201007023 九、發明說明： 【發明所屬之技術領域】 本發明係有關-種摩擦材料，尤指一種摩擦材料及立 製法（二）。 〃 【先前技術】 按，一十世紀初，世界各國皆以石棉來當作主要的摩擦 材料’-直沿用了七、八十個年代；惟，石棉材料在生產 ❾或制動摩擦的過程中，將產生許多石棉粉末且大都懸浮於 空中’如被人體吸入，會造成肺及氣管的嚴重疾病，甚至 還會致癌，對於環境污染也是一大課題，為此，各國無非 積極研究及開發無石棉型摩擦材料。 早期的無石棉型摩擦材料主要是鋼纖維型和玻璃纖維 i摩擦材料’鋼纖維型摩擦材料在國際上已成功的使用了 一 一十年’諸如1982年英國專利21〇〇275號，其存在著 參加工忍料不易均勻、容易刺激人體皮膚、摩擦元件比重較 大及易產生火花等問題；同時，在使用期間又容易損傷對 偶件、產生低頻嚼音及容易鏽餘等缺點，雖然其摩擦性能 佳，但種種缺點卻大大阻礙了後續的發展。 而玻璃纖維型摩擦材料卻存在有其摩擦性能普遍不理 1之缺點’諸如1983年德國專利3225214號其玻璃纖維 I摩擦材料的磨損率是石棉材料的數倍，而对磨性差即會 直接縮紐使用壽命，更別提安全及可靠度的問題’且其熱 5 201007023 衰退性及熱恢復性能之表現亦不理想。 另外，如美國專利5662993所揭示之摩擦材料，係使 用編織的碳纖維織物’並塗覆有樹脂，而構成一種非常堅 固及耐用的復合結構；又，如美國專利公開號20060016550 所揭不之摩擦材料，係於兩片碳纖維布間直接塗佈環氧樹 脂或盼搭樹脂’再以熱壓設備將兩片碳纖維布熱壓接合在 ❹一起，然而當兩片碳纖維布相對接合時，位於兩片碳纖維 布之間的樹脂’勢必會受到擠壓而往外擴散，如此將造成 碳纖維布其股線間之孔隙有被樹脂阻塞之情形發生，並導 致透氣性不佳之缺點，因此當所欲接合之碳纖維布數量越 多時’其散熱效果也會相對大幅降低’再者，當兩片碳纖 維布熱壓接合後’其中樹脂在兩片碳纖維布的中間會呈現 向外梯狀分佈的現象，意即樹脂含量係由中間層漸漸遞減 參至摩擦表面，樹脂的分佈並不均勻。 因此，有鑑於上述缺失，故本案創作人乃憑藉著從事 •相關產業之多年經驗，並經不斷苦思及試作後，才終於有 本發明之產生。 【發明内容】 本發明目的之一，在於提供一種摩擦材料及其製法（ 一），其係藉由可準確的控制浸潰於摩擦材料上之樹脂量， 6 201007023 乂使樹士可均勻附著於碳纖維之纖維上，且纖維與纖維之 間並不會被樹脂完全覆蓋，因此具有極佳之孔隙率，而使 散熱性可有效提高。 本發明目的之二’在於提供-種摩擦材料及其製法（ .二），其係可藉由單層或多層堆叠碳纖維布，以達到所需之 摩擦材料的厚度需求。 ❹ ㈣前述之目的，本發明係提供-種摩擦材料（二）， 係由浸潰樹脂及烘烤後的碳纖維布單層或多層堆叠，並經 熱壓成型後而構成，且於該碳纖維布之纖維上係均句附含 有樹脂，而使摩擦材料上係形成有多數孔隙。 且為製成上述之摩擦材料，本發明所使用之 則包含有以下步驟： 万击 A ·碳化處理： ❹㈣化纖維錢行—冑溫碳化處理，而絲化纖維 碳化形成碳纖維布，其中加熱溫度係介於棚。c〜观代 之間，加熱時間在30分鐘〜48小時之間； B ·浸潰處理： 將故纖維布浸漬樹脂，並藉由控制樹脂的固含量及浸 潰時間，使碳纖維布之纖維上均勻附含樹脂，其中樹脂的 固含量係控制在1%〜95%之間，浸潰的時間控制在5曰秒 〜20分鐘之間’浸溃的溫度控制在1G°C〜5G°C之間； 7 201007023 c·烘烤處理： 將附含樹脂的碳纖維布烘烤處理，烘烤溫度在5(Tc〜 150°C之間，時間在30秒〜20分鐘之間； D·熱壓處理： 將洪烤處理後之碳纖維布進行堆疊，並視所需的厚度 進行堆疊調控，而後進行一熱壓成型處理，即得一碳纖維 摩擦材料’其中熱壓之溫度介於60 ΐ〜400 °C之間，時 間在1刀鐘〜450分鐘之間，壓力值係介於1 kg/cm2〜 kg/cm2之間。 而本發明之上述及其他目的與優點，不難從下述所選 用實施例之詳細說明與附圖甲，獲得深入了解。 當然’本發明在某些另件上’或另件之安排上容許有 所不同，但所選用之實施例，則於本說明書中，予以詳細 0 說明’並於附圖中展示其構造。 【實施方式】 本發明係提供之一種摩擦材料（二），係將浸漬樹脂及 烘烤後的碳纖維布視所需的厚度進行堆疊，並經熱壓成型 後而構成，且於該碳纖維布之纖維上係均勻附含有樹脂， 而使摩擦材料上係形成有多數孔隙。 而如第1圖所示，本發明所之製法係包含有以下步驟： 201007023 A ·碳化處理： 將氧化纖維布置於一具有保護性氣體或真空環境下進 行高溫碳化處理，且該碳纖維布係可由單層氧化纖維布， 或多層氧化纖維布所構成，而該保護性氣體係可為氮氣、 氦氣、氬氣其中之一，以使氧化纖維布碳化形成碳纖維布， 其中加熱溫度係介於40CTC〜3000Ϊ之間，加熱時間在3〇 ❹ ❹ 分鐘〜48小時之間，而氧化纖維布係包含有編織物或非編 織物’且氧化纖維布係可為聚丙缚腈（pAN)織維、遞青 (Pitch)織維或嫘縈（RayQn)織維其中之—所構成，並 以聚丙烯腈（簡）纖維所製成之氧化纖維布最佳。 B·浸潰處理： 將碳纖維布浸潰樹脂，並藉由控制__含量及浸 :時間，使碳纖維布之纖維上均句附含樹脂，其中該樹脂 瑗pu樹脂、壓克力樹脂，齡樹脂、變性祕樹脂、 ^:脂、變性環氧樹脂”夫喃_或其組合所構成並 ::樹脂中係更可添加石墨粉、碳黑、乙炔黑、奈米碳管、 瀝月粉末、有機纖維、無機纖維、金屬纖維或上述添加物 ^組合’其中樹脂的固含量係控制在1%〜95%之間浸 潰的時間控制在5秒〜2〇分鐘 v 。 <間浸潰的溫度控制在10 C〜50 C之間。 c·烘烤處理： 9 201007023 將附含樹脂的碳纖維布進行烘烤處理，其中烘烤溫度 在50°C〜150°C之間，時間在30秒〜2〇分鐘之間。 D·熱壓處理： 將烘烤處理後之碳纖維布進行堆疊，並視所需的厚度 進行堆疊作業以調控摩擦材料厚度，而後進行一熱壓成型 處理，即得一碳纖維摩擦材料，其中熱壓之溫度介於6〇 t201007023 IX. Description of the invention: [Technical field to which the invention pertains] The present invention relates to a friction material, particularly a friction material and a standing method (2). 〃 【Prior Art】 According to the beginning of the 10th century, asbestos was used as the main friction material in all countries of the world. It used seven or eighty years. However, in the process of producing ❾ or brake friction, asbestos materials Many asbestos powders will be produced and mostly suspended in the air. If inhaled by the human body, it will cause serious diseases of the lungs and trachea, and even cause cancer. It is also a major issue for environmental pollution. Therefore, all countries are actively researching and developing non-asbestos-type products. Friction material. The early non-asbestos friction materials were mainly steel fiber and glass fiber i friction materials. Steel fiber friction materials have been successfully used internationally