KR20200123296A - Mothod for manufacturing brake disc pad and brake disc pad for vehicles - Google Patents

Mothod for manufacturing brake disc pad and brake disc pad for vehicles Download PDF

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KR20200123296A
KR20200123296A KR1020190045174A KR20190045174A KR20200123296A KR 20200123296 A KR20200123296 A KR 20200123296A KR 1020190045174 A KR1020190045174 A KR 1020190045174A KR 20190045174 A KR20190045174 A KR 20190045174A KR 20200123296 A KR20200123296 A KR 20200123296A
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powder
carbon fiber
weight
green body
brake disc
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KR1020190045174A
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KR102208646B1 (en
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김영근
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(주)에스모터스
김영근
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62645—Thermal treatment of powders or mixtures thereof other than sintering
    • C04B35/6267—Pyrolysis, carbonisation or auto-combustion reactions
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • C04B35/83—Carbon fibres in a carbon matrix
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D65/12—Discs; Drums for disc brakes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2061/00—Use of condensation polymers of aldehydes or ketones or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/07—Parts immersed or impregnated in a matrix
    • B32B2305/076—Prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/604—Pressing at temperatures other than sintering temperatures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/612—Machining

Abstract

Disclosed is a method for manufacturing a brake disc pad for a vehicle to provide excellent high temperature strength and wear-resistance. According to the present invention, the method comprises: a step of impregnating carbon fiber with a dipping resin, in which a phenolic resin, pitch, and carbon nanotubes are mixed, to prepare a carbon fiber prepreg; a step of coating an oxidation prevention film forming powder, in which MoSi_2 powder, BN powder, MoS_2 powder, and FeS powder are mixed, on a surface of the prepared carbon fiber prepreg; a green body molding step of putting the carbon fiber prepreg coated with the oxidation prevention film in a mold and pressing the mold in a vacuum atmosphere while gradually heating the same to mold a planar green body; a carbonization step of carbonizing the molded green body at a temperature condition of 1,250-1,500°C in a vacuum inert gas atmosphere; and a processing step of processing the carbonized green body into a brake disk pad.

Description

차량용 브레이크 디스크 패드 제조방법 및 차량용 브레이크 디스크 패드{Mothod for manufacturing brake disc pad and brake disc pad for vehicles}TECHNICAL FIELD The manufacturing method of a brake disk pad for a vehicle and a brake disk pad for a vehicle TECHNICAL FIELD

이 발명은 차량용 브레이크 디스크 패드의 제조방법 및 브레이크 디스크 패드에 관한 것으로, 더욱 상세하게는 카본-카본 복합재료로 브레이크 디스크 패드를 성형 및 가공함으로써 금속제 브레이크 디스크 패드에 비하여 경량이면서 고온강도 및 내마모성이 우수한 제품의 제공할 수 있고 제공 공정이 단순하여 생산성이 좋은 차량용 브레이크 디스크 패드 제조방법 및 브레이크 디스크 패드에 관한 것이다.The present invention relates to a method of manufacturing a brake disk pad for a vehicle and a brake disk pad, and more particularly, by molding and processing a brake disk pad from a carbon-carbon composite material, it is lighter than a metal brake disk pad, and has excellent high temperature strength and abrasion resistance. The present invention relates to a vehicle brake disk pad manufacturing method and a brake disk pad having good productivity due to a product offering and a simple provision process.

전기 자동차, 자율주행 자동차를 포함한 새로운 형태의 자동차 개발과 함께 안정성을 담보하면서 에너지의 효율적 사용을 위해 자동차의 무게를 줄이기 위한 노력이 계속되고 있다. 이러한 노력의 일환으로 철 소재의 자동차 부품을 대체할 수 있는 신소재의 개발의 개발도 적극적으로 이루어지고 있는 실정이다.Efforts to reduce the weight of the vehicle for efficient use of energy while ensuring stability are continuing along with the development of new types of vehicles including electric vehicles and autonomous vehicles. As part of these efforts, the development of new materials that can replace auto parts made of iron is also actively being developed.

자동차의 루프, 후드 등 부품과 부품 간에 직접적인 마찰이 없는 일부 부품들은 차량의 경량화를 위해서 탄소섬유를 포함하는 복합재료로 제작되기도 한다. 다만, 브레이크 디스크와 브레이크 디스크 패드와 같이 부품과 부품이 직접 마찰하는 부품의 경우에는 아직 이를 대체하기에 충분한 소재 개발이 이루어지지 않았거나, 일부 개발이 된 경우에도 상용차에 적용하기에는 강도, 가격, 경량화 정도 등 여러 측면을 고려할 때 충분하게 만족할 정도가 아니다.Some parts that do not have direct friction between parts and parts, such as roofs and hoods of automobiles, are also made of composite materials containing carbon fiber to reduce vehicle weight. However, in the case of parts with direct friction between parts and parts, such as brake discs and brake disc pads, sufficient material to replace them has not yet been developed, or even if some have been developed, strength, price, and weight are reduced to be applied to commercial vehicles. It is not enough to be satisfied when considering various aspects such as degree.

