WO2020021645A1 - Back plate, disc brake pad and caliper assembly - Google Patents

Back plate, disc brake pad and caliper assembly Download PDF

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Publication number
WO2020021645A1
WO2020021645A1 PCT/JP2018/027776 JP2018027776W WO2020021645A1 WO 2020021645 A1 WO2020021645 A1 WO 2020021645A1 JP 2018027776 W JP2018027776 W JP 2018027776W WO 2020021645 A1 WO2020021645 A1 WO 2020021645A1
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WO
WIPO (PCT)
Prior art keywords
back plate
disc brake
brake pad
resin
friction material
Prior art date
Application number
PCT/JP2018/027776
Other languages
French (fr)
Japanese (ja)
Inventor
一 豊田
泰啓 原
良尚 高橋
Original Assignee
日立化成株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 日立化成株式会社 filed Critical 日立化成株式会社
Priority to PCT/JP2018/027776 priority Critical patent/WO2020021645A1/en
Priority to JP2020531885A priority patent/JP7226448B2/en
Publication of WO2020021645A1 publication Critical patent/WO2020021645A1/en

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    • 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
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/02—Composition of linings ; Methods of manufacturing
    • F16D69/025—Compositions based on an organic binder
    • F16D69/026—Compositions based on an organic binder containing fibres
    • 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
    • F16D65/04—Bands, shoes or pads; Pivots or supporting members therefor
    • F16D65/092—Bands, shoes or pads; Pivots or supporting members therefor for axially-engaging brakes, e.g. disc brakes
    • 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
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0004—Materials; Production methods therefor metallic
    • 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
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0004—Materials; Production methods therefor metallic
    • F16D2200/0026—Non-ferro
    • F16D2200/003—Light metals, e.g. aluminium

Definitions

  • the present invention relates to a back plate, a disc brake pad, and a caliper assembly.
  • FIGS. 1A and 1B show an example of a disc brake pad as a friction member for braking attached to a motorcycle or a four-wheeled vehicle.
  • FIG. 1A is a top view of the disc brake pad
  • FIG. 1B is an example of a cross-sectional view taken along line AA in FIG. 1A.
  • the disc brake pad is composed of a back plate 1 and a friction material 2, and the friction material 2 is directly fixed to one surface of the back plate 1 (here, the upper surface of the back plate 1).
  • the friction material 2 is made of, for example, a so-called resin mold material including a binder, an organic filler, an inorganic filler, and a fiber base material.
  • a preform of a friction material composed of a binder, an organic filler, an inorganic filler, and a fiber base material is preliminarily superimposed on one surface of the back plate 1 and then hot-pressed to form an integrated body. It is manufactured by applying a surface treatment after being fixed to the surface.
  • FIG. 1C is another example of a cross-sectional view taken along line AA in FIG.
  • the disk brake pad shown in FIG. 1C includes a back plate 1, a friction material 2, and an intermediate layer 3, and is provided on one surface of the back plate 1 (the upper surface of the back plate 1) via the intermediate layer 3.
  • the friction material 2 is fixed.
  • the disc brake pad is formed by laminating a preform of a friction material and an intermediate layer composed of a binder, an organic filler, an inorganic filler, and a fiber base material on one surface of the back plate 1 in advance, and hot pressing. It is manufactured by performing surface processing after being fixed integrally.
  • the present inventors have been studying to change the back plate from a conventional steel plate to a lighter material such as aluminum or resin in order to reduce the weight of the disc brake pad. It has been found that the lightweight material has insufficient durability as compared with the conventional steel back plate. In particular, it has been found that the torque receiving portion of the back plate, which plays a role of receiving a force that tends to rotate with the rotation of the rotor during braking, is likely to be deformed, and is further susceptible to wear due to rubbing during braking.
  • the present inventors have conducted intensive research to solve the above-described problems, and as a result, by improving the durability of a torque receiving portion that plays a role of receiving a force that tries to rotate with the rotor during braking, the back plate is formed. It has been found that the durability of the back plate is improved even when the weight is reduced, and the present invention has been completed. That is, the present invention relates to the following [1] to [6].
  • a back plate for a disc brake wherein a material of a body portion of the back plate contains a material having a specific gravity lower than steel, and a metal plate is disposed on at least a part of a torque receiving portion of the back plate; A back plate, wherein a material of the metal plate is at least one selected from the group consisting of iron and an iron alloy.
  • the material having a lower specific gravity than the steel is at least one selected from the group consisting of an aluminum alloy, an aluminum composite material, a magnesium alloy, and a fiber-reinforced resin.
  • a disc brake pad comprising the back plate according to any one of [1] to [4] and a friction material on one surface of the back plate.
  • a caliper assembly comprising: the disc brake pad according to [5]; and a caliper for pressing the disc brake pad against a counterpart material.
  • the present invention it is possible to provide a back plate, a disc brake pad, and a caliper assembly in which the weight of the back plate is reduced and the durability during braking is improved.
  • the back plate according to the present embodiment is a back plate for a disc brake, wherein the material of the main body portion of the back plate contains a material having a specific gravity lower than steel, and at least a part of the torque receiving portion of the back plate has a metal plate. And the material of the metal plate is at least one selected from the group consisting of iron and iron alloys.
  • the back plate 1 according to the present embodiment can take various forms.
  • the back plate 1 according to the present embodiment includes a main body 11, a first pad guide 12 protruding from the reciprocating side of the main body 11, A configuration including a second pad guide portion 13 protruding from the leading side of the main body portion 11 can be adopted.
  • the first pad guide portion 12 has an outer peripheral side root 4 and an inner peripheral side root 5.
  • the second pad guide portion 13 has an outer peripheral root 6 and an inner peripheral root 7.
  • the pad guide portions (the first pad guide portion 12 and the second pad guide portion 13) have a shape corresponding to a support portion of a caliper (not shown), thereby facilitating installation of the back plate 1 on the caliper.
  • the pad guide portions (the first pad guide portion 12 and the second pad guide portion 13) have a nested shape when supported by the vehicle.
  • the material of the first pad guide 12 and the second pad guide 13 is preferably the same as the material of the main body 11 from the viewpoint of improving durability.
  • the torque receiving portion 14 in the back plate 1 shown in FIGS. 2A and 3A is a projecting side surface of the main body 11 on which the second pad guide portion 13 is projectingly provided. 2 (b), 2 (c) and 3 (b), 3 (c), the torque receiving portion 14 of the back plate 1 is an end of the second pad guide portion 13 projecting from the main body portion 11.
  • the torque receiving portion 14 in the back plate 1 shown in FIGS. 2D and 3D is a side surface of the main body portion 11 on the circulation side.
  • a metal plate 15 is arranged on at least a part of each torque receiving portion 14.
  • the metal plate 15 is arranged on at least a part of the torque receiving portion 14 in the back plate 1.
  • the metal plate 15 is preferably disposed on the entire torque receiving portion 14 from the viewpoint of suppressing deformation and wear of the torque receiving portion 14 due to torque during braking.
  • the back plate 1 arranged on the caliper 20 comes into contact with the caliper 20 during braking, so that the caliper 20 is in an open state.
  • the torque is biased, and stress is concentrated on a part, so that deformation and wear are likely to occur.
  • the provision of the metal plate 15 reduces the stress concentration, as shown by the hatched portion in FIG. 5B, and can suppress deformation and abrasion.
  • the material of the metal plate 15 is at least one selected from the group consisting of iron and iron alloys.
  • the iron alloy include those containing iron such as carbon, silicon, magnesium, nickel, chromium, molybdenum, and copper, and specifically, steel and cast iron.
  • the thickness T of the metal plate 15 is preferably 0.1 mm or more, more preferably 0.2 mm or more, and more preferably 0.3 mm or more from the end of the back plate 1. More preferably, there is.
  • the upper limit of the thickness T of the metal plate 15 is not particularly limited, but is preferably 5.0 mm or less, and more preferably 2.0 mm or less. When the thickness T of the metal plate 15 is within the above range, deformation and wear of the torque receiving portion due to torque during braking can be suppressed.
  • the material of the outer portion 11 of the back plate 1 contains a material having a specific gravity lower than that of steel.
  • the material of the outer portion 11 of the back plate 1 contains a material having a specific gravity lower than steel, preferably 50% by volume or more, more preferably 80% by volume or more, and still more preferably 90% by volume or more. It is particularly preferable that the material be made of a light material.
  • the material having a specific gravity lower than that of steel is preferably a material having a specific gravity of 5 or less, more preferably a material having a specific gravity of 3 or less, and further preferably a material having a specific gravity of 2 or less.
  • Materials having a lower specific gravity than steel include, for example, aluminum alloys, aluminum composite materials, magnesium alloys, and fiber reinforced resins. That is, the material of the back plate is preferably at least one selected from the group consisting of an aluminum alloy, an aluminum composite material, a magnesium alloy, and a fiber reinforced resin.
  • Aluminum has a small specific gravity of about 2.7 and is therefore suitable as a lightweight material. However, from the viewpoint of strength, it is preferable to use an aluminum alloy as the back plate.
  • Aluminum alloys include 2XXX (Al-Cu), 3XXX (Al-Mn), 4XXX (Al-Si), 5XXX (Al-Mg), and 6XXX (Al-Mg-Si).
  • AC1C Al-Cu-based
  • AC1B Al-Cu-based
  • AC2A Al-Cu-Si-based
  • AC2B Al-Cu-) Si-based
  • AC3A Al-Si-based
  • AC4A AC4C
  • AC4C Al-Si-Mg-based
  • AC4B Al-Si-Cu-based
  • AC4D Al-Si-Cu-Mg-based
  • AC5A Al- Cu-Ni-Mg
  • AC7A Al-Mg
  • AC8A Al-Si-Cu-Ni-Mg
  • AC8B Al-Si-Cu-Ni-Mg
  • AC9A Al-Si-) Cu-Mg type , AC9B (Al-Si-Cu-Mg) and other casting aluminum alloys
  • ADC1 Al-Si
  • ADC3 Al-Si
  • An aluminum composite material in which ceramic particles are dispersed in aluminum or the above-mentioned aluminum alloy (ceramic particle reinforced aluminum-based composite material) has a higher Young's modulus than an aluminum alloy. This is preferable because the rigidity of the sheet can be increased.
