower mold, an upper mold having a mold hole forming an outer peripheral shape of the friction member, and a convex portion formed on the upper end surface of the friction member are formed. Formed by a lower mold and a mold hole of an upper mold using a mold device consisting of a first mold to be molded and a second mold for forming a recess formed on the upper end surface of a friction member. The cavity to be formed is filled with a raw material made of a friction member composition, and the second molding die for forming the recess formed on the upper end surface of the friction member is lowered to reduce the volume of the recess formed by the second molding die. The raw material corresponding to the minute is previously flowed to the surroundings, and then the first molding die for forming the convex portion formed on the upper end surface of the friction member is lowered and the second molding die is lowered to hot-press form the raw material. Using the premolding step of obtaining a premolded body having irregularities on the upper end surface and the thermal pressure molding die having irregularities on the molding surface corresponding to the positions of the irregularities of the preformed body. Includes a hot-press molding step of hot-press molding to obtain a hot-pressure molded body having irregularities on the upper end surface, and a machining step of flattening the upper end surface of the hot-pressure molded body having irregularities on the upper end surface. It is characterized by.

上記のディスクブレーキパッドの製造方法においては、前記予備成形工程において、摩擦部材の上端面に形成される凸部を成形する第１成形型を降下させて、前記第２成形型と前記第１成形型の凹凸を所定の位置で一致させた後、前記第１成形型と前記第２成形型を同期して降下させて予備成形をおこなうことが好ましく、また、前記熱圧成形工程において、前記熱圧成形用成形型の成形面に形成された凹凸が、熱圧成形体の圧縮比として等しくなる高さに形成されていることが好ましい。 In the above-mentioned method for manufacturing a disc brake pad, in the preforming step, the first molding die for molding the convex portion formed on the upper end surface of the friction member is lowered, and the second molding die and the first molding are performed. After matching the unevenness of the mold at a predetermined position, it is preferable that the first molding mold and the second molding mold are lowered in synchronization to perform premolding, and in the thermal pressure molding step, the heat It is preferable that the unevenness formed on the molding surface of the compaction mold for pressure molding is formed at a height equal to the compression ratio of the hot-press molded product.

本発明のディスクブレーキパッドの製造方法は、摩擦材となる上端面に凹凸を形成するとともに、摩擦材を比較的一様な密度とし、機械加工により摩擦材上端面の凸部のみ除去するようにしたことから、摩擦材の機械加工による廃棄量が削減でき、その分、製造コストを小さくできるという効果を奏する。 In the method for manufacturing a disc brake pad of the present invention, unevenness is formed on the upper end surface of the friction material, the friction material has a relatively uniform density, and only the convex portion of the upper end surface of the friction material is removed by machining. As a result, the amount of waste due to machining of the friction material can be reduced, and the manufacturing cost can be reduced accordingly.

ディスクブレーキパッドの形状を示す模式図であり、図１（ａ）は上面図であり、図１（ｂ）はバックプレート上に摩擦材が直接積層された構造の場合の図１（ａ）のＡ−Ａ断面を示す模式図であり、図１（ｃ）はバックプレート上に摩擦材が中間層を介して積層された構造の場合の図１（ａ）のＡ−Ａ断面を示す模式図である。FIG. 1A is a schematic view showing the shape of a disc brake pad, FIG. 1A is a top view, and FIG. 1B is FIG. 1B in the case of a structure in which a friction material is directly laminated on a back plate. FIG. 1C is a schematic view showing a cross section taken along the line AA, and FIG. 1C is a schematic view showing a cross section taken along the line AA in FIG. 1A in the case of a structure in which a friction material is laminated on a back plate via an intermediate layer. Is. 本発明のディスクブレーキパッドの製造方法における、金型装置の構造と摩擦材組成物の充填工程を示す模式図である。It is a schematic diagram which shows the structure of the mold apparatus and the filling process of a friction material composition in the manufacturing method of the disc brake pad of this invention. 本発明のディスクブレーキパッドの製造方法における、摩擦材組成物の予備成形工程において、第２成形型を降下させた状態を示す模式図である。It is a schematic diagram which shows the state which the 2nd molding mold was lowered in the pre-molding step of the friction material composition in the manufacturing method of the disc brake pad of this invention. 本発明のディスクブレーキパッドの製造方法における、摩擦材組成物の予備成形工程において、第１成形型を降下させて、第１成形型と第２成形型の下端面のプロファイルを一致させた状態を示す模式図である。In the preforming step of the friction material composition in the method for manufacturing a disc brake pad of the present invention, the first molding die is lowered to match the profiles of the lower end surfaces of the first molding die and the second molding die. It is a schematic diagram which shows. 本発明のディスクブレーキパッドの製造方法における、摩擦材組成物の予備成形工程において、第１成形型と第２成形型を同期して降下させて摩擦材組成物の予備成形を行う状態を示す模式図である。A model showing a state in which the first molding die and the second molding die are synchronously lowered to perform preforming of the friction material composition in the preforming step of the friction material composition in the method for manufacturing a disc brake pad of the present invention. It is a figure. 本発明のディスクブレーキパッドの製造方法における、熱圧成形工程を示す模式図である。It is a schematic diagram which shows the thermal pressure molding process in the manufacturing method of the disc brake pad of this invention. 本発明のディスクブレーキパッドの製造方法における、機械加工部分を示す模式図である。It is a schematic diagram which shows the machined part in the manufacturing method of the disc brake pad of this invention.