한편, 항공기, 열차, 일부의 자동차 등에는 카본 복합소재로 제작된 브레이크 디스크 및 브레이크 디스크 패드가 일부 적용이 되고 있기는 하지만 제조 과정이 복잡할 뿐만 아니라 그 가격이 고가이기 때문에 상용 자동차에 적용하기에는 여러 어려움이 있는 현실이다.On the other hand, although some of the brake discs and brake disc pads made of carbon composite materials are applied to aircraft, trains, and some automobiles, the manufacturing process is complicated and the price is high, so it is difficult to apply them to commercial vehicles. It is a reality with difficulties.

대한민국특허청 등록특허공보 제10-1610131호Korean Intellectual Property Office Registered Patent Publication No. 10-1610131 대한민국특허청 공개특허공보 제10-2019-0001633호Korean Intellectual Property Office Publication No. 10-2019-0001633

이 발명은 카본-카본 복합재료로 브레이크 디스크를 성형 및 가공함으로써 금속제 브레이크 디스크에 비하여 경량이면서도 고온강도, 내마모성이 우수한 부품을 제공할 수 있을 뿐만 아니라 제공 공정이 단순하여 생산성이 우수한 차량용 브레이크 디스크 제조방법 및 브레이크 디스크를 제공하는 데 목적이 있다.This invention is a manufacturing method for vehicle brake discs with excellent productivity due to simple provisioning process, as well as being able to provide parts that are lightweight, high-temperature strength, and abrasion resistance superior to metal brake discs by molding and processing a brake disc with a carbon-carbon composite material. And to provide a brake disk.

이 발명의 일 실시 예에 따른 차량용 브레이크 디스크 패드 제조방법은 카본섬유 100중량부에 대하여 페놀계 수지 10~25 중량%, 피치 10~25 중량%, 탄소나노튜브 0.3~5 중량%가 혼합된 함침수지를 준비하는 함침수지 준비단계; 함침수지에 카본섬유를 함침하여 카본섬유 프리프레그를 준비하는 카본섬유 프리프레그 준비단계; 준비된 카본섬유 프리프레그의 표면에 산화방지막 형성을 위한 MoSi2 분말, BN 분말, MoS2 분말, FeS 분말이 혼합된 산화방지막 형성분말을 도포하되 산화방지막 형성분말은 카본섬유 100중량부에 대하여 MoSi2 분말 15~25 중량%, BN 분말 15~35 중량%, MoS2 분말 3~7 중량%, FeS 분말 1~5 중량%로 이루어지는 산화방지막 형성분말 도포단계; 산화방지막 형성분말이 도포된 카본섬유 프리프레그를 금형에 넣은 후 단계적으로 가온하는 가운데 진공 분위기에서 압축하여 판 형태의 그린 바디를 성형하는 그린 바디 성형단계; 1,250~1,500℃ 온도 조건과 진공의 불활성 가스 분위기에서 성형된 그린 바디를 탄화시키는 탄화단계; 및 탄화된 그린 바디를 브레이크 디스크 패드로 가공하는 가공단계; 를 포함하여 이루어질 수 있다.The vehicle brake disc pad manufacturing method according to an embodiment of the present invention is impregnated in which 10 to 25% by weight of phenolic resin, 10 to 25% by weight of pitch, and 0.3 to 5% by weight of carbon nanotubes are mixed with respect to 100 parts by weight of carbon fiber. Preparing the impregnated resin to prepare the resin; Carbon fiber prepreg preparation step of impregnating the impregnated resin with carbon fiber to prepare a carbon fiber prepreg; On the surface of the prepared carbon fiber prepreg, apply an antioxidant film-forming powder mixed with MoSi 2 powder, BN powder, MoS 2 powder, and FeS powder for forming an antioxidant film, but the antioxidant film-forming powder is MoSi 2 per 100 parts by weight of carbon fiber. Powder coating step consisting of 15 to 25% by weight of powder, 15 to 35% by weight of BN powder, 3 to 7% by weight of MoS 2 powder, and 1 to 5% by weight of FeS powder; A green body forming step of forming a plate-shaped green body by placing the carbon fiber prepreg coated with the antioxidant film forming powder in a mold and then compressing it in a vacuum atmosphere while heating in stages; A carbonization step of carbonizing the green body molded under a temperature condition of 1,250 to 1500°C and an inert gas atmosphere of a vacuum; And a processing step of processing the carbonized green body into a brake disk pad. It can be made including.

이 발명의 일 실시 예에 따른 차량용 브레이크 디스크 패드 제조방법에서 카본섬유는 UD 직물 또는 평직 직물로 형성되며, 인장탄성률은 250~450 Gpa인 것이 사용될 수 있다.In the method for manufacturing a vehicle brake disk pad according to an embodiment of the present invention, the carbon fiber is formed of UD fabric or plain weave fabric, and a tensile modulus of 250 to 450 Gpa may be used.

이 발명의 일 실시 예에 따른 차량용 브레이크 디스크 패드 제조방법에서 그린 바디 성형단계에서의 단계적 가온은 40~80℃ 온도 조건의 1차 가열, 80~90℃ 온도 조건의 2차 가열, 140~150℃ 온도 조건의 3차 가열로 구분될 수 있다.In the method for manufacturing a brake disk pad for a vehicle according to an embodiment of the present invention, the stepwise heating in the green body forming step is the primary heating at 40 to 80°C, the secondary heating at 80 to 90°C, and 140 to 150°C. It can be classified as a third heating of temperature conditions.