  • oxide ceramics such as Al 2 O 3 , TiO 2 , SiO 2 , ZrO 2 , carbide ceramics such as SiC and TiC, and nitride ceramics such as TiN can be used.
  • magnesium alloy Since magnesium has a small specific gravity of 1.74, it is suitable as a lightweight material, but from the viewpoint of strength, it is preferable to use a magnesium alloy as the back plate.
  • magnesium alloys include M1 (Mg-Mn alloy), AZ-based (Mg-Al-Zn alloy) such as AZ61 and AZ91, ZK-based (Mg-Zn-Zr alloy) such as ZK51 and ZK60, and ZH-based such as ZH62.
  • magnesium alloys for casting such as EK-based (Mg-rare earth element alloy) such as EK30, HK-based (Mg-Th-based alloy) such as HK31, and K1 (Mg-Zr alloy);
  • EK-based Mg-rare earth element alloy
  • HK-based Mg-Th-based alloy
  • K1 Mg-Zr alloy
  • a magnesium alloy for processing can be used.
  • a flame-retardant magnesium alloy to which calcium is added by several% can be used.
  • the fiber-reinforced resin refers to a composite of fiber and resin, that is, a composite of fiber and resin. Since the specific gravity of the fiber reinforced resin is about 1, it is suitable as a lightweight material.
  • the fiber used for the fiber-reinforced resin examples include glass fiber, alumina fiber such as ⁇ -alumina type and ⁇ -alumina type, and inorganic fiber such as boron fiber; aramid fiber such as para-aramid fiber and meta-aramid fiber; At least one selected from the group consisting of cellulose fibers, nanocellulose fibers, PBO (polyparaphenylenebenzoxazole) fibers, or oxidized fibers, pitch-based fibers, and carbon-based fibers such as PAN (polyacrylonitrile) -based carbon fibers; Can be used. Particularly when used as a back plate, glass fibers and carbon fibers are preferred from the viewpoint of strength and rigidity, and carbon fibers are more preferred from the viewpoint of high thermal conductivity.
  • the thermal conductivity of the back plate can be further improved, and when the braking temperature is increased by frictional heat due to repeated braking, the temperature distribution in the back plate can be made uniform. In addition, there is a tendency that a local temperature rise is prevented, and cracks and cracks due to thermal decomposition and a decrease in strength of the resin are easily prevented.
  • the fiber length of the fiber used for the fiber reinforced resin is not particularly limited, but from the viewpoint of strength, a fiber length of 1 mm or more is preferable, and a long fiber of 10 mm or more is more preferable.
  • the upper limit of the fiber length of the fiber is not particularly limited, and may be 100 mm or less, 70 mm or less, 50 mm or less, or 35 mm or less.
  • a nonwoven fabric such as felt, a paper product, a woven fabric made of continuous fibers, a knitted fabric, and a woven fabric such as a mixed fabric can also be used.
  • a thermosetting resin is preferable from the viewpoint of heat resistance
  • a phenol resin, an epoxy resin, and a polyimide resin are preferable from the viewpoint of heat resistance and strength. It is preferable to use a curing agent in combination with the phenol resin and the epoxy resin.
  • the resin used for the fiber reinforced resin one type may be used alone, or two or more types may be used in combination.
  • the phenol resin a commercially available product can be used, and the phenol resin can be synthesized by a conventional method.
  • the phenol resin examples include a resol type phenol resin, a straight novolak type phenol resin, an aralkyl-modified phenol resin, an elastomer-modified phenol resin modified with an acrylic elastomer, a silicone elastomer, and the like. From the viewpoint of heat resistance, the phenol resin is preferably a straight novolak type phenol resin or a resol type phenol resin.
  • the epoxy resin is preferably an epoxy resin having an aromatic ring from the viewpoint of strength and heat resistance.
  • a phenol novolak type epoxy resin, a cresol novolak type epoxy resin, a naphthalene type epoxy resin, or the like can be suitably used.
  • epoxy resin modified with silicone, acrylonitrile, butadiene, isopropyl rubber, polyamide resin, or the like can also be used.
  • additives can be blended in addition to the above fibers and resin.
  • Other additives include inorganic fillers, organic fillers, metal powders and the like.
  • the other additives one kind may be used alone, and two kinds or more may be used in combination. It is preferably a particulate inorganic filler, organic filler, or metal powder.
  • the particle diameter is preferably small.
  • graphite, molybdenum disulfide, tungsten sulfide, fluororesin, coke, and the like are mentioned.
  • magnesium hydroxide and aluminum hydroxide are used.
  • antimony compounds, etc. from the viewpoint of weight reduction, hollow inorganic particles, etc., from the viewpoint of improving the curing speed of the resin, calcium oxide, calcium hydroxide, etc., to improve the thermal conductivity From the point of view, metal powder, graphite, magnesium oxide, zinc oxide and the like can be mentioned.
  • the fiber reinforced resin preferably has a thermal conductivity in the thickness direction of 0.4 W / m ⁇ K or more, and more preferably 0.45 W / m ⁇ K or more in order to prevent a local temperature rise of the back plate. More preferably, it is more preferably 1 W / m ⁇ K or more.
  • a method of adding an additive having a high thermal conductivity such as metal powder, graphite, magnesium oxide, and zinc oxide to the fiber reinforced resin examples include a method using a fiber having a high thermal conductivity such as a carbon fiber as the fiber, and a fiber reinforced resin employing one of these methods alone or a combination of two or more thereof can be used.
  • the fiber reinforced resin is molded and, if necessary, shaped to produce a fiber reinforced resin back plate.
  • the above friction member can be manufactured. That is, the preformed friction material composition is inserted into the mold hole of the thermoforming mold of the friction material as necessary, and then the adhesive is preliminarily applied to the back plate made of fiber reinforced resin in contact with the preformed body. Place the applied material. Then, by forming the friction material by thermoforming the friction material composition, the fiber reinforced resin and the friction material can be integrated to form a friction member.
  • thermoforming of the back plate made of the fiber reinforced resin and the thermoforming of the friction material are performed separately, so that the energy efficiency is not necessarily good. Therefore, energy efficiency can be improved by simultaneously performing thermoforming of the back plate made of fiber reinforced resin and thermoforming of the friction material. That is, the fiber reinforced resin in the state before the thermosetting and the friction material composition which has been preformed as necessary are inserted, and simultaneously thermoformed, and the thermosetting property in the fiber reinforced resin in the thermoforming step is changed. By melting and curing the resin and the thermosetting resin in the friction material, the resin and the thermosetting resin can be integrated without the need for an adhesive.
  • the disc brake pad according to the present embodiment includes the above-described back plate 1 and a friction material 2 on one surface of the back plate 1.
  • a friction material formed from a friction material composition containing a binder, an organic filler, an inorganic filler, and a fibrous base material is used.
  • the friction material can be formed by laminating the friction material composition or the preform of the friction material composition on the back plate 1 and hot-pressing the same, and then heat-treating the thermosetting resin as the binder.
  • the thickness of the friction material 2 is preferably 4 mm or more and 15 mm or less, more preferably 6 mm or more and 15 mm or less, and even more preferably 7 mm or more and 13 mm or less.
  • the disc brake pad according to the present embodiment can take a form in which the friction material 2 is formed on the back plate 1 via the intermediate layer 3 as shown in FIG.
  • a friction material formed from a friction material composition containing a binder, an organic filler, an inorganic filler, and a fibrous base material is used.
  • the friction material composition and the composition of the intermediate layer or the preform of the friction material composition and the composition of the intermediate layer are overlapped with the back plate 1. And then heat-treated, and then heat-treated to cure the thermosetting resin as a binder.
  • the thickness of the intermediate layer 3 is preferably 1 mm or more and 5 mm or less from the viewpoint that the heat insulating effect between the friction material 2 and the back plate 1 increases and cracks and cracks of the back plate 1 can be effectively suppressed.
  • it is 1 mm or more and 3 mm or less, more preferably 1 mm or more and 2 mm or less.
  • the back plate 1 contains a fiber reinforced resin, and the thermosetting resin contained in the friction material 2 is used for the back plate 1. It is preferable that By doing so, the back plate 1 and the friction material 2 can be integrally formed by hot pressing without using an adhesive, so that not only the strength and toughness of the disc brake pad are improved but also the manufacturing process is simplified. It is preferable from the viewpoint of.
  • the thermosetting resin used for the back plate 1 is the thermosetting resin contained in the friction material 2 and the intermediate layer 3. It is preferable to use a combination of chemical components capable of forming a chemical bond with each other upon curing.
  • the back plate 1, the intermediate layer 3, and the friction material 2 can be integrally formed by hot-pressure molding without using an adhesive, so that not only the strength of the disc brake pad is improved but also the manufacturing process is improved. It is preferable from the viewpoint of simplification. Further, when the back plate 1 includes an aluminum alloy or an aluminum composite material containing Cu, Zn, or the like, the aging precipitation process can be performed simultaneously with the hot pressing and the heat treatment. In this case, it is preferable not only from the viewpoint of improving the strength of the disc brake pad but also simplifying the manufacturing process.
  • the caliper assembly includes the above-described disc brake pad and a caliper that presses the disc brake pad against a mating member.
  • the caliper assembly plays a role of braking by rubbing a friction material provided on the disc brake pad with a disc rotor or the like as a mating material.
  • Example 1 a back plate having a thickness of the main body of 6.0 mm and a width of the pad guide of 10 mm was formed using 5083-O (Al-Mg based), which is an aluminum alloy, as the material of the back plate. .
  • an adhesive (trade name “JB Weld Auto Weld AW-20Z” manufactured by Ryusei Community Co., Ltd.) was applied to the torque receiving portion of the formed back plate, and a 0.2 mm thick stainless steel plate (metal plate) was applied. ) was arranged and pressed to obtain a back plate of Example 1.
  • the surface on which the stainless steel plate (metal plate) of the torque receiving portion of the back plate is disposed is ground in advance by the thickness of the stainless steel plate (metal plate) to be disposed, so that the torque receiving portion of the back plate can be rotated.