for a decade. For example, the British Patent No. 21〇〇275 in 1982, its existence It is difficult to be uniform, easy to stimulate human skin, large proportion of friction elements and easy to generate sparks. At the same time, it is easy to damage the dual parts, produce low frequency chewing sound and easy rust, etc. Good performance, but the shortcomings have greatly hindered the subsequent development. However, the glass fiber type friction material has the disadvantage that its friction performance is generally ignored. For example, in 1983, German Patent No. 3225214, the wear rate of the glass fiber I friction material is several times that of the asbestos material, and the difference in the grinding property is directly reduced. New life, not to mention safety and reliability issues' and its thermal 5 201007023 degrading and heat recovery performance is not satisfactory. In addition, the friction material disclosed in U.S. Patent No. 5,662,993, which uses a woven carbon fiber fabric and is coated with a resin, constitutes a very strong and durable composite structure; and, as disclosed in U.S. Patent Publication No. 20060016550, a friction material. Applying epoxy resin or expecting resin directly between two carbon fiber cloths, and then thermocompression bonding two pieces of carbon fiber cloth together in a crucible, but when two carbon fiber cloths are relatively joined, they are located in two carbon fibers. The resin between the cloths is bound to be squeezed and spread out, which will cause the pores between the strands of the carbon fiber cloth to be blocked by the resin, and cause the disadvantage of poor gas permeability, so when the carbon fiber cloth to be joined is used The more the quantity, the lower the heat dissipation effect will be. In addition, when two carbon fiber cloths are thermocompression bonded, the resin will appear outwardly in the middle of the two carbon fiber cloths, meaning that the resin content The phase is gradually reduced from the intermediate layer to the friction surface, and the distribution of the resin is not uniform. Therefore, in view of the above-mentioned shortcomings, the creator of the case finally relied on years of experience in the relevant industries, and after continuous hard work and trials, finally the invention was produced. SUMMARY OF THE INVENTION One object of the present invention is to provide a friction material and a method for manufacturing the same (1), which can accurately control the amount of resin impregnated on a friction material, 6 201007023 The fiber of the carbon fiber, and the fiber and the fiber are not completely covered by the resin, so that the porosity is excellent, and the heat dissipation can be effectively improved. The second object of the present invention is to provide a friction material and a method for producing the same (2), which can be stacked by a single layer or a plurality of layers to achieve the desired thickness of the friction material.