이 발명의 일 실시 예에 따른 차량용 브레이크 디스크 패드 제조방법에서 카본섬유 프리프레그는 복수의 층으로 형성될 수 있다.In the method for manufacturing a vehicle brake disk pad according to an embodiment of the present invention, the carbon fiber prepreg may be formed of a plurality of layers.

이 발명의 일 실시 예에 따른 차량용 브레이크 디스크 패드 제조방법에서 탄화단계에 의해 탄화된 브레이크 디스크 소재는 함침수지에 2차 함침한 후 2차 탄화시키는 2차 탄화단계; 를 더 포함하여 이루어질 수 있다.In the method of manufacturing a brake disk pad for a vehicle according to an embodiment of the present invention, the brake disk material carbonized by the carbonization step is secondary carbonization step of secondary carbonization after secondary impregnation with the impregnating resin; It may be made including more.

이 발명의 실시 예에 따른 차량용 브레이크 디스크 패드 제조방법에 따르면 탄소 복합소재를 이용하여 브레이크 디스크 패드를 제조하는 과정에서 그린 바디를 여러 차례 만들지 않고, 한번 또는 두번 정도의 그린 바디 형성공정을 통해서도 브레이크 디스크 패드의 가공이 가능하기 때문에 전체적인 공정을 단순화할 수 있는 장점이 있다.According to the method of manufacturing a brake disk pad for a vehicle according to an embodiment of the present invention, a brake disk is not made several times in the process of manufacturing a brake disk pad using a carbon composite material, but a green body forming process is performed once or twice. Since the pad can be processed, there is an advantage of simplifying the entire process.

또한, 탄소섬유 프리프레그 사이에 층간 접착제를 사용하지 않고도 성분의 분포가 균일한 브레이크 디스크 패드 소재를 제공할 수 있으며, 페놀계 수지 40~60 중량%와 피치 40~60 중량%의 비율로 혼합된 함침수지를 사용함으로써 제조 단가를 낮출 수 있는 장점이 있다.In addition, it is possible to provide a brake disc pad material with a uniform distribution of components without using an interlayer adhesive between carbon fiber prepregs, and a mixture of 40-60% by weight of phenolic resin and 40-60% by weight of pitch. There is an advantage of lowering the manufacturing cost by using the impregnated resin.

도1은 이 발명의 실시 예에 따른 차량용 브레이크 디스크 패드 제조방법을 설명하기 위한 도면.
도2는 이 발명의 실시 예에 따라 카본섬유 프리프레그의 구성을 설명하기 위한 도면.
도3은 이 발명의 실시 예에 따라 프리프레그에 산화방지막을 형성하기 위한 공정을 보인 도면.
도4는 이 발명의 실시 예에 따른 그린 바디를 탄화시켜 획득된 브레이크 디스크 패드 소재를 보인 도면.1 is a view for explaining a method of manufacturing a vehicle brake disk pad according to an embodiment of the present invention.
2 is a view for explaining the configuration of a carbon fiber prepreg according to an embodiment of the present invention.
3 is a view showing a process for forming an antioxidant film on a prepreg according to an embodiment of the present invention.
4 is a view showing a brake disk pad material obtained by carbonizing a green body according to an embodiment of the present invention.

이하에서는 첨부된 도면을 참조하면서 이 발명의 실시 예에 따른 차량용 브레이크 디스크 패드 및 그 제조방법에 대해서 상세하게 설명한다.Hereinafter, a brake disk pad for a vehicle according to an embodiment of the present invention and a method of manufacturing the same will be described in detail with reference to the accompanying drawings.

도1은 이 발명의 실시 예에 따른 차량용 브레이크 디스크 패드 제조방법을 설명하기 위한 도면이고, 도2는 이 발명의 실시 예에 따라 카본섬유 프리프레그의 구성을 설명하기 위한 도면이며, 도3은 이 발명의 실시 예에 따라 프리프레그에 산화방지막을 형성하기 위한 공정을 보인 도면이고, 도4는 이 발명의 실시 예에 따른 그린 바디를 탄화시켜 획득된 브레이크 디스크 패드 소재를 보인 도면이다. 도면 중에 표시되는 도면부호 100은 이 발명의 실시 예에 따라 형성되는 브레이크 디스크 패드 소재를 지시하는 것이다.1 is a view for explaining a method of manufacturing a brake disk pad for a vehicle according to an embodiment of the present invention, FIG. 2 is a view for explaining the configuration of a carbon fiber prepreg according to an embodiment of the present invention, and FIG. A view showing a process for forming an antioxidant film on a prepreg according to an embodiment of the present invention, and FIG. 4 is a view showing a brake disk pad material obtained by carbonizing a green body according to an embodiment of the present invention. Reference numeral 100 indicated in the drawings denotes a material of a brake disk pad formed according to an embodiment of the present invention.