  • the dimensions at the end corresponding to the torque receiving part on the entry side have been unified.
  • Example 2 As Example 2, a back plate of Example 2 was obtained in the same manner as Example 1 except that the thickness of the stainless steel plate (metal plate) was changed to 0.5 mm.
  • Example 3 As Example 3, a back plate of Example 3 was obtained in the same manner as Example 1 except that the thickness of the stainless steel plate (metal plate) was changed to 1.0 mm.
  • Comparative Example 1 As Comparative Example 1, a back plate of Comparative Example 1 was obtained in the same manner as in Example 1 except that a stainless steel plate (metal plate) was omitted.
  • a back plate of Reference Example 1 was obtained in the same manner as in Example 1 except that a stainless steel plate (metal plate) was used without using steel as the material of the back plate.
  • Durability test of back plate Appearance A brake dynamo test was performed using the disc brake pads of each example prepared above, and the durability of the back plate was evaluated. In the evaluation, a general pin-slide type caliper compatible with a collet and a ventilated disc rotor were used to evaluate the inertia at 7 kgf ⁇ m ⁇ s 2 . After repeating five times of braking for 5 seconds at a vehicle speed of 65 km / h and a deceleration of 1.5 G, the appearance of the back plate was checked for defects (crushing, buckling, breakage, chipping, cracks), and according to the following evaluation criteria. evaluated.
  • Table 1 shows the evaluation results.
  • B At least one of crushing and buckling exceeding 0.1 mm occurred on the back plate, but no breakage, chipping or cracking occurred.
  • C At least one of crushing and buckling exceeding 0.1 mm occurred on the back plate, and at least one of breakage, chipping and cracking occurred.
  • Comparative Example 1 which is a lightweight material back plate using 5083-O (Al-Mg based) as an aluminum alloy as a material of the back plate has collapsed appearance, buckling, breakage, and the like after the durability test. It was confirmed that there was chipping and cracks, and a dimensional change of 1.0 mm or more occurred before and after the test, confirming that there was a practical problem.
  • the conventional disk brake pad using the steel back plate of Reference Example 1 had no problem in appearance after the test. However, the mass of the steel back plate in the disc brake pad of Reference Example 1 was 250 g, and the mass of the back plate in the disc brake pads of Examples 1 to 3 was 90 g. When one to three disc brake pads are used, the mass of 160 g per disc brake pad can be reduced.
  • the back plate, the disc brake pad, and the caliper assembly of the present invention have durability that is practically no problem, and are light in weight, so that the back plate, the disc brake pad, and the like are used for braking a two-wheeled or four-wheeled vehicle. It is suitable as a caliper assembly.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)

Abstract

A back plate for disc brakes, which is configured such that: the material of a main body part of the back plate contains a material which has a lighter specific gravity than steel; a metal plate is arranged on at least a part of a torque receiving part of the back plate; and the material of the metal plate is composed of at least one substance selected from the group consisting of iron and iron alloys.

Description

バックプレート、ディスクブレーキパッド及びキャリパーアッセンブリBack plate, disc brake pad and caliper assembly
　本発明は、バックプレート、ディスクブレーキパッド及びキャリパーアッセンブリに関する。 The present invention relates to a back plate, a disc brake pad, and a caliper assembly.
　二輪車及び四輪の自動車等に取り付けられている制動用の摩擦部材として、ディスクブレーキパッドの一例を図１（ａ）及び（ｂ）に示す。なお、図１（ａ）はディスクブレーキパッドの上面図であり、図１（ｂ）は図１（ａ）のＡ－Ａ線における断面図の一例である。本例においては、ディスクブレーキパッドは、バックプレート１と摩擦材２から構成され、摩擦材２がバックプレート１の一方の面（ここではバックプレート１の上面）に直接固着されている。摩擦材２は、例えば、結合材、有機充填材、無機充填材及び繊維基材からなる、いわゆるレジンモールド材により構成される。このようなディスクブレーキパッドは、バックプレート１の一方の面に、予め結合材、有機充填材、無機充填材及び繊維基材からなる摩擦材の予備成形体を重ね合わせ、熱圧成形して一体に固着した後、表面加工を施すことにより製造されている。 FIGS. 1A and 1B show an example of a disc brake pad as a friction member for braking attached to a motorcycle or a four-wheeled vehicle. FIG. 1A is a top view of the disc brake pad, and FIG. 1B is an example of a cross-sectional view taken along line AA in FIG. 1A. In this example, the disc brake pad is composed of a back plate 1 and a friction material 2, and the friction material 2 is directly fixed to one surface of the back plate 1 (here, the upper surface of the back plate 1). The friction material 2 is made of, for example, a so-called resin mold material including a binder, an organic filler, an inorganic filler, and a fiber base material. In such a disc brake pad, a preform of a friction material composed of a binder, an organic filler, an inorganic filler, and a fiber base material is preliminarily superimposed on one surface of the back plate 1 and then hot-pressed to form an integrated body. It is manufactured by applying a surface treatment after being fixed to the surface.
　また、ディスクブレーキパッドの他の例を図１（ｃ）に示す。図１（ｃ）は図１（ａ）のＡ－Ａ線における断面図の他の例である。図１（ｃ）のディスクブレーキパッドは、バックプレート１、摩擦材２及び中間層３から構成され、バックプレート１の一方の面（ここではバックプレート１の上面）に、中間層３を介して摩擦材２が固着されたものである。この場合、ディスクブレーキパッドは、バックプレート１の一方の面に、予め結合材、有機充填材、無機充填材及び繊維基材からなる摩擦材及び中間層の予備成形体を重ね合わせ、熱圧成形して一体に固着した後、表面加工を施すことにより製造されている。 (1) Another example of the disc brake pad is shown in FIG. FIG. 1C is another example of a cross-sectional view taken along line AA in FIG. The disk brake pad shown in FIG. 1C includes a back plate 1, a friction material 2, and an intermediate layer 3, and is provided on one surface of the back plate 1 (the upper surface of the back plate 1) via the intermediate layer 3. The friction material 2 is fixed. In this case, the disc brake pad is formed by laminating a preform of a friction material and an intermediate layer composed of a binder, an organic filler, an inorganic filler, and a fiber base material on one surface of the back plate 1 in advance, and hot pressing. It is manufactured by performing surface processing after being fixed integrally.
　近年、自動車の環境対応化及び低燃費化の進行に伴い、自動車の各部品の軽量化が検討及び実施されている。通常、自動車における原材料の構成は、金属材が半分以上を占めているが、車体の軽量化のため、その使用量は年々低下傾向にある。また、車体の軽量化にあたっては、近年、素材としてアルミニウム（アルミニウム合金又はアルミニウム複合材）又は樹脂の使用が増加傾向にある。鋼板の比重は約７．８であり、これに比べてアルミニウムの比重は約２．７、樹脂の比重は約１であって軽いため、アルミニウム及び樹脂等の素材を使用することにより、車体の５０％以下の軽量化が見込める。このような軽量化への動きの中、車両においては、ボディ、フレームのみならず、車両を構成する各要素に対しても軽量化の要求が大きくなってきている。 In recent years, with the progress of environmental friendliness and fuel economy of automobiles, the weight reduction of each component of automobiles has been studied and implemented. Normally, metal materials occupy more than half of the raw material composition in automobiles, but the amount of use is decreasing year by year due to weight reduction of vehicle bodies. Further, in reducing the weight of a vehicle body, in recent years, the use of aluminum (aluminum alloy or aluminum composite material) or resin as a material has been increasing. The specific gravity of the steel sheet is about 7.8, the specific gravity of aluminum is about 2.7, and the specific gravity of the resin is about 1, which is lighter. A weight reduction of 50% or less can be expected. In such a movement to reduce the weight, in the vehicle, there is an increasing demand for weight reduction not only of the body and the frame but also of each element constituting the vehicle.
　このような車体軽量化の要求は、車両の制動に用いられるブレーキシステムの構成要素の一つであるディスクブレーキパッドにおいても同様に大きくなってきている。具体的には、従来、ディスクブレーキパッドには鋼製の板材からなるバックプレートが用いられていたが、近年では軽量素材であるアルミニウム又はその合金からなるバックプレートに関する提案がされている（例えば、特許文献１～３参照）。 要求 The demand for such a reduction in the weight of the vehicle body is also increasing in a disc brake pad which is one of the components of a brake system used for braking the vehicle. Specifically, conventionally, a back plate made of a steel plate material has been used for a disc brake pad, but in recent years, a proposal has been made regarding a back plate made of aluminum or an alloy thereof which is a lightweight material (for example, Patent Documents 1 to 3).
特開２０００－０４６０７８号公報JP 2000-046078 A 特開２０１３－０６０９７４号公報JP 2013-060974 A 特開２０１５－１３５１７７号公報JP-A-2005-135177
　本発明者らは、ディスクブレーキパッドの軽量化のため、バックプレートをこれまでの鋼製のものから、アルミニウム製又は樹脂製等の軽量化素材に変更することを検討していたところ、これらの軽量化素材は、従来の鋼製のバックプレートに比べて耐久性が不十分であることが判明した。特に、制動時にロータの回転に供回りしようとする力を受けとめる役割を担うバックプレートのトルク受部では、変形が生じやすく、さらに制動中の擦れによって摩滅が生じやすいことが判明した。 The present inventors have been studying to change the back plate from a conventional steel plate to a lighter material such as aluminum or resin in order to reduce the weight of the disc brake pad. It has been found that the lightweight material has insufficient durability as compared with the conventional steel back plate. In particular, it has been found that the torque receiving portion of the back plate, which plays a role of receiving a force that tends to rotate with the rotation of the rotor during braking, is likely to be deformed, and is further susceptible to wear due to rubbing during braking.
　これらのことから、本発明は、バックプレートの軽量化を図ると共に、制動時の耐久性を向上させたバックプレート、ディスクブレーキパッド及びキャリパーアッセンブリを提供することを目的とする。 Accordingly, it is an object of the present invention to provide a back plate, a disc brake pad, and a caliper assembly in which the weight of the back plate is reduced and the durability during braking is improved.