四 (4) For the purpose of the foregoing, the present invention provides a friction material (2) which is formed by laminating a resin and a baked carbon fiber cloth in a single layer or a plurality of layers, and is formed by hot press forming, and is formed on the carbon fiber cloth. The fibers are attached to the resin, and the friction material is formed with a plurality of pores. In order to produce the above friction material, the present invention comprises the following steps: 10,000 A: carbonization treatment: ❹ (four) chemical fiber money line - 胄 temperature carbonization treatment, and the filamentized fiber carbonization to form carbon fiber cloth, wherein the heating temperature The system is in the shed. Between c and Guanyin, the heating time is between 30 minutes and 48 hours; B · impregnation treatment: impregnating the resin with the fiber cloth, and controlling the resin's solid content and impregnation time to make the fiber of the carbon fiber cloth Uniformly containing resin, wherein the solid content of the resin is controlled between 1% and 95%, and the time of impregnation is controlled between 5 sec and 20 minutes. The temperature of the immersion is controlled at 1 G ° C to 5 G ° C. 7 201007023 c· Baking treatment: Baking the resin-containing carbon fiber cloth at a baking temperature of 5 (Tc~150 °C, time between 30 seconds and 20 minutes; D·hot pressing treatment) : The carbon fiber cloth after the bake treatment is stacked, and stacked and adjusted according to the required thickness, and then subjected to a hot press forming process, that is, a carbon fiber friction material is obtained, wherein the hot pressing temperature is between 60 ΐ and 400 ° C. Between 1 kn. and 450 minutes, the pressure is between 1 kg/cm 2 and kg/cm 2 . The above and other objects and advantages of the present invention are not difficult to select from the following examples. The detailed description and the figure A are obtained in-depth understanding. Of course, the invention is in some parts. 'Or the arrangement of the parts is allowed to be different, but the selected embodiment is described in detail in the specification, and the structure is shown in the drawing. [Embodiment] The present invention provides a friction The material (2) is obtained by stacking the impregnated resin and the baked carbon fiber cloth according to the required thickness, and after being formed by hot press forming, and uniformly attaching the resin to the fiber of the carbon fiber cloth to make the friction The material is formed with a plurality of pores. As shown in Fig. 1, the method of the present invention comprises the following steps: 201007023 A · Carbonization treatment: Arranging the oxidized fibers in a protective gas or vacuum environment for high-temperature carbonization The carbon fiber cloth may be composed of a single layer of oxidized fiber cloth or a plurality of layers of oxidized fiber cloth, and the protective gas system may be one of nitrogen, helium and argon to carbonize the oxidized fiber cloth to form a carbon fiber cloth. , wherein the heating temperature is between 40CTC and 3000Ϊ, and the heating time is between 3〇❹ 〜 minutes and 48 hours, and the oxidized fiber cloth contains woven or non-woven fabric The braided fabric and the oxidized fiber fabric can be composed of polyacrylonitrile (pAN) weave, Pitch weave or RayQn weave, and polyacrylonitrile (simplified) fiber. The oxidized fiber cloth is best prepared. B·impregnation treatment: the carbon fiber cloth is impregnated with the resin, and by controlling the __ content and the immersion: time, the fiber of the carbon fiber cloth is coated with a resin, wherein the resin 瑗Pu resin, acrylic resin, age resin, denatured resin, ^: grease, denatured epoxy resin, "fu" or a combination thereof: and: graphite powder, carbon black, acetylene black, Nano carbon tube, lyophilized powder, organic fiber, inorganic fiber, metal fiber or the above-mentioned additive combination] wherein