이 발명의 실시 예에 따른 차량용 브레이크 디스크 패드 소재(100)는 카본-카본 복합재료(Carbon-Carbon Composition)로 구성이 됨으로서, 이 발명에 따른 브레이크 디스크 패드 소재(100)로 브레이크 디스크 패드를 제작하게 되면 금속제 제품에 비하여 경량의 부품 공급이 가능하기 때문에 배터리로 구동이 되는 자동차(예를 들어, 전기자동차, 자율주행자동차)에서 더 나은 효과를 기대할 수 있게 된다. 이와 같은 카본-카본 복합재료로 이루어진 차량용 브레이크 디스크 패드 소재(100)의 제작을 위한 그린 바디(green body)의 성형에는 카본섬유, 수지, 탄소나노튜브(CNT, Carbon Nano Tube), 산화방지막 형성 분말을 포함한 재료가 필요하다.The vehicle brake disc pad material 100 according to the embodiment of the present invention is composed of a carbon-carbon composite material, so that a brake disc pad is manufactured from the brake disc pad material 100 according to the present invention. In this case, lighter parts can be supplied compared to metal products, so better effects can be expected in battery-powered vehicles (for example, electric vehicles and autonomous vehicles). Carbon fiber, resin, carbon nanotube (CNT, Carbon Nano Tube), antioxidant film-forming powder for forming a green body for manufacturing the vehicle brake disc pad material 100 made of such a carbon-carbon composite material Materials including

이 발명의 실시 예에 따른 차량용 브레이크 디스크 패드 제조방법은 도1에서 보이는 바와 같이 카본섬유 프리프레그 준비단계, 준비된 카본섬유 프리프레그에 산화방지막 형성 분말을 도포하면서 일정 두께의 그린 바디를 성형하는 단계, 성형된 그린 바디를 고온에서 탄화시켜 카본-카본 복합재 브레이크 디스크 패드 소재를 제작하는 단계 및 브레이크 디스크 패드 소재를 가공하는 단계를 포함하여 공정이 이루어진다.As shown in FIG. 1, a method for manufacturing a vehicle brake disc pad according to an embodiment of the present invention includes a carbon fiber prepreg preparation step, a step of forming a green body having a predetermined thickness while applying an antioxidant film forming powder to the prepared carbon fiber prepreg, A process is performed including the step of producing a carbon-carbon composite brake disc pad material by carbonizing the molded green body at high temperature and processing the brake disc pad material.

< < 카본섬유 프리프레그 준비단계Carbon fiber prepreg preparation stage > >

보다 구체적으로 설명하면, 카본섬유 프리프레그는 UD 직물 또는 평직 직물로 형성되며 250~600 Gpa의 인장탄성률의 성질을 갖는 카본섬유를 탄소나노튜브(CNT)가 함유된 함침수지에 함침하는 공정을 통해 준비된다. 카본섬유의 규격은 1 ~48k가 적용될 수 있으며, 제작을 원하는 카본섬유 프리프레그의 두께에 따라 카본섬유의 규격은 1 ~48k 범위 내에서 선택될 수 있다.More specifically, the carbon fiber prepreg is formed of UD fabric or plain weave fabric, and carbon fibers having a tensile modulus of 250 to 600 Gpa are impregnated in an impregnated resin containing carbon nanotubes (CNT). Ready. The standard of carbon fiber may be 1 ~ 48k, and the standard of carbon fiber can be selected within the range of 1 ~ 48k depending on the thickness of the carbon fiber prepreg desired to be produced.

함침수지는 카본섬유 100중량부에 대하여 페놀계 수지 10~25 중량%, 피치 10~25 중량%, 탄소나노튜브 0.3~5 중량%의 비율로 혼합된다. 이때, 탄소나노튜브는 10~20 ㎛의 길이와 0.3~0.6 ㎚의 직경을 갖는 제품을 사용하는 것이 바람직하다. 카본섬유 프리프레그의 형성을 위해 함침수지에 함유되는 탄소나노튜브는 카본섬유 100중량부에 대하여 3~5 중량% 혼합되는 것이 바람직하다. 한편, 브레이크 디스크의 제조에서 사용되는 함침수지에는 카본섬유 100중량부에 대하여 0.3~3 중량%의 탄소나노튜브가 혼합되는 것이 바람직하다.The impregnated resin is mixed at a ratio of 10 to 25% by weight of phenolic resin, 10 to 25% by weight of pitch, and 0.3 to 5% by weight of carbon nanotubes based on 100 parts by weight of carbon fiber. At this time, it is preferable to use a product having a length of 10 to 20 μm and a diameter of 0.3 to 0.6 nm as the carbon nanotubes. For the formation of the carbon fiber prepreg, the carbon nanotubes contained in the impregnated resin are preferably mixed in an amount of 3 to 5% by weight based on 100 parts by weight of the carbon fiber. On the other hand, it is preferable that 0.3 to 3% by weight of carbon nanotubes are mixed with the impregnating resin used in the manufacture of the brake disc based on 100 parts by weight of the carbon fiber.

함침수지 준비 과정에서 페놀계 수지와 피치의 혼합비율은 페놀계 수지 40~60 중량%와 피치 40~60 중량%의 비율로 준비될 수 있다. 페놀계 수지와 피치의 혼합 비율을 동등하게 할 수 있다. 페놀계 수지에 비하여 상대적으로 소재의 단가가 낮은 피치를 혼합함으로써 전체적으로는 생산 단가를 줄일 수 있다.In the process of preparing the impregnated resin, the mixing ratio of the phenolic resin and the pitch may be prepared in a ratio of 40 to 60% by weight of the phenolic resin and 40 to 60% by weight of the pitch. The mixing ratio of the phenolic resin and pitch can be made equal. By mixing pitches, which have a relatively low material cost compared to phenolic resins, the overall production cost can be reduced.