　本発明者らは、上記の課題を解決すべく鋭意研究した結果、制動時にロータの回転に供回りしようとする力を受けとめる役割を担うトルク受部の耐久性を向上させることによって、バックプレートを軽量化したときにもバックプレートの耐久性が向上することを見出し、本発明を完成するに至った。すなわち、本発明は、下記［１］～［６］に関する。 The present inventors have conducted intensive research to solve the above-described problems, and as a result, by improving the durability of a torque receiving portion that plays a role of receiving a force that tries to rotate with the rotor during braking, the back plate is formed. It has been found that the durability of the back plate is improved even when the weight is reduced, and the present invention has been completed. That is, the present invention relates to the following [1] to [6].
［１］ディスクブレーキ用のバックプレートであって、前記バックプレートの本体部の材質が鋼より比重の軽い素材を含有し、前記バックプレートにおけるトルク受部の少なくとも一部に金属板を配置し、前記金属板の材質が鉄及び鉄合金からなる群から選択される少なくとも１種である、バックプレート。
［２］前記鋼より比重の軽い素材は、アルミニウム合金、アルミニウム複合材料、マグネシウム合金及び繊維強化樹脂からなる群から選択される少なくとも１種である、［１］に記載のバックプレート。
［３］前記金属板の厚さは、０．１ｍｍ以上である、［１］又は［２］に記載のバックプレート。
［４］パッドガイド部をさらに備える、［１］～［３］のいずれかに記載のバックプレート。
［５］［１］～［４］のいずれかに記載のバックプレートと、前記バックプレートの一方の面に摩擦材を備える、ディスクブレーキパッド。
［６］［５］に記載のディスクブレーキパッドと、前記ディスクブレーキパッドを相手材に押さえつけるキャリパーを備える、キャリパーアッセンブリ。 [1] A back plate for a disc brake, wherein a material of a body portion of the back plate contains a material having a specific gravity lower than steel, and a metal plate is disposed on at least a part of a torque receiving portion of the back plate; A back plate, wherein a material of the metal plate is at least one selected from the group consisting of iron and an iron alloy.
[2] The back plate according to [1], wherein the material having a lower specific gravity than the steel is at least one selected from the group consisting of an aluminum alloy, an aluminum composite material, a magnesium alloy, and a fiber-reinforced resin.
[3] The back plate according to [1] or [2], wherein the thickness of the metal plate is 0.1 mm or more.
[4] The back plate according to any one of [1] to [3], further comprising a pad guide portion.
[5] A disc brake pad comprising the back plate according to any one of [1] to [4] and a friction material on one surface of the back plate.
[6] A caliper assembly comprising: the disc brake pad according to [5]; and a caliper for pressing the disc brake pad against a counterpart material.
　本発明によれば、バックプレートの軽量化を図ると共に、制動時の耐久性を向上させたバックプレート、ディスクブレーキパッド及びキャリパーアッセンブリを提供することができる。 According to the present invention, it is possible to provide a back plate, a disc brake pad, and a caliper assembly in which the weight of the back plate is reduced and the durability during braking is improved.
ディスクブレーキパッドの模式図である。It is a schematic diagram of a disc brake pad. バックプレートの様々な形態を示す模式図である。It is a mimetic diagram showing various forms of a back plate. 様々な形態のバックプレートとキャリパーの関係を示す模式図である。It is a schematic diagram which shows the relationship between the back plate of various forms, and a caliper. 制動時のキャリパーの状態を示す模式図である。It is a schematic diagram which shows the state of the caliper at the time of braking. 金属板の機能を示すための模式図である。It is a schematic diagram for showing the function of a metal plate. 金属板の厚さを示す模式図である。It is a schematic diagram which shows the thickness of a metal plate.
　以下、本発明について詳細に説明する。但し、以下の実施形態において、その構成要素は、特に明示した場合を除き、必須ではない。数値及びその範囲についても同様であり、本発明を制限するものではない。
　本明細書中に記載されている数値範囲において、その数値範囲の上限値又は下限値は、実施例に示されている値に置き換えてもよい。
　また、本明細書における記載事項を任意に組み合わせた態様も本発明に含まれる。 Hereinafter, the present invention will be described in detail. However, in the following embodiments, the components are not essential unless otherwise specified. The same applies to numerical values and their ranges, and does not limit the present invention.
In the numerical ranges described in this specification, the upper limit or the lower limit of the numerical range may be replaced with the value shown in the embodiment.
In addition, embodiments in which the items described in this specification are arbitrarily combined are also included in the present invention.
［バックプレート］
　本実施形態に係るバックプレートは、ディスクブレーキ用のバックプレートであって、バックプレートの本体部の材質が鋼より比重の軽い素材を含有し、バックプレートにおけるトルク受部の少なくとも一部に金属板を配置し、金属板の材質が鉄及び鉄合金からなる群から選択される少なくとも１種である。 [Back plate]
The back plate according to the present embodiment is a back plate for a disc brake, wherein the material of the main body portion of the back plate contains a material having a specific gravity lower than steel, and at least a part of the torque receiving portion of the back plate has a metal plate. And the material of the metal plate is at least one selected from the group consisting of iron and iron alloys.
　本実施形態に係るバックプレートは、様々な形態をとり得る。例えば、本実施形態に係るバックプレート１は、図２（ａ）～（ｄ）に示すように、本体部１１と、本体部１１の回入側に突設した第１パッドガイド部１２と、本体部１１の回出側に突設した第２パッドガイド部１３とを備える形態をとり得る。第１パッドガイド部１２は、外周側付根４及び内周側付根５を有する。第２パッドガイド部１３は、外周側付根６及び内周側付根７を有する。パッドガイド部（第１パッドガイド部１２及び第２パッドガイド部１３）は、キャリパー（図示せず）の支持部に対応する形状とすることで、キャリパーに対するバックプレート１の設置を容易にする。また、パッドガイド部（第１パッドガイド部１２及び第２パッドガイド部１３）は、車両に支持される際、入れ子型にはめ込まれる形状であることが好ましい。
　第１パッドガイド部１２及び第２パッドガイド部１３の材質は、耐久性を向上させる観点から、本体部１１の材質と同じ材質であることが好ましい。 The back plate according to the present embodiment can take various forms. For example, as shown in FIGS. 2A to 2D, the back plate 1 according to the present embodiment includes a main body 11, a first pad guide 12 protruding from the reciprocating side of the main body 11, A configuration including a second pad guide portion 13 protruding from the leading side of the main body portion 11 can be adopted. The first pad guide portion 12 has an outer peripheral side root 4 and an inner peripheral side root 5. The second pad guide portion 13 has an outer peripheral root 6 and an inner peripheral root 7. The pad guide portions (the first pad guide portion 12 and the second pad guide portion 13) have a shape corresponding to a support portion of a caliper (not shown), thereby facilitating installation of the back plate 1 on the caliper. Further, it is preferable that the pad guide portions (the first pad guide portion 12 and the second pad guide portion 13) have a nested shape when supported by the vehicle.
The material of the first pad guide 12 and the second pad guide 13 is preferably the same as the material of the main body 11 from the viewpoint of improving durability.
　バックプレート１におけるトルク受部１４は、図３（ａ）～（ｄ）に示すように、バックプレート１をキャリパー２０に配置した場合において、制動時にキャリパー２０と接触することでバックプレート１にトルクがかかる箇所であり、ディスクロータの回転に供回りしようとする力を受けとめる役割を担っている。
　図２（ａ）及び図３（ａ）で示すバックプレート１におけるトルク受部１４は、第２パッドガイド部１３が突設された本体部１１の回出側の突設側面である。図２（ｂ）、（ｃ）及び図３（ｂ）、（ｃ）で示すバックプレート１におけるトルク受部１４は、本体部１１から突設した第２パッドガイド部１３の端部である。図２（ｄ）及び図３（ｄ）で示すバックプレート１におけるトルク受部１４は、本体部１１の回出側の側面である。図２（ａ）～（ｄ）及び図３（ａ）～（ｄ）に示すバックプレート１は、それぞれのトルク受部１４の少なくとも一部に金属板１５を配置する。 As shown in FIGS. 3A to 3D, when the back plate 1 is disposed on the caliper 20, the torque receiving portion 14 of the back plate 1 comes into contact with the caliper 20 during braking, so that the torque is applied to the back plate 1. And plays a role of receiving a force that tries to rotate with the rotation of the disk rotor.
The torque receiving portion 14 in the back plate 1 shown in FIGS. 2A and 3A is a projecting side surface of the main body 11 on which the second pad guide portion 13 is projectingly provided. 2 (b), 2 (c) and 3 (b), 3 (c), the torque receiving portion 14 of the back plate 1 is an end of the second pad guide portion 13 projecting from the main body portion 11. The torque receiving portion 14 in the back plate 1 shown in FIGS. 2D and 3D is a side surface of the main body portion 11 on the circulation side. In the back plate 1 shown in FIGS. 2A to 2D and 3A to 3D, a metal plate 15 is arranged on at least a part of each torque receiving portion 14.
＜金属板＞
　金属板１５は、バックプレート１におけるトルク受部１４の少なくとも一部に配置される。金属板１５は、制動時のトルクによるトルク受部１４の変形及び摩滅を抑制する観点から、トルク受部１４の全部に配置されることが好ましい。
　金属板１５のトルク受部１４への配置方法としては、接着、加締め及び溶接等の手段を採用することができる。 <Metal plate>
The metal plate 15 is arranged on at least a part of the torque receiving portion 14 in the back plate 1. The metal plate 15 is preferably disposed on the entire torque receiving portion 14 from the viewpoint of suppressing deformation and wear of the torque receiving portion 14 due to torque during braking.
As a method of arranging the metal plate 15 on the torque receiving portion 14, means such as adhesion, caulking, and welding can be adopted.
　金属板１５の機能について、図４及び図５を参照して説明する。
　キャリパー２０に配置されたバックプレート１は、図４に示すように、制動時にキャリパー２０と接触することで、キャリパー２０が開いたような状態となる。従来のバックプレート（金属板１５なし）の場合、図５（ａ）の斜線部で示すように、トルクが偏当たりすることになり、一部に応力が集中するので変形及び摩滅が発生しやすい。一方、本実施形態のバックプレート１の場合、金属板１５を備えることで、図５（ｂ）の斜線部で示すように、応力集中が緩和され、変形及び摩滅を抑制することができる。 The function of the metal plate 15 will be described with reference to FIGS.