以下に本発明のディスクブレーキパッドの製造方法について説明する。 The method for manufacturing the disc brake pad of the present invention will be described below.

図２に示すように、摩擦部材の下端面を成形する下部金型１１と、摩擦部材の外周形状を形成する型孔１２ａを有する上部金型１２と、摩擦部材の上端面に形成される凸部を成形する第１成形型１３ａと、摩擦部材の上端面に形成される凹部を成形する第２成形型１３ｂからなる金型装置を用意する。すなわち、成形型１３は、第１成形型１３ａと第２成形型１３ｂから構成される。ここで、第１成形型１３ａの下端面と、第２成形型１３ｂの下端面は滑らかに接続するプロファイルに形成されている。 As shown in FIG. 2, a lower mold 11 for forming the lower end surface of the friction member, an upper mold 12 having a mold hole 12a for forming the outer peripheral shape of the friction member, and a protrusion formed on the upper end surface of the friction member. A mold device including a first molding die 13a for molding a portion and a second molding die 13b for molding a concave portion formed on the upper end surface of the friction member is prepared. That is, the molding die 13 is composed of the first molding die 13a and the second molding die 13b. Here, the lower end surface of the first molding die 13a and the lower end surface of the second molding die 13b are formed in a profile that smoothly connects.

まず、摩擦部材の上端面に形成される凹部を成形する第２成形型１３ｂを降下させて、図３に示すように、摩擦材の凹部に相当する体積分の摩擦材組成物Ｍを、第２成形型１３ｂの周囲に流動（図中矢印の方向）させる。次いで、図４に示すように、摩擦部材の上端面に形成される凸部を成形する第１成形型１３ａを降下させて、第１成形型の下端面のプロファイルと、予め降下している第２成形型１３ｂの下端面のプロファイルを一致させ、その後、図５に示すように、第１成形型１３ａと第２成形型１３ｂを同期して降下させて、摩擦材組成物Ｍの予備成形を行う。予備成形された予備成形体Ｐは上端面に凹凸を有するものとなるが、予め摩擦材の凹部に相当する体積分の摩擦材組成物Ｍを、第２成形型１３ｂの周囲に流動させた後、予備成形を行うため、予備成形体Ｐの密度分布は比較的均一となる。 First, the second molding die 13b for forming the concave portion formed on the upper end surface of the friction member is lowered, and as shown in FIG. 3, the friction material composition M having a volume corresponding to the concave portion of the friction material is formed. 2 Flow around the molding die 13b (in the direction of the arrow in the figure). Next, as shown in FIG. 4, the first molding die 13a for forming the convex portion formed on the upper end surface of the friction member is lowered, and the profile of the lower end surface of the first molding die and the previously lowered first molding die 13a are lowered. 2 The profile of the lower end surface of the molding die 13b is matched, and then, as shown in FIG. 5, the first molding die 13a and the second molding die 13b are lowered in synchronization to premold the friction material composition M. Do. The preformed preformed body P has irregularities on the upper end surface, but after the friction material composition M having a volume corresponding to the concave portion of the friction material is previously flowed around the second molding die 13b. Since pre-molding is performed, the density distribution of the pre-molded body P becomes relatively uniform.