이렇게 페놀계 수지, 피치 및 탄소나노튜브가 혼합된 함침수지에 카본섬유를 함침시켜 카본섬유 프리프레그(10)를 준비하는 과정에서는 여러 장의 카본섬유를 겹쳐 일정 두께 이상의 카본섬유 프리프레그가 되도록 할 수 있다.In the process of preparing the carbon fiber prepreg 10 by impregnating carbon fiber in the impregnated resin mixed with phenolic resin, pitch, and carbon nanotubes, several sheets of carbon fiber can be stacked to form a carbon fiber prepreg with a certain thickness or more. have.

< < 그린 바디 성형단계Green body shaping stage > >

전술한 바와 같은 공정을 통해 사전에 준비된 카본섬유 프리프레그(10)를 사용하여 형성되는 그린 바디의 양쪽 표면에는 산화방지막 형성을 위한 산화방지막 형성 분말이 고르게 도포된다. 차량용 브레이크 디스크 패드를 가공하기 위한 브레이크 디스크 패드 소재(100)를 준비하기 위한 공정에서 적용되는 산화방지막 형성 분말은 MoSi2 분말, BN 분말, MoS2(몰리브덴 황화물) 분말, FeS(철황화물) 분말이 혼합된 것이 사용된다.Antioxidant film-forming powder for forming an anti-oxidation film is evenly applied to both surfaces of the green body formed using the carbon fiber prepreg 10 prepared in advance through the process as described above. The antioxidant film-forming powder applied in the process of preparing the brake disk pad material 100 for processing the vehicle brake disk pad includes MoSi 2 powder, BN powder, MoS 2 (molybdenum sulfide) powder, and FeS (iron sulfide) powder. Mixed ones are used.

산화방지막 형성 분말(30)은 카본섬유 100중량부에 대하여 MoSi2 분말 15~25 중량%, BN 분말 15~35 중량%, MoS2 분말 3~7 중량%, FeS 분말 1~5 중량%의 비율로 혼합된다. 더 구체적으로는 카본섬유 100중량부에 대하여 MoSi2 분말 18~22 중량%, BN 분말 22~27 중량%, MoS2 분말 4.5~6.5 중량%, FeS 분말 2.5~3.5 중량%의 비율로 혼합된 산화방지막 형성 분말을 사용될 수 있다. 바람직하게는 카본섬유 100중량부에 대하여 MoSi2 분말 20중량%, BN 분말 25중량%, MoS2 분말 5.5중량%, FeS 분말 3중량%의 비율로 혼합될 수 있다.Antioxidant film forming powder 30 is a ratio of 15 to 25% by weight of MoSi 2 powder, 15 to 35% by weight of BN powder, 3 to 7% by weight of MoS 2 powder, and 1 to 5% by weight of FeS powder based on 100 parts by weight of carbon fiber Is mixed into. More specifically, oxidation mixed at a ratio of 18-22% by weight of MoSi 2 powder, 22-27% by weight of BN powder, 4.5-6.5% by weight of MoS 2 powder, and 2.5-3.5% by weight of FeS powder based on 100 parts by weight of carbon fiber An anti-film forming powder may be used. Preferably, it may be mixed in a ratio of 20% by weight of MoSi 2 powder, 25% by weight of BN powder, 5.5% by weight of MoS 2 powder, and 3% by weight of FeS powder based on 100 parts by weight of carbon fiber.

카본섬유 프리프레그는 목표로 하는 차량용 브레이크 디스크 패드 소재(100)의 두께를 갖도록 하기 위해서 복수의 층으로 형성될 수 있다. 한겹 또는 여러 겹으로 쌓인 카본섬유 프리프레그의 양 표면에는 산화방지막 형성 분말을 도포하는 공정을 통해서 산화방지막 형성분말이 도포된다. 한편, 카본섬유 프리프레그가 여러 겹으로 형성되는 경우에 각 카본섬유 프리프레그 층의 사이에도 산화방지막 형성분말(30)이 도포될 수 있다.The carbon fiber prepreg may be formed of a plurality of layers in order to have the thickness of the target vehicle brake disc pad material 100. The antioxidant layer forming powder is applied to both surfaces of the carbon fiber prepreg stacked in one or multiple layers through a process of applying the antioxidant layer forming powder. On the other hand, when the carbon fiber prepreg is formed in multiple layers, the antioxidant film-forming powder 30 may also be applied between each carbon fiber prepreg layer.