As shown in FIG. 4, the back plate 1 arranged on the caliper 20 comes into contact with the caliper 20 during braking, so that the caliper 20 is in an open state. In the case of a conventional back plate (without the metal plate 15), as shown by the hatched portion in FIG. 5A, the torque is biased, and stress is concentrated on a part, so that deformation and wear are likely to occur. . On the other hand, in the case of the back plate 1 of the present embodiment, the provision of the metal plate 15 reduces the stress concentration, as shown by the hatched portion in FIG. 5B, and can suppress deformation and abrasion.
　金属板１５の材質は、鉄及び鉄合金からなる群から選択される少なくとも１種である。
　鉄合金としては、炭素、ケイ素、マグネシウム、ニッケル、クロム、モリブデン、及び銅等を鉄に含有させたものが挙げられ、具体的には、鋼及び鋳鉄等を挙げられる。 The material of the metal plate 15 is at least one selected from the group consisting of iron and iron alloys.
Examples of the iron alloy include those containing iron such as carbon, silicon, magnesium, nickel, chromium, molybdenum, and copper, and specifically, steel and cast iron.
　金属板１５の厚さＴは、図６に示すように、バックプレート１の端部から、０．１ｍｍ以上であることが好ましく、０．２ｍｍ以上であることがより好ましく、０．３ｍｍ以上であることがさらに好ましい。金属板１５の厚さＴの上限については特には制限されないが、５．０ｍｍ以下であることが好ましく、２．０ｍｍ以下であることがより好ましい。金属板１５の厚さＴが上記範囲であることによって、制動時のトルクによるトルク受部の変形及び摩滅を抑制することができる。 As shown in FIG. 6, the thickness T of the metal plate 15 is preferably 0.1 mm or more, more preferably 0.2 mm or more, and more preferably 0.3 mm or more from the end of the back plate 1. More preferably, there is. The upper limit of the thickness T of the metal plate 15 is not particularly limited, but is preferably 5.0 mm or less, and more preferably 2.0 mm or less. When the thickness T of the metal plate 15 is within the above range, deformation and wear of the torque receiving portion due to torque during braking can be suppressed.
＜材質＞
　バックプレート１の本外部１１の材質は、鋼より比重の軽い素材を含有するものである。バックプレート１の本外部１１の材質は、鋼より比重の軽い素材を、好ましくは５０体積％以上、より好ましくは８０体積％以上、さらに好ましくは９０体積％以上含有するものであり、鋼より比重の軽い素材からなるものであることが特に好ましい。
　鋼より比重の軽い素材は、比重５以下の素材であることが好ましく、比重３以下の素材であることがより好ましく、比重２以下の素材であることがさらに好ましい。
　鋼より比重の軽い素材としては、例えば、アルミニウム合金、アルミニウム複合材料、マグネシウム合金及び繊維強化樹脂が挙げられる。つまり、バックプレートの材質は、アルミニウム合金、アルミニウム複合材料、マグネシウム合金及び繊維強化樹脂からなる群から選択される少なくとも１種であることが好ましい。 <Material>
The material of the outer portion 11 of the back plate 1 contains a material having a specific gravity lower than that of steel. The material of the outer portion 11 of the back plate 1 contains a material having a specific gravity lower than steel, preferably 50% by volume or more, more preferably 80% by volume or more, and still more preferably 90% by volume or more. It is particularly preferable that the material be made of a light material.
The material having a specific gravity lower than that of steel is preferably a material having a specific gravity of 5 or less, more preferably a material having a specific gravity of 3 or less, and further preferably a material having a specific gravity of 2 or less.
Materials having a lower specific gravity than steel include, for example, aluminum alloys, aluminum composite materials, magnesium alloys, and fiber reinforced resins. That is, the material of the back plate is preferably at least one selected from the group consisting of an aluminum alloy, an aluminum composite material, a magnesium alloy, and a fiber reinforced resin.
（アルミニウム合金）
　アルミニウムは比重が約２．７と小さいため、軽量化素材として好適であるが、強度の観点から、バックプレートとしてはアルミニウム合金を用いることが好ましい。
　アルミニウム合金としては、２ＸＸＸ系（Ａｌ－Ｃｕ系）、３ＸＸＸ系（Ａｌ－Ｍｎ系）、４ＸＸＸ系（Ａｌ－Ｓｉ系）、５ＸＸＸ系（Ａｌ－Ｍｇ系）、６ＸＸＸ系（Ａｌ－Ｍｇ－Ｓｉ系）、７ＸＸＸ系（Ａｌ－Ｚｎ系）等の展伸用アルミニウム合金；ＡＣ１Ｃ（Ａｌ－Ｃｕ系）、ＡＣ１Ｂ（Ａｌ－Ｃｕ系）、ＡＣ２Ａ（Ａｌ－Ｃｕ－Ｓｉ系）、ＡＣ２Ｂ（Ａｌ－Ｃｕ－Ｓｉ系）、ＡＣ３Ａ（Ａｌ－Ｓｉ系）、ＡＣ４Ａ、ＡＣ４Ｃ（Ａｌ－Ｓｉ－Ｍｇ系）、ＡＣ４Ｂ（Ａｌ－Ｓｉ－Ｃｕ系）、ＡＣ４Ｄ（Ａｌ－Ｓｉ－Ｃｕ－Ｍｇ系）、ＡＣ５Ａ（Ａｌ－Ｃｕ－Ｎｉ－Ｍｇ系）、ＡＣ７Ａ（Ａｌ－Ｍｇ系）、ＡＣ８Ａ（Ａｌ－Ｓｉ－Ｃｕ－Ｎｉ－Ｍｇ系）、ＡＣ８Ｂ（Ａｌ－Ｓｉ－Ｃｕ－Ｎｉ－Ｍｇ系）、ＡＣ９Ａ（Ａｌ－Ｓｉ－Ｃｕ－Ｍｇ系）、ＡＣ９Ｂ（Ａｌ－Ｓｉ－Ｃｕ－Ｍｇ系）等の鋳物用アルミニウム合金；ＡＤＣ１（Ａｌ－Ｓｉ系）、ＡＤＣ３（Ａｌ－Ｓｉ－Ｍｇ系）、ＡＤＣ５（Ａｌ－Ｍｇ系）、ＡＤＣ６（Ａｌ－Ｍｇ－Ｍｎ系）、ＡＤＣ１０（Ａｌ－Ｓｉ－Ｃｕ系）、ＡＤＣ１２（Ａｌ－Ｓｉ－Ｃｕ系）、ＡＤＣ１４（Ａｌ－Ｓｉ－Ｃｕ－Ｍｇ系）等のダイキャスト用アルミニウム合金などを用いることができる。また、これらを熱処理（時効処理）等して調質したものを用いることができる。 (Aluminum alloy)
Aluminum has a small specific gravity of about 2.7 and is therefore suitable as a lightweight material. However, from the viewpoint of strength, it is preferable to use an aluminum alloy as the back plate.
Aluminum alloys include 2XXX (Al-Cu), 3XXX (Al-Mn), 4XXX (Al-Si), 5XXX (Al-Mg), and 6XXX (Al-Mg-Si). ), 7XXX (Al-Zn-based) and other aluminum alloys for spreading; AC1C (Al-Cu-based), AC1B (Al-Cu-based), AC2A (Al-Cu-Si-based), AC2B (Al-Cu-) Si-based), AC3A (Al-Si-based), AC4A, AC4C (Al-Si-Mg-based), AC4B (Al-Si-Cu-based), AC4D (Al-Si-Cu-Mg-based), AC5A (Al- Cu-Ni-Mg), AC7A (Al-Mg), AC8A (Al-Si-Cu-Ni-Mg), AC8B (Al-Si-Cu-Ni-Mg), AC9A (Al-Si-) Cu-Mg type , AC9B (Al-Si-Cu-Mg) and other casting aluminum alloys; ADC1 (Al-Si), ADC3 (Al-Si-Mg), ADC5 (Al-Mg), ADC6 (Al-Mg) -Mn-based), die-cast aluminum alloys such as ADC10 (Al-Si-Cu-based), ADC12 (Al-Si-Cu-based), and ADC14 (Al-Si-Cu-Mg-based). In addition, those obtained by tempering these materials by heat treatment (aging treatment) or the like can be used.
（アルミニウム複合材）
　アルミニウム又は上記のアルミニウム合金中にセラミックス粒子を分散させたアルミニウム複合材（セラミックス粒子強化アルミニウム基複合材料）は、アルミニウム合金に比してヤング率が高くなるため、バックプレートとして用いると、ディスクブレーキパッドの剛性を高くすることができ、好適である。分散強化するセラミックス粒子としては、Ａｌ２Ｏ３、ＴｉＯ２、ＳｉＯ２、ＺｒＯ２等の酸化物系セラミックス、ＳｉＣ、ＴｉＣ等の炭化物系セラミックス、ＴｉＮ等の窒化物系セラミックスを用いることができる。 (Aluminum composite)
An aluminum composite material in which ceramic particles are dispersed in aluminum or the above-mentioned aluminum alloy (ceramic particle reinforced aluminum-based composite material) has a higher Young's modulus than an aluminum alloy. This is preferable because the rigidity of the sheet can be increased. As the ceramic particles to be dispersion strengthened, oxide ceramics such as Al 2 O 3 , TiO 2 , SiO 2 , ZrO 2 , carbide ceramics such as SiC and TiC, and nitride ceramics such as TiN can be used.