the solid content of the resin is controlled between 1% and 95%, and the time of impregnation is controlled in 5 seconds to 2 〇 Minutes v. <The temperature of the interleaching is controlled between 10 C and 50 C. c· Baking treatment: 9 201007023 The resin-containing carbon fiber cloth is subjected to baking treatment, wherein the baking temperature is between 50 ° C and 150 ° C, and the time is between 30 seconds and 2 minutes. D·Hot pressing treatment: stacking the carbon fiber cloth after baking treatment, and performing stacking operation according to the required thickness to adjust the thickness of the friction material, and then performing a hot press forming process to obtain a carbon fiber friction material, wherein the hot pressing The temperature is between 6〇 t
〜400 〇C之間，時間在！分鐘〜45〇分鐘之間，壓力值係 介於 1 kg/cm2 〜200 kg/cm2 之間。 而本發明的摩擦材料主要係由碳纖維所製成，因此具 有良好的導熱性、耐熱性、耐磨性及穩㈣摩擦係數之外 ’並藉由樹脂係可均㈣含於錢維布 械強度、高孔隙率、高彈性及高結合度 ^1!r^(noise resistance) 對偶易產生火花及不易碎裂等優點。 的摩擦材鏡圈其係為使用本發明製法所製成 ，可準確控制樹及由浸潰樹脂的方式 於纖維與纖維之間，作光非/又凊時間使樹脂均勻地附著 隙率，且當本發明為二：：部覆蓋，因此具有極高的孔 亦仍具有極佳之透氣之厚度而堆叠多層時， 固含量，一般而言，乂 士發明可依需求調整樹脂的 好，相對地彈性摩擦材的剛性及勁度愈 固含量，才能同時兼具彈性唯有調整適當的樹脂 柔軟性、剛性及勁度等特性 201007023 ，因此，本發明可輕易的控制摩擦材料之彈性及柔軟性且 兼具剛性及勁度，使摩擦材具備可壓縮性，進而提升順滑 度、減少頓挫及噪音、更不易刮傷對偶件、產生火花及碎 裂等問題。 並由以上詳細說明，可使熟知本項技藝者明瞭本發明 的確可達成前述目的，實已符合專利法之規定，爰提出專 利申請。Between ~400 〇C, time is up! Between minutes and 45 minutes, the pressure is between 1 kg/cm2 and 200 kg/cm2. However, the friction material of the present invention is mainly made of carbon fiber, and therefore has good thermal conductivity, heat resistance, wear resistance and stability (four) friction coefficient' and can be contained in the fiber strength by the resin system. High porosity, high elasticity and high degree of bonding ^1!r^(noise resistance) It is easy to produce sparks and is not easy to break. The friction material mirror ring is made by using the method of the invention, and can accurately control the tree and the method of impregnating the resin between the fiber and the fiber, so as to make the resin uniformly adhere to the gap time, and When the present invention is a two-part:: cover, it has an extremely high hole and still has an excellent gas permeable thickness. When stacking a plurality of layers, the solid content, in general, the gentleman invention can adjust the resin according to the demand, relatively The elastic material of the elastic friction material has a higher solidity and stiffness, and can simultaneously have the elasticity. Only the characteristics such as softness, rigidity and stiffness of the resin can be adjusted. 201007023, therefore, the invention can easily control the elasticity and softness of the friction material. It has both rigidity and stiffness, which makes the friction material compressible, which improves the smoothness, reduces the frustration and noise, and is less prone to scratching the dual parts, causing sparks and chipping. And from the above detailed description, it will be apparent to those skilled in the art that the present invention can achieve the above-mentioned objects and is in accordance with the provisions of the Patent Law.
11 201007023 【圖式簡單說明】 第1圖係本發明之流程示意圖 附件一係本發明摩擦材料之電子顯微鏡圖 【主要元件符號說明】 (無） ❹11 201007023 [Simplified description of the drawings] Fig. 1 is a schematic flow chart of the present invention. Annex I is an electron microscope image of the friction material of the present invention [Explanation of main component symbols] (None) ❹
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