예를 들어, 두께가 10mm인 차량용 브레이크 디스크 패드를 가공하기 위한 카본-카본 복합재 브레이크 디스크 패드 소재는 10mm 이상의 두께를 가져야 한다. 이를 위해, 탄화 공정에서 감소되는 두께를 반영하여 그린 바디의 두께가 15mm로 이루어져야 할 경우에, 1.5mm의 두께를 갖는 카본섬유 프리프레그는 10장이 적층될 수 있다. 이와 같이 10장의 카본섬유 프리프레그가 적층이 된 양쪽의 표면에는 각각 산화방지막 형성분말이 도포된다. 또한, 필요에 따라서는 카본섬유 프리프레그를 적층하는 과정에서 각 카본섬유 프리프레그의 층 사이 또는 일부 카본섬유 프리프레그 사이에 산화방지막 형성 분말이 고르게 도포되도록 할 수도 있다.For example, a carbon-carbon composite brake disc pad material for processing brake disc pads for vehicles with a thickness of 10 mm must have a thickness of 10 mm or more. To this end, when the thickness of the green body should be 15 mm to reflect the reduced thickness in the carbonization process, 10 carbon fiber prepregs having a thickness of 1.5 mm may be stacked. Antioxidant film-forming powder is applied to both surfaces on which 10 carbon fiber prepregs are laminated. In addition, if necessary, in the process of laminating the carbon fiber prepreg, the antioxidant film-forming powder may be evenly applied between layers of each carbon fiber prepreg or between some carbon fiber prepregs.

전술한 바와 같은 공정을 통해서, 산화방지막 형성 분말이 도포된 카본섬유 프리프레그는 금형에 넣어진 상태에서 단계적으로 가온하는 가운데 진공의 분위기에서 가압이 되어 일정 두께를 갖는 판 형태의 그린 바디(20)로 성형된다.Through the process as described above, the carbon fiber prepreg coated with the antioxidant film-forming powder is pressed in a vacuum atmosphere while being gradually heated while being put in a mold to form a plate-shaped green body 20 having a predetermined thickness. Is molded into

이와 같이 그린 바디를 성형하는 공정에서는 40~80℃ 온도 조건의 1차 가열, 80~90℃ 온도 조건의 2차 가열, 140~150℃ 온도 조건의 3차 가열을 단계적으로 수행하면서 압축하는 가운데 진공의 분위기가 지속됨으로써 기포가 효과적으로 제거될 수 있다. 이와 같은 그린 바디 성형 공정을 통해서 카본섬유, 탄소나노튜브, 산화방지막 형성 분말은 수지에 고르게 분포된 상태가 된다.In the process of shaping the green body, the vacuum while compressing while performing stepwise heating at 40~80℃, second heating at 80~90℃, and third heating at 140~150℃ The air bubbles can be effectively removed by the sustained atmosphere. Through such a green body molding process, carbon fibers, carbon nanotubes, and antioxidant film-forming powder are evenly distributed in the resin.

< < 그린 바디 탄화단계Green body carbonization stage > >

전술한 공정을 통해서 성형된 그린 바디는 1,250~1,500℃ 온도 조건과 진공의 불활성 가스 분위기에서 2~10 시간 동안의 탄화 공정을 통해서 탄화가 이루어진다. 탄화 공정에서의 탄화 시간은 그린 바디의 형성에 적용되는 카본섬유의 스펙, 그린 바디의 두께 등을 고려하여 설정될 수 있다.The green body molded through the above-described process is carbonized through a carbonization process for 2 to 10 hours in a temperature condition of 1,250 to 1,500° C. and an inert gas atmosphere in a vacuum. The carbonization time in the carbonization process may be set in consideration of the specifications of carbon fibers applied to the formation of the green body and the thickness of the green body.

고온의 탄화 공정을 통해서 페놀계 수지 10~25 중량%, 피치 10~25 중량%, 탄소나노튜브 0.3~5 중량%의 비율로 혼합된 함침수지에 함침된 카본섬유는 카본-카본 복합재료(Carbon-Carbon Composition)로 경량이면서도 고온강도와 내마모성이 우수한 성질을 갖는 브레이크 디스크 패드 소재로 제작된다.Carbon fibers impregnated in an impregnated resin mixed in a ratio of 10 to 25% by weight of a phenolic resin, 10 to 25% by weight of a pitch, and 0.3 to 5% by weight of carbon nanotubes through a high-temperature carbonization process are used as a carbon-carbon composite material (Carbon -Carbon Composition), lightweight, and made of brake disc pad material that has excellent properties of high temperature strength and abrasion resistance.

나아가, 브레이크 디스크 패드 소재(100)의 표면에는 구리 분말 15~25 중량%, SiC 분말 10~20 중량%, MoSi2 분말 3~7 중량%, 그라파이트 분말 1~5 중량%의 비율로 혼합된 산화방지막 형성분말이 도포된 후 탄화공정을 통해서 산화방지막(110)이 일체로 이루어지게 된다.Further, on the surface of the brake disc pad material 100, oxidation mixed in a ratio of 15 to 25% by weight of copper powder, 10 to 20% by weight of SiC powder, 3 to 7% by weight of MoSi 2 powder, and 1 to 5% by weight of graphite powder. After the anti-film forming powder is applied, the anti-oxidation film 110 is integrally formed through a carbonization process.

전술한 바와 같은 탄화단계에서 탄화되어 형성된 브레이크 디스크 패드 소재(100)는 2차 탄화단계를 통해 2차 탄화가 될 수 있다. 2차 탄화단계에서는 1차 탄화된 소재를 함침수지에 함침한 후 2차 탄화를 하게 된다.The brake disc pad material 100 formed by carbonization in the carbonization step as described above may be secondary carbonization through the second carbonization step. In the second carbonization step, the first carbonized material is impregnated in the impregnating resin and then the second carbonization is performed.