（マグネシウム合金）
　マグネシウムは比重が１．７４と小さいため、軽量化素材として好適であるが、強度の観点から、バックプレートとしてはマグネシウム合金を用いることが好ましい。
　マグネシウム合金としては、Ｍ１（Ｍｇ－Ｍｎ合金）、ＡＺ６１、ＡＺ９１等のＡＺ系（Ｍｇ－Ａｌ－Ｚｎ合金）、ＺＫ５１、ＺＫ６０等のＺＫ系（Ｍｇ－Ｚｎ－Ｚｒ合金）、ＺＨ６２等のＺＨ系（Ｍｇ－Ｚｎ－Ｚｒ合金）、ＥＫ３０等のＥＫ系（Ｍｇ－希土類元素合金）、ＨＫ３１等のＨＫ系（Ｍｇ－Ｔｈ系合金）、Ｋ１（Ｍｇ－Ｚｒ合金）等の各種鋳造用マグネシウム合金及び加工用マグネシウム合金を用いることができる。また、カルシウムを数％添加した難燃性マグネシウム合金を用いることができる。 (Magnesium alloy)
Since magnesium has a small specific gravity of 1.74, it is suitable as a lightweight material, but from the viewpoint of strength, it is preferable to use a magnesium alloy as the back plate.
Examples of magnesium alloys include M1 (Mg-Mn alloy), AZ-based (Mg-Al-Zn alloy) such as AZ61 and AZ91, ZK-based (Mg-Zn-Zr alloy) such as ZK51 and ZK60, and ZH-based such as ZH62. (Mg-Zn-Zr alloy), various magnesium alloys for casting such as EK-based (Mg-rare earth element alloy) such as EK30, HK-based (Mg-Th-based alloy) such as HK31, and K1 (Mg-Zr alloy); A magnesium alloy for processing can be used. In addition, a flame-retardant magnesium alloy to which calcium is added by several% can be used.
（繊維強化樹脂）
　繊維強化樹脂とは、繊維と樹脂とを複合化したもの、つまり繊維と樹脂との複合材を指す。繊維強化樹脂の比重は約１程度であるため軽量化素材として好適である。 (Fiber reinforced resin)
The fiber-reinforced resin refers to a composite of fiber and resin, that is, a composite of fiber and resin. Since the specific gravity of the fiber reinforced resin is about 1, it is suitable as a lightweight material.
　繊維強化樹脂に用いられる繊維としては、例えば、ガラス繊維、α－アルミナタイプ、γ－アルミナタイプ等のアルミナ繊維、ボロン繊維等の無機繊維；パラ系アラミド繊維、メタ系アラミド繊維等のアラミド繊維；セルロース繊維、ナノセルロース繊維、ＰＢＯ（ポリパラフェニレンベンズオキサゾール）繊維、又は耐炎化繊維、ピッチ系、ＰＡＮ（ポリアクリロニトリル）系の炭素繊維等の炭素系繊維、からなる群から選ばれる少なくとも１種を用いることができる。特にバックプレートとして用いる場合、強度及び剛性の観点から、ガラス繊維、炭素繊維が好ましく、高熱伝導率の観点から、炭素繊維がさらに好ましい。炭素繊維を用いることで、バックプレートの熱伝導率をより一層向上することができ、繰り返し制動を行い摩擦熱でブレーキ温度が上昇したときに、バックプレート内の温度分布を均一にすることができ、局所的な温度上昇を防ぎ、樹脂の熱分解及び強度低下に伴うクラック、割れを防止し易い傾向にある。 Examples of the fiber used for the fiber-reinforced resin include glass fiber, alumina fiber such as α-alumina type and γ-alumina type, and inorganic fiber such as boron fiber; aramid fiber such as para-aramid fiber and meta-aramid fiber; At least one selected from the group consisting of cellulose fibers, nanocellulose fibers, PBO (polyparaphenylenebenzoxazole) fibers, or oxidized fibers, pitch-based fibers, and carbon-based fibers such as PAN (polyacrylonitrile) -based carbon fibers; Can be used. Particularly when used as a back plate, glass fibers and carbon fibers are preferred from the viewpoint of strength and rigidity, and carbon fibers are more preferred from the viewpoint of high thermal conductivity. By using carbon fiber, the thermal conductivity of the back plate can be further improved, and when the braking temperature is increased by frictional heat due to repeated braking, the temperature distribution in the back plate can be made uniform. In addition, there is a tendency that a local temperature rise is prevented, and cracks and cracks due to thermal decomposition and a decrease in strength of the resin are easily prevented.
　繊維強化樹脂に用いられる繊維の繊維長は特に制限されないが、強度の観点から、１ｍｍ以上の繊維長が好ましく、１０ｍｍ以上の長繊維であることがさらに好ましい。該繊維の繊維長の上限値に特に制限はなく、１００ｍｍ以下であってもよいし、７０ｍｍ以下であってもよいし、５０ｍｍ以下であってもよいし、３５ｍｍ以下であってもよい。
　また、繊維強化樹脂に用いる繊維としては、フェルト等の不織布、抄造品、連続繊維からなる織物、編物、交織物等の織布も用いることができる。 The fiber length of the fiber used for the fiber reinforced resin is not particularly limited, but from the viewpoint of strength, a fiber length of 1 mm or more is preferable, and a long fiber of 10 mm or more is more preferable. The upper limit of the fiber length of the fiber is not particularly limited, and may be 100 mm or less, 70 mm or less, 50 mm or less, or 35 mm or less.
Further, as the fiber used for the fiber reinforced resin, a nonwoven fabric such as felt, a paper product, a woven fabric made of continuous fibers, a knitted fabric, and a woven fabric such as a mixed fabric can also be used.
　繊維強化樹脂に用いられる樹脂としては、耐熱性の観点から、熱硬化性樹脂が好ましく、耐熱性及び強度の観点から、フェノール樹脂、エポキシ樹脂、ポリイミド樹脂が好ましい。フェノール樹脂、エポキシ樹脂は、硬化剤を併用することが好ましい。繊維強化樹脂に用いられる樹脂は、１種を単独で使用してもよいし、２種以上を併用してもよい。フェノール樹脂としては、市販品の使用も可能であり、常法により合成することもできる。 樹脂 As the resin used for the fiber reinforced resin, a thermosetting resin is preferable from the viewpoint of heat resistance, and a phenol resin, an epoxy resin, and a polyimide resin are preferable from the viewpoint of heat resistance and strength. It is preferable to use a curing agent in combination with the phenol resin and the epoxy resin. As the resin used for the fiber reinforced resin, one type may be used alone, or two or more types may be used in combination. As the phenol resin, a commercially available product can be used, and the phenol resin can be synthesized by a conventional method.
　フェノール樹脂としては、レゾールタイプのフェノール樹脂、ストレートノボラックタイプのフェノール樹脂、アラルキル変性タイプのフェノール樹脂、アクリルエラストマー、シリコーンエラストマー等で変性したエラストマー変性タイプのフェノール樹脂等が挙げられる。耐熱性の観点から、フェノール樹脂としてはストレートノボラックタイプのフェノール樹脂、レゾールタイプのフェノール樹脂が好ましい。 (4) Examples of the phenol resin include a resol type phenol resin, a straight novolak type phenol resin, an aralkyl-modified phenol resin, an elastomer-modified phenol resin modified with an acrylic elastomer, a silicone elastomer, and the like. From the viewpoint of heat resistance, the phenol resin is preferably a straight novolak type phenol resin or a resol type phenol resin.
　エポキシ樹脂としては、市販品の使用も可能であり、常法により合成することもできる。エポキシ樹脂としては、強度及び耐熱性の観点から、芳香環を有するエポキシ樹脂であることが好ましい。具体的には、フェノールノボラック型エポキシ樹脂、クレゾールノボラック型エポキシ樹脂、ナフタレン型エポキシ樹脂等を好適に使用することができる。また、シリコーン、アクリロニトリル、ブタジエン、イソプロピル系ゴム、ポリアミド系樹脂等により変性したエポキシ樹脂等についても使用することができる。 市 販 A commercial product can be used as the epoxy resin, and the epoxy resin can be synthesized by an ordinary method. The epoxy resin is preferably an epoxy resin having an aromatic ring from the viewpoint of strength and heat resistance. Specifically, a phenol novolak type epoxy resin, a cresol novolak type epoxy resin, a naphthalene type epoxy resin, or the like can be suitably used. Further, epoxy resin modified with silicone, acrylonitrile, butadiene, isopropyl rubber, polyamide resin, or the like can also be used.
　繊維強化樹脂においては、上記の繊維及び樹脂以外に、その他の添加剤を配合することができる。その他の添加剤としては、無機充填材、有機充填材、金属粉等が挙げられる。その他の添加剤は、１種を単独で使用してもよいし、２種以上を併用してもよい。粒子状の無機充填材、有機充填材、金属粉であることが好ましく、繊維集合体中に分散させるためには粒子径が小さいことが好ましい。具体的には、摺動性を向上させる観点からは、黒鉛、二硫化モリブデン、硫化タングステン、フッ素樹脂及びコークス等が挙げられ、難燃性を向上させる観点からは、水酸化マグネシウム、水酸化アルミニウム及びアンチモン化合物等が挙げられ、軽量化の観点からは、中空無機粒子等が挙げられ、樹脂の硬化速度を向上させる観点からは、酸化カルシウム、水酸化カルシウム等が挙げられ、熱伝導率を向上させる観点からは、金属粉、黒鉛、酸化マグネシウム、酸化亜鉛等が挙げられる。 In the fiber reinforced resin, other additives can be blended in addition to the above fibers and resin. Other additives include inorganic fillers, organic fillers, metal powders and the like. As the other additives, one kind may be used alone, and two kinds or more may be used in combination. It is preferably a particulate inorganic filler, organic filler, or metal powder. In order to disperse the filler in the fiber aggregate, the particle diameter is preferably small. Specifically, from the viewpoint of improving slidability, graphite, molybdenum disulfide, tungsten sulfide, fluororesin, coke, and the like are mentioned. From the viewpoint of improving flame retardancy, magnesium hydroxide and aluminum hydroxide are used. And antimony compounds, etc., from the viewpoint of weight reduction, hollow inorganic particles, etc., from the viewpoint of improving the curing speed of the resin, calcium oxide, calcium hydroxide, etc., to improve the thermal conductivity From the point of view, metal powder, graphite, magnesium oxide, zinc oxide and the like can be mentioned.