得られた予備成形体Ｐを用いて熱圧成形を行う。熱圧成形は、図６に示すように、熱圧成形用の金型２２の型孔２２ａと熱成形用成形型２３で形成されるキャビティに予備成形体Ｐを挿入するとともに、バックプレート１を予備成形体Ｐ上に積層して配置し、熱圧成形用の金型２２と熱成形用成形型２３により予備成形体Ｐを加熱して熱圧成形を行い、熱成形体Ｔとするとともに、熱圧成形体とバックプレートの一体化を行う。熱成形用成形型２３の端面は、凹部２３ａと凸部２３ｂが形成されており、熱成形用成形型２３の凹部２３ａは予備成形体Ｐの凸部Ｐ２に、熱成形用成形型２３の凹部２２ｂは予備成形体Ｐの凸部Ｐ１に、それぞれ対応する位置に形成されている。このとき、熱成形用成形型の凹部２３ａと凸部２３ｂのプロファイルは、熱圧成形体Ｔの上端面に形成される凹凸の各部で圧縮比が等しくなるよう形成することが好ましい。 Thermal pressure molding is performed using the obtained preformed body P. In the hot pressure molding, as shown in FIG. 6, the preformed body P is inserted into the mold hole 22a of the hot pressure molding mold 22 and the cavity formed by the hot forming mold 23, and the back plate 1 is inserted. The preformed body P is laminated and arranged on the preformed body P, and the preformed body P is heated by the hot-press molding die 22 and the hot-molding mold 23 to perform hot-press molding to obtain the hot-molded body T. The hot-press molded body and the back plate are integrated. A concave portion 23a and a convex portion 23b are formed on the end surface of the thermoforming molding die 23, and the concave portion 23a of the thermoforming molding die 23 is formed on the convex portion P2 of the preformed body P and the concave portion of the thermoforming molding die 23. 22b is formed at a position corresponding to each of the convex portions P1 of the preformed body P. At this time, it is preferable that the profiles of the concave portions 23a and the convex portions 23b of the thermoforming molding die are formed so that the compression ratios are the same at each of the uneven portions formed on the upper end surface of the thermoformed body T.

得られた熱成形体Ｔは、図７（ａ）に示すように上端面に凹部Ｔａおよび凸部Ｔｂが形成されたものとなっている。この後、図７（ａ）の点線部より上部にあたる凹部Ｔａおよび凸部Ｔｂを研削等の機械加工により除去して平坦な摩擦面を形成するとともに、チャンファ部および溝部の機械加工を行い、図７（ｂ）に示すディスクブレーキパッドとする。摩擦面の機械加工においては、摩擦材の凸部Ｔａの分は廃棄することとなるが、摩擦材の凹部Ｔｂの分だけ廃棄量が削減でき、その分製造コストを低減することができる。 As shown in FIG. 7A, the obtained thermoformed body T has a concave portion Ta and a convex portion Tb formed on the upper end surface. After that, the concave portion Ta and the convex portion Tb above the dotted line portion in FIG. 7A are removed by machining such as grinding to form a flat friction surface, and the chamfer portion and the groove portion are machined. The disc brake pad shown in 7 (b) is used. In the machining of the friction surface, the convex portion Ta of the friction material is discarded, but the waste amount can be reduced by the amount of the concave portion Tb of the friction material, and the manufacturing cost can be reduced accordingly.

上記の形態は、凹凸を波形として形成した例であるが、矩形、台形等としてもよい。また、上記の形態は、成形型１３および熱圧成形用成形型２３の凹凸の間隔を等間隔に配置した例であるが、成形型１３および熱圧成形用成形型２３の凹凸の間隔を不等間隔に配置することもできる。また、凹凸は一方向に連続した形状とすることもできるし、斑状に形成することもできる。 The above form is an example in which the unevenness is formed as a waveform, but it may be a rectangle, a trapezoid, or the like. Further, the above-mentioned form is an example in which the unevenness of the molding die 13 and the hot-press molding molding die 23 is arranged at equal intervals, but the spacing between the unevenness of the molding die 13 and the hot-press forming molding die 23 is not equal. It can also be arranged at equal intervals. Further, the unevenness can be formed in a continuous shape in one direction, or can be formed in a mottled shape.