< < 브레이크 디스크 패드 가공단계Brake disc pad processing step > >

전술한 공정을 통해서 형성된 브레이크 디스크 패드 소재는 목표로 하는 차량용 브레이크 디스크 패드로 가공이 된다.The brake disk pad material formed through the above-described process is processed into a target vehicle brake disk pad.

전술한 바와 같은 차량용 브레이크 디스크 패드 제조방법에 따라 브레이크 디스크 패드를 제조하는 과정에서는 그린 바디를 여러 차례 만들지 않고, 한번 또는 두번 정도의 그린 바디를 만드면 되기 때문에 전체적인 공정을 단순화할 수 있는 장점이 있다.In the process of manufacturing the brake disk pad according to the vehicle brake disk pad manufacturing method as described above, there is an advantage that the overall process can be simplified because the green body can be made once or twice without making the green body several times. .

또한, 탄소섬유 프리프레그 사이에 층간 접착제를 사용하지 않고도 성분의 분포가 균일한 브레이크 디스크 패드 소재를 제공할 수 있게 된다.In addition, it is possible to provide a brake disc pad material having a uniform distribution of components without using an interlayer adhesive between carbon fiber prepregs.

함침수지는 페놀계 수지 40~60 중량%와 피치 40~60 중량%의 비율로 혼합된 것을 사용함으로써 제조 단가를 낮출 수 있다.The impregnated resin can lower the manufacturing cost by using a mixture of 40 to 60% by weight of a phenolic resin and 40 to 60% by weight of pitch.

특히, 그린 바디의 성형 과정에서 도포되는 산화방지막 형성 분말은 분말 형태의 것이 사용이 됨으로써 각 성분의 함량을 쉽게 조절할 수 있다.In particular, the antioxidant film-forming powder applied in the process of forming the green body is in the form of a powder, so that the content of each component can be easily adjusted.

나아가, 이 발명의 실시 예에 따른 차량용 브레이크 디스크의 제작을 위한 그린 바디의 성형과정에서 적용되는 산화방지막 형성분말은 카본섬유 100중량부에 대하여 구리 분말 15~25 중량%, SiC 분말 10~20 중량%, MoSi2 분말 3~7 중량%, 그라파이트 분말 1~5 중량%이 혼합된 조성으로 이루어지나, 차량용 브레이크 디스크 패드의 제작을 위한 그린 바디의 성형과정에 적용되는 산화방지막 형성분말은 카본섬유 100중량부에 대하여 MoSi2 분말 15~25 중량%, BN 분말 15~35 중량%, MoS2 분말 3~7 중량%, FeS 분말 1~5 중량%이 혼합된 조성으로 이루어질 수 있다.Further, the antioxidant film-forming powder applied in the process of forming a green body for manufacturing a vehicle brake disk according to an embodiment of the present invention is 15 to 25% by weight of copper powder and 10 to 20% by weight of SiC powder based on 100 parts by weight of carbon fiber. %, MoSi 2 powder 3~7% by weight, graphite powder 1~5% by weight, but the antioxidant film-forming powder applied to the green body molding process for manufacturing vehicle brake disc pads is carbon fiber 100 MoSi 2 powder 15 to 25% by weight, BN powder 15 to 35% by weight, MoS 2 powder 3 to 7% by weight, FeS powder 1 to 5% by weight may be a mixed composition.

즉, 브레이크 디스크 소재에 적용되는 산화막 형성분말과, 브레이크 디스크 패드 소재에 적용되는 산화막 형성분말의 성분을 달리 할 수 있다. 이를 통해, 브레이크 디스크 패드의 내열성 및 발열반응이 브레이크 디스크에 비하여 상대적으로 우수하게 할 수 있다. 부연하면, 브레이크 디스크 패드 소재에 적용되는 성분에는 SiC와 BN을 상대적으로 더 많이 포함되도록 함으로써 발열 및 내구성이 상대적으로 좋게 함으로써 마모 특성을 달리할 수 있다.That is, the composition of the oxide film-forming powder applied to the brake disc material and the oxide film-forming powder applied to the brake disc pad material may be different. Through this, the heat resistance and exothermic reaction of the brake disk pad can be relatively superior to that of the brake disk. Incidentally, by making relatively more SiC and BN contained in the components applied to the brake disc pad material, heat generation and durability are relatively good, so that the wear characteristics can be different.

이상에서는 첨부된 도면들을 참조하면서 이 발명의 실시 예에 따른 차량용 브레이크 디스크 패드 제조방법 및 차량용 브레이크 디스크 패드의 구성에 대하여 설명하였다. 이러한 실시 예들은 이 발명의 청구범위에 기재된 기술 사상에 포함되는 것이다. 또한, 전술한 실시 예들은 예시적인 것에 불과한 것으로 한정 해석해서는 안될 것이다.In the above, a method of manufacturing a brake disk pad for a vehicle and a configuration of a brake disk pad for a vehicle according to an embodiment of the present invention have been described with reference to the accompanying drawings. These embodiments are included in the technical idea described in the claims of this invention. In addition, the above-described embodiments are merely exemplary and should not be construed as limited.