　繊維強化樹脂は、バックプレートの局所的な温度上昇を防ぐために、厚み方向の熱伝導率が０．４Ｗ／ｍ・Ｋ以上であることが好ましく、０．４５Ｗ／ｍ・Ｋ以上であることがより好ましく、１Ｗ／ｍ・Ｋ以上であることがさらに好ましい。繊維強化樹脂の厚み方向の熱伝導率を範囲にする方法としては、金属粉、黒鉛、酸化マグネシウム、酸化亜鉛等の熱伝導率の高い添加剤を繊維強化樹脂に添加する方法、繊維強化樹脂の繊維として炭素繊維等の熱伝導率の高い繊維を用いる方法などが挙げられ、これらの方法を１種単独で又は２種以上の組合せで採用した繊維強化樹脂を用いることができる。 The fiber reinforced resin preferably has a thermal conductivity in the thickness direction of 0.4 W / m · K or more, and more preferably 0.45 W / m · K or more in order to prevent a local temperature rise of the back plate. More preferably, it is more preferably 1 W / m · K or more. As a method of adjusting the thermal conductivity in the thickness direction of the fiber reinforced resin to a range, a method of adding an additive having a high thermal conductivity such as metal powder, graphite, magnesium oxide, and zinc oxide to the fiber reinforced resin, Examples of the method include a method using a fiber having a high thermal conductivity such as a carbon fiber as the fiber, and a fiber reinforced resin employing one of these methods alone or a combination of two or more thereof can be used.
　バックプレートに繊維強化樹脂を用いる場合、繊維強化樹脂を成形し、必要に応じて形状加工を施すことによって繊維強化樹脂製のバックプレートを製作した後、繊維強化樹脂製バックプレートを従来の鋼製のバックプレートに替えて用いることで、上記の摩擦部材を製造することができる。すなわち、摩擦材の熱成形金型の型孔に必要に応じて予備成形を行った摩擦材組成物を挿入し、次いで、予備成形体に接して繊維強化樹脂からなるバックプレートに予め接着剤を塗布したものを配置する。そして、摩擦材組成物を熱成形して摩擦材を形成することで繊維強化樹脂と摩擦材を一体化し、摩擦部材を形成することができる。以上の工程によると、繊維強化樹脂からなるバックプレートの熱成形と、摩擦材の熱成形を別に行うことから、エネルギー効率が必ずしも良いとは言えない。そこで、繊維強化樹脂からなるバックプレートの熱成形と、摩擦材の熱成形を同時に行うことにより、エネルギー効率を高めることもできる。すなわち、熱硬化前の状態の繊維強化樹脂と、必要に応じて予備成形を行った摩擦材組成物とを挿入し、同時に熱成形を行い、熱成形の工程において繊維強化樹脂中の熱硬化性樹脂と摩擦材中の熱硬化性樹脂が溶融及び硬化することで、接着剤の必要なく一体化することができる。 When a fiber reinforced resin is used for the back plate, the fiber reinforced resin is molded and, if necessary, shaped to produce a fiber reinforced resin back plate. By using the back plate instead of the above, the above friction member can be manufactured. That is, the preformed friction material composition is inserted into the mold hole of the thermoforming mold of the friction material as necessary, and then the adhesive is preliminarily applied to the back plate made of fiber reinforced resin in contact with the preformed body. Place the applied material. Then, by forming the friction material by thermoforming the friction material composition, the fiber reinforced resin and the friction material can be integrated to form a friction member. According to the above steps, the thermoforming of the back plate made of the fiber reinforced resin and the thermoforming of the friction material are performed separately, so that the energy efficiency is not necessarily good. Therefore, energy efficiency can be improved by simultaneously performing thermoforming of the back plate made of fiber reinforced resin and thermoforming of the friction material. That is, the fiber reinforced resin in the state before the thermosetting and the friction material composition which has been preformed as necessary are inserted, and simultaneously thermoformed, and the thermosetting property in the fiber reinforced resin in the thermoforming step is changed. By melting and curing the resin and the thermosetting resin in the friction material, the resin and the thermosetting resin can be integrated without the need for an adhesive.
［ディスクブレーキパッド］
　本実施形態に係るディスクブレーキパッドは、図１（ａ）及び（ｂ）に示すように、上述のバックプレート１と、バックプレート１の一方の面に摩擦材２を備える。 [Disc brake pad]
As shown in FIGS. 1A and 1B, the disc brake pad according to the present embodiment includes the above-described back plate 1 and a friction material 2 on one surface of the back plate 1.
＜摩擦材＞
　摩擦材２としては、例えば、結合材、有機充填材、無機充填材及び繊維基材を含有する摩擦材組成物から形成された摩擦材が好ましい一態様である。摩擦材組成物又は摩擦材組成物の予備成形体をバックプレート１と重ね合わせて熱圧成形し、次いで加熱処理して結合材である熱硬化樹脂を硬化させることで摩擦材を形成できる。 <Friction material>
As a preferred example of the friction material 2, a friction material formed from a friction material composition containing a binder, an organic filler, an inorganic filler, and a fibrous base material is used. The friction material can be formed by laminating the friction material composition or the preform of the friction material composition on the back plate 1 and hot-pressing the same, and then heat-treating the thermosetting resin as the binder.
　摩擦材２の厚さは、耐久性の観点から、４ｍｍ以上１５ｍｍ以下であることが好ましく、６ｍｍ以上１５ｍｍ以下であることがより好ましく、７ｍｍ以上１３ｍｍ以下であることがさらに好ましい。 か ら From the viewpoint of durability, the thickness of the friction material 2 is preferably 4 mm or more and 15 mm or less, more preferably 6 mm or more and 15 mm or less, and even more preferably 7 mm or more and 13 mm or less.
＜中間層＞
　本実施形態に係るディスクブレーキパッドは、図１（ｃ）に示すように、摩擦材２が中間層３を介してバックプレート１上に形成される形態をとり得る。
　中間層３としては、例えば、結合材、有機充填材、無機充填材及び繊維基材を含有する摩擦材組成物から形成された摩擦材が好ましい一態様である。中間層３を介して摩擦材２をバックプレート１に固着する場合、摩擦材組成物及び中間層の組成物あるいは摩擦材組成物及び中間層の組成物の予備成形体をバックプレート１と重ね合わせて熱圧成形し、次いで加熱処理して結合材である熱硬化樹脂を硬化させて形成するものである。 <Intermediate layer>
The disc brake pad according to the present embodiment can take a form in which the friction material 2 is formed on the back plate 1 via the intermediate layer 3 as shown in FIG.
As a preferable example of the intermediate layer 3, a friction material formed from a friction material composition containing a binder, an organic filler, an inorganic filler, and a fibrous base material is used. When the friction material 2 is fixed to the back plate 1 via the intermediate layer 3, the friction material composition and the composition of the intermediate layer or the preform of the friction material composition and the composition of the intermediate layer are overlapped with the back plate 1. And then heat-treated, and then heat-treated to cure the thermosetting resin as a binder.
　中間層３の厚さは、摩擦材２とバックプレート１間の断熱効果が高くなり、バックプレート１のクラック及び割れを効果的に抑制することができる観点から、１ｍｍ以上５ｍｍ以下であることが好ましく、１ｍｍ以上３ｍｍ以下であることがより好ましく、１ｍｍ以上２ｍｍ以下であることがさらに好ましい。 The thickness of the intermediate layer 3 is preferably 1 mm or more and 5 mm or less from the viewpoint that the heat insulating effect between the friction material 2 and the back plate 1 increases and cracks and cracks of the back plate 1 can be effectively suppressed. Preferably, it is 1 mm or more and 3 mm or less, more preferably 1 mm or more and 2 mm or less.
　バックプレート１が繊維強化樹脂を含むものであって、摩擦材２に含まれる熱硬化性樹脂をバックプレート１に用いる熱硬化性樹脂が熱硬化で相互に化学結合を形成し得る化学成分の組合せとすることが好ましい。こうすることで、バックプレート１と摩擦材２とを接着剤を用いなくても熱圧成形で一体成形することができ、ディスクブレーキパッドの強度、靭性が向上するだけでなく製造工程の簡略化の観点から好ましい。
　また、バックプレート１が繊維強化樹脂を含むものであって、中間層３を設ける場合は、摩擦材２及び中間層３に含まれる熱硬化性樹脂をバックプレート１に用いる熱硬化性樹脂が熱硬化で相互に化学結合を形成し得る化学成分の組合せとすることが好ましい。こうすることで、バックプレート１と中間層３と摩擦材２とを接着剤を用いなくても熱圧成形で一体成形することができ、ディスクブレーキパッドの強度が向上するだけでなく製造工程の簡略化の観点から好ましい。
　さらに、バックプレート１が、Ｃｕ、Ｚｎ等を含むアルミニウム合金又はアルミニウム複合材料を含む場合、時効析出処理を熱圧成形及び加熱処理時に同時に行うことができる。この場合、ディスクブレーキパッドの強度が向上するだけでなく、製造工程の簡略化の観点から好ましい。 The back plate 1 contains a fiber reinforced resin, and the thermosetting resin contained in the friction material 2 is used for the back plate 1. It is preferable that By doing so, the back plate 1 and the friction material 2 can be integrally formed by hot pressing without using an adhesive, so that not only the strength and toughness of the disc brake pad are improved but also the manufacturing process is simplified. It is preferable from the viewpoint of.
When the back plate 1 contains a fiber reinforced resin and the intermediate layer 3 is provided, the thermosetting resin used for the back plate 1 is the thermosetting resin contained in the friction material 2 and the intermediate layer 3. It is preferable to use a combination of chemical components capable of forming a chemical bond with each other upon curing. By doing so, the back plate 1, the intermediate layer 3, and the friction material 2 can be integrally formed by hot-pressure molding without using an adhesive, so that not only the strength of the disc brake pad is improved but also the manufacturing process is improved. It is preferable from the viewpoint of simplification.
Further, when the back plate 1 includes an aluminum alloy or an aluminum composite material containing Cu, Zn, or the like, the aging precipitation process can be performed simultaneously with the hot pressing and the heat treatment. In this case, it is preferable not only from the viewpoint of improving the strength of the disc brake pad but also simplifying the manufacturing process.
［キャリパーアッセンブリ］
　本実施形態に係るキャリパーアッセンブリは、上述のディスクブレーキパッドと、ディスクブレーキパッドを相手材に押さえつけるキャリパーを備える。
　キャリパーアッセンブリは、ディスクブレーキパッドに備える摩擦材を、相手材となるディスクロータ等と摩擦することによって制動の役割を果たす。 [Caliper assembly]
The caliper assembly according to the present embodiment includes the above-described disc brake pad and a caliper that presses the disc brake pad against a mating member.
The caliper assembly plays a role of braking by rubbing a friction material provided on the disc brake pad with a disc rotor or the like as a mating material.
　以下、実施例により本実施形態の摩擦材及び摩擦材組成物をさらに詳細に説明するが、本発明は何らこれらに限定されるものではない。 Hereinafter, the friction material and the friction material composition of the present embodiment will be described in more detail by way of examples, but the invention is not limited thereto.
［バックプレートの作製］
＜実施例１＞
　実施例１として、アルミニウム合金である５０８３－Ｏ（Ａｌ－Ｍｇ系）をバックプレートの素材として使用し、本体部の厚さを６．０ｍｍ、パッドガイド部の幅を１０ｍｍのバックプレートを成形した。
　次いで、成形したバックプレートのトルク受部に、接着剤（株式会社隆成コミュニティ製、商品名「Ｊ－Ｂウエルドオートウエルド ＡＷ－２０Ｚ」）を塗布し、厚さ０．２ｍｍのステンレス板（金属板）を配置して、圧着することで実施例１のバックプレートを得た。
　なお、バックプレートのトルク受部のステンレス板（金属板）を配置する面に対して、配置するステンレス板（金属板）の厚さ分を予め研削することで、バックプレートのトルク受部と回入側のトルク受部に相当する位置の端部との寸法を統一した。 [Preparation of back plate]
<Example 1>
In Example 1, a back plate having a thickness of the main body of 6.0 mm and a width of the pad guide of 10 mm was formed using 5083-O (Al-Mg based), which is an aluminum alloy, as the material of the back plate. .
Next, an adhesive (trade name “JB Weld Auto Weld AW-20Z” manufactured by Ryusei Community Co., Ltd.) was applied to the torque receiving portion of the formed back plate, and a 0.2 mm thick stainless steel plate (metal plate) was applied. ) Was arranged and pressed to obtain a back plate of Example 1.
The surface on which the stainless steel plate (metal plate) of the torque receiving portion of the back plate is disposed is ground in advance by the thickness of the stainless steel plate (metal plate) to be disposed, so that the torque receiving portion of the back plate can be rotated. The dimensions at the end corresponding to the torque receiving part on the entry side have been unified.
＜実施例２＞
　実施例２として、ステンレス板（金属板）の厚さを０．５ｍｍに変えた以外は実施例１と同様にして、実施例２のバックプレートを得た。 <Example 2>
Example 2 As Example 2, a back plate of Example 2 was obtained in the same manner as Example 1 except that the thickness of the stainless steel plate (metal plate) was changed to 0.5 mm.
＜実施例３＞
　実施例３として、ステンレス板（金属板）の厚さを１．０ｍｍに変えた以外は実施例１と同様にして、実施例３のバックプレートを得た。 <Example 3>
Example 3 As Example 3, a back plate of Example 3 was obtained in the same manner as Example 1 except that the thickness of the stainless steel plate (metal plate) was changed to 1.0 mm.
＜比較例１＞
　比較例１として、ステンレス板（金属板）をなしにした以外は実施例１と同様にして、比較例１のバックプレートを得た。 <Comparative Example 1>
As Comparative Example 1, a back plate of Comparative Example 1 was obtained in the same manner as in Example 1 except that a stainless steel plate (metal plate) was omitted.
＜参考例１＞
　参考例１として、バックプレートの素材として鋼を用いて、ステンレス板（金属板）をなしにした以外は実施例１と同様にして、参考例１のバックプレートを得た。 <Reference Example 1>
As Reference Example 1, a back plate of Reference Example 1 was obtained in the same manner as in Example 1 except that a stainless steel plate (metal plate) was used without using steel as the material of the back plate.
［ディスクブレーキパッドの作製］
＜実施例１～３、比較例１、参考例１＞
　実施例１～３、比較例１、参考例１のディスクブレーキパッドの作製にあたっては、得られたバックプレートに接着剤を塗布し、塗布した接着剤上に摩擦材を配置し、圧着することでディスクブレーキパッドを得た。
　なお、摩擦材は、自動車用に用いられる一般的なノンアスベストオーガニック材（日立化成株式会社製、商品名「ＨＰ６３Ｈ」）を用いた。 [Production of disc brake pad]
<Examples 1 to 3, Comparative Example 1, Reference Example 1>
In producing the disc brake pads of Examples 1 to 3, Comparative Example 1, and Reference Example 1, an adhesive was applied to the obtained back plate, a friction material was arranged on the applied adhesive, and pressure was applied. I got a disc brake pad.
The friction material used was a general non-asbestos organic material used for automobiles (trade name “HP63H” manufactured by Hitachi Chemical Co., Ltd.).
［評価方法］
（１）バックプレートの耐久性試験：外観
　上記で作製した各例のディスクブレーキパッドを用いてブレーキダイナモ試験を行い、バックプレートの耐久性の評価を行った。評価にあたっては、一般的なピンスライド式のコレット対応のキャリパー、ベンチレーテッドディスクローターを用い、イナーシャ７ｋｇｆ・ｍ・ｓ２で評価を行った。車速６５ｋｍ／ｈ、減速度１．５Ｇの５秒間制動を５回繰り返した後、バックプレート部の外観の欠陥（つぶれ、座屈、折損、欠け、クラック）の有無を確認し、下記評価基準に従って評価した。また、バックプレートの温度を、バックプレート中に埋め込んだ熱電対で計測した。評価結果を表１に示す。
　Ａ：バックプレートに０．１ｍｍを超えるつぶれ、座屈、折損、欠け及びクラックの発生が無い。
　Ｂ：バックプレートに０．１ｍｍを超えるつぶれ及び座屈の少なくともいずれかが発生したが、折損、欠け及びクラックの発生が無い。
　Ｃ：バックプレートに０．１ｍｍを超えるつぶれ及び座屈の少なくともいずれかが発生し、さらに、折損、欠け及びクラックの少なくともいずれかが発生した。 [Evaluation method]
(1) Durability test of back plate: Appearance A brake dynamo test was performed using the disc brake pads of each example prepared above, and the durability of the back plate was evaluated. In the evaluation, a general pin-slide type caliper compatible with a collet and a ventilated disc rotor were used to evaluate the inertia at 7 kgf · m · s 2 . After repeating five times of braking for 5 seconds at a vehicle speed of 65 km / h and a deceleration of 1.5 G, the appearance of the back plate was checked for defects (crushing, buckling, breakage, chipping, cracks), and according to the following evaluation criteria. evaluated. Further, the temperature of the back plate was measured with a thermocouple embedded in the back plate. Table 1 shows the evaluation results.
A: There is no crushing, buckling, breakage, chipping or cracking of the back plate exceeding 0.1 mm.
B: At least one of crushing and buckling exceeding 0.1 mm occurred on the back plate, but no breakage, chipping or cracking occurred.
C: At least one of crushing and buckling exceeding 0.1 mm occurred on the back plate, and at least one of breakage, chipping and cracking occurred.
（２）バックプレートの耐久性試験：変化量
　バックプレートのトルク受部と回出側のトルク受部に相当する位置の端部との寸法を試験前後で計測し、変化量を記録した。このとき、パックプレートの表面の最大温度が１５０℃以下となるよう、制動ごとの時間の間隔をあけることで調整し試験を行った。この評価結果を表１に示す。 (2) Durability test of back plate: amount of change The dimensions of the torque receiving portion of the back plate and the end corresponding to the torque receiving portion on the outlet side were measured before and after the test, and the amount of change was recorded. At this time, the test was performed by adjusting the time interval of each braking so that the maximum temperature of the surface of the pack plate would be 150 ° C. or less. Table 1 shows the evaluation results.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　表１より、トルク受部に０．５ｍｍ、１．０ｍｍのステンレス板を配置した実施例２、３のディスクブレーキパッド試料は、耐久性試験後の外観につぶれ、座屈、折損、欠け及びクラックが認められず実用上問題ない耐久性を有することが確認された。また、トルク受部に０．２ｍｍのステンレス板を配置した実施例１のディスクブレーキパッド試料は、折損、欠け及びクラックの発生が認められず実用上問題ない耐久性を有することが確認された。
　これに対し、アルミニウム合金である５０８３－Ｏ（Ａｌ－Ｍｇ系）をバックプレートの素材として使用した軽量素材バックプレートである比較例１は、耐久性試験後の外観につぶれ、座屈、折損、欠け、クラックがあることが確認され、試験前後で１．０ｍｍ以上の寸法変化が発生し、実用上問題があることが確認された。
　また、参考例１の鋼からなるバックプレートを用いた従来のディスクブレーキパッドは、試験後の外観については問題なかった。しかし、参考例１のディスクブレーキパッドにおける鋼製バックプレートの質量は２５０ｇで、実施例１～３のディスクブレーキパッドにおけるバックプレートの質量が９０ｇであり、従来のディスクブレーキパッドに替えて、実施例１～３のディスクブレーキパッドを用いると、１つのディスクブレーキパッドあたり１６０ｇの質量の低減を図ることができる。 According to Table 1, the disc brake pad samples of Examples 2 and 3 in which the 0.5 mm and 1.0 mm stainless steel plates were arranged in the torque receiving portion collapsed, buckled, broken, chipped, and cracked in appearance after the durability test. Was not observed, and it was confirmed that the film had durability that was not problematic in practical use. Further, it was confirmed that the disc brake pad sample of Example 1 in which a 0.2 mm stainless steel plate was disposed in the torque receiving portion did not show breakage, chipping, or cracking, and had practically no problematic durability.
On the other hand, Comparative Example 1 which is a lightweight material back plate using 5083-O (Al-Mg based) as an aluminum alloy as a material of the back plate has collapsed appearance, buckling, breakage, and the like after the durability test. It was confirmed that there was