以上は、バックプレート上に直接摩擦材を積層したディスクブレーキパッドの製造方法の例であるが、充填工程において、下部金型１０と、上部金型１１の型孔１１ａにより形成されるキャビティに中間層を形成する中間層組成物を充填した後、充填された中間層組成物の上に摩擦材組成物を積層して充填し、後の工程は上記と同様にすることで、バックプレート上に、摩擦材が中間層を介して積層されたディスクブレーキパッドを製造することができる。 The above is an example of a method for manufacturing a disc brake pad in which a friction material is directly laminated on a back plate. In the filling process, the lower mold 10 and the cavity formed by the mold hole 11a of the upper mold 11 are intermediate. After filling the intermediate layer composition forming the layer, the friction material composition is laminated and filled on the filled intermediate layer composition, and the subsequent steps are carried out in the same manner as described above on the back plate. , It is possible to manufacture a disc brake pad in which a friction material is laminated via an intermediate layer.

なお、摩擦材の組成としては、従来の摩擦材組成物をそのまま用いることができる。すなわち、摩擦材組成物として、繊維基材、結合剤、有機充填材および無機充填材を含む摩擦材組成物を用いることができる。基材繊維としては、ガラス繊維、炭素繊維、金属繊維、セラミック繊維、ロックウール、アラミド繊維、アクリル繊維等を用いることができる。結合材としては、熱硬化性樹脂であって、フェノール骨格を有する、熱劣化しても炭素として残りにくい樹脂が好ましく、フェノール樹脂やアクリルや各種エラストマで変性したフェノール樹脂等を用いることができる。有機充填材としては、カシューダスト、ゴムダスト等の有機粉末を用いることができる。無機充填材としては、アルミナやジルコニア等の無機粉末粒子、黒鉛、硫化アンチモン、硫化錫等の潤滑剤、銅、アルミニウム、亜鉛等の金属粉末粒子を用いることができる。 As the composition of the friction material, the conventional friction material composition can be used as it is. That is, as the friction material composition, a friction material composition containing a fiber base material, a binder, an organic filler and an inorganic filler can be used. As the base fiber, glass fiber, carbon fiber, metal fiber, ceramic fiber, rock wool, aramid fiber, acrylic fiber and the like can be used. As the binder, a thermosetting resin having a phenolic skeleton and which does not easily remain as carbon even after thermal deterioration is preferable, and a phenolic resin, acrylic, or a phenolic resin modified with various elastomas can be used. As the organic filler, organic powder such as cashew dust and rubber dust can be used. As the inorganic filler, inorganic powder particles such as alumina and zirconia, lubricants such as graphite, antimony sulfide and tin sulfide, and metal powder particles such as copper, aluminum and zinc can be used.

また、上記の予備成形工程、熱圧成形工程および機械加工工程の他、従来から行われている他の工程を必要に応じ追加してもよい。すなわち本発明のディスクブレーキパッドの製造方法においては、樹脂の硬化を促進する熱処理工程を設けてもよく、摩擦材の表面をスコーチ処理するスコーチ処理工程を設けてもよく、ディスクブレーキパッドの塗装工程を追加してもよい。 Further, in addition to the above-mentioned preforming step, hot pressure forming step and machining step, other conventional steps may be added as necessary. That is, in the method for manufacturing a disc brake pad of the present invention, a heat treatment step for promoting curing of the resin may be provided, a scorch treatment step for scorching the surface of the friction material may be provided, and a disc brake pad coating step may be provided. May be added.

本発明のディスクブレーキパッドは、機械加工により廃棄される素材の量を低減でき、その分廃棄コストが抑制できるものであり、自動車や自動二輪車等の制動に用いられるディスクブレーキパッドの製造方法として好適なものである。 The disc brake pad of the present invention can reduce the amount of material discarded by machining and can suppress the disposal cost accordingly, and is suitable as a method for manufacturing a disc brake pad used for braking automobiles, motorcycles, etc. It is a thing.

１…バックプレート、２…摩擦材、２ａ…摩擦材の上端面、２ｂ…摩擦材のチャンファ、２ｃ…摩擦材のスリット、３…中間層、
１１…下部金型、１２…上部金型、１２ａ…上部金型の型孔、１３…成形型、１３ａ…第１成形型、１３ｂ…第２成形型、
２２…熱圧成形用の金型、２２ａ…熱圧成形用の金型の型孔、２３…熱成形用成形型、２３ａ…熱成形用成形型の凹部、２３ｂ…熱成形用成形型の凸部、
Ｐ…予備成形体、Ｐａ…予備成形体の凹部、Ｐｂ…予備成形体の凸部、
Ｔ…熱成形体、Ｔａ…熱成形体の凹部、Ｔｂ…熱成形体の凸部 1 ... back plate, 2 ... friction material, 2a ... upper end surface of friction material, 2b ... friction material chamfer, 2c ... friction material slit, 3 ... intermediate layer,
11 ... Lower mold, 12 ... Upper mold, 12a ... Upper mold hole, 13 ... Molding mold, 13a ... First molding mold, 13b ... Second molding mold,
22 ... Thermoforming mold, 22a ... Thermoforming mold hole, 23 ... Thermoforming mold, 23a ... Thermoforming mold concave, 23b ... Thermoforming mold convex Department,
P ... Preformed body, Pa ... Recessed part of preformed body, Pb ... Convex part of preformed body,
T ... thermoformed body, Ta ... concave portion of thermoformed body, Tb ... convex portion of thermoformed body

Claims (3)

下部金型と、摩擦部材の外周形状を形成する型孔を有する上部金型と、摩擦部材の上端面に形成される凸部を成形する第１成形型と、摩擦部材の上端面に形成される凹部を成形する第２成形型と、からなる金型装置を用いて、
下部金型と、上部金型の型孔とにより形成されるキャビティに摩擦部材組成物からなる原材料を充填するとともに、
前記摩擦部材の上端面に形成される凹部を成形する第２成形型を下降させて、第２成形型によって形成される凹部の体積分に相当する原材料を予め周囲に流動させ、
次いで、摩擦部材の上端面に形成される凸部を成形する第１成形型を降下させるとともに前記第２成形型を降下させて原材料を熱圧成形して予備成形を行い、上端面に凹凸を有する予備成形体を得る予備成形工程と、
成形面に前記予備成形体の凹凸の位置に対応する凹凸を有する熱圧成形用成形型を用いて熱圧成形して、上端面に凹凸を有する熱圧成形体を得る熱圧成形工程と、
前記上端面に凹凸を有する熱圧成形体の上端面を平坦に機械加工する機械加工工程を含むことを特徴とするディスクブレーキパッドの製造方法。 The lower mold, the upper mold having a mold hole for forming the outer peripheral shape of the friction member, the first molding mold for forming the convex portion formed on the upper end surface of the friction member, and the upper end surface of the friction member are formed. Using a mold device consisting of a second molding mold for molding the concave portion
The cavity formed by the lower mold and the mold hole of the upper mold is filled with a raw material made of a friction member composition, and at the same time.
The second molding die for forming the recess formed on the upper end surface of the friction member is lowered, and the raw material corresponding to the volume of the recess formed by the second molding die is previously flowed around.
Next, the first molding die for forming the convex portion formed on the upper end surface of the friction member is lowered, and the second molding die is lowered to hot-press mold the raw material to perform preforming, and unevenness is formed on the upper end surface. Pre-molding process to obtain a pre-molded body to have
A hot-press molding step of obtaining a hot-press molded body having irregularities on the upper end surface by hot-press molding using a hot-pressure molding mold having irregularities corresponding to the positions of the irregularities on the preformed surface.
A method for manufacturing a disc brake pad, which comprises a machining step of flatly machining the upper end surface of a hot-pressure molded product having irregularities on the upper end surface. 前記予備成形工程において、摩擦部材の上端面に形成される凸部を成形する第１成形型を降下させて、前記第２成形型と前記第１成形型の凹凸を所定の位置で一致させた後、前記第１成形型と前記第２成形型を同期して降下させて予備成形をおこなうことを特徴とする請求項１に記載のディスクブレーキパッドの製造方法。 In the pre-molding step, the first molding die for forming the convex portion formed on the upper end surface of the friction member was lowered to match the unevenness of the second molding die with the unevenness of the first molding die at a predetermined position. The method for manufacturing a disc brake pad according to claim 1, wherein after that, the first molding die and the second molding die are lowered in synchronization to perform premolding. 前記熱圧成形工程において、前記熱圧成形用成形型の成形面に形成された凹凸が、熱圧成形体の上端面における凹部と凸部とで圧縮比として等しくなる高さに形成されていることを特徴とする請求項１または２に記載のディスクブレーキパッドの製造方法。 In the hot pressure molding step, the unevenness formed on the molding surface of the hot pressure molding mold is formed at a height at which the concave portion and the convex portion on the upper end surface of the hot pressure molding body have the same compression ratio. The method for manufacturing a disc brake pad according to claim 1 or 2, wherein the disc brake pad is manufactured.
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