10 : 카본섬유 프리프레그
20 : 그린 바디
30 : 산화방지막 형성분말
100 : 브레이크 디스크 패드 소재
110 : 산화방지막10: carbon fiber prepreg
20: green body
30: Antioxidant film forming powder
100: brake disc pad material
110: antioxidant film

Claims (6)

카본섬유 100중량부에 대하여 페놀계 수지 10~25 중량%, 피치 10~25 중량%, 탄소나노튜브 0.3~5 중량%가 혼합된 함침수지를 준비하는 함침수지 준비단계;
상기 함침수지에 카본섬유를 함침하여 카본섬유 프리프레그를 준비하는 카본섬유 프리프레그 준비단계;
상기 준비된 카본섬유 프리프레그의 표면에 산화방지막 형성을 위한 MoSi2 분말, BN 분말, MoS2 분말, FeS 분말이 혼합된 산화방지막 형성분말을 도포하되, 상기 산화방지막 형성분말은 상기 카본섬유 100중량부에 대하여 MoSi2 분말 15~25 중량%, BN 분말 15~35 중량%, MoS2 분말 3~7 중량%, FeS 분말 1~5 중량%로 이루어지는 산화방지막 형성분말 도포단계;
상기 산화방지막 형성분말이 도포된 카본섬유 프리프레그를 금형에 넣은 후 단계적으로 가온하는 가운데 진공 분위기에서 압축하여 판 형태의 그린 바디를 성형하는 그린 바디 성형단계;
1,250~1,500℃ 온도 조건과 진공의 불활성 가스 분위기에서 상기 성형된 그린 바디를 탄화시키는 탄화단계; 및
상기 탄화된 그린 바디를 브레이크 디스크 패드로 가공하는 가공단계; 를 포함하여 이루어지는 것을 특징으로 하는 브레이크 디스크 패드 제조방법.
Preparing an impregnated resin in which 10 to 25% by weight of phenolic resin, 10 to 25% by weight of pitch, and 0.3 to 5% by weight of carbon nanotubes are mixed with respect to 100 parts by weight of carbon fiber;
A carbon fiber prepreg preparation step of preparing a carbon fiber prepreg by impregnating the impregnating resin with carbon fibers;
On the surface of the prepared carbon fiber prepreg, an antioxidant film-forming powder mixed with MoSi 2 powder, BN powder, MoS 2 powder, and FeS powder for forming an antioxidant film is applied, and the antioxidant film-forming powder is 100 parts by weight of the carbon fiber. MoSi 2 powder 15 ~ 25% by weight, BN powder 15 ~ 35% by weight, MoS 2 powder 3 ~ 7% by weight, FeS powder 1 ~ 5% by weight of the antioxidant film forming powder coating step;
A green body forming step of placing the carbon fiber prepreg coated with the antioxidant film forming powder in a mold and then compressing it in a vacuum atmosphere while heating in stages to form a plate-shaped green body;
A carbonization step of carbonizing the molded green body under a temperature condition of 1,250 to 1500°C and an inert gas atmosphere of vacuum; And
A processing step of processing the carbonized green body into a brake disk pad; Brake disk pad manufacturing method comprising a.
 제1항에 있어서,
상기 카본섬유는 UD 직물 또는 평직 직물로 형성되며, 인장탄성률은 250~450 Gpa인 것을 특징으로 하는 브레이크 디스크 패드 제조방법.
The method of claim 1,
The carbon fiber is formed of UD fabric or plain weave fabric, and a tensile modulus of elasticity is 250 to 450 Gpa.
 제1항에 있어서,
상기 그린 바디 성형단계에서의 단계적 가온은 40~80℃ 온도 조건의 1차 가열, 80~90℃ 온도 조건의 2차 가열, 140~150℃ 온도 조건의 3차 가열로 구분되는 것을 특징으로 하는 브레이크 디스크 패드 제조방법.
The method of claim 1,
The stepwise heating in the green body forming step is divided into a first heating at a temperature of 40 to 80°C, a second heating at a temperature of 80 to 90°C, and a third heating at a temperature of 140 to 150°C. Disc pad manufacturing method.
 제1항에 있어서,
상기 카본섬유 프리프레그는 복수의 층으로 형성되는 것을 특징으로 하는 차량용 브레이크 디스크 패드 제조방법.
The method of claim 1,
The carbon fiber prepreg is a vehicle brake disc pad manufacturing method, characterized in that formed of a plurality of layers.
 제1항에 있어서,
상기 탄화단계에 의해 탄화된 브레이크 디스크 소재는 상기 함침수지에 2차 함침한 후 2차 탄화시키는 2차 탄화단계; 를 더 포함하여 이루어지는 것을 특징으로 하는 차량용 브레이크 디스크 패드 제조방법.
The method of claim 1,
A secondary carbonization step of secondary carbonization of the brake disc material carbonized by the carbonization step after secondary impregnation with the impregnating resin; A method for manufacturing a vehicle brake disk pad, characterized in that it further comprises a.
 제1 항 내지 제5항의 방법 중 어느 하나의 방법에 의해서 제조된 브레이크 디스크 패드.
A brake disc pad manufactured by the method of any one of claims 1 to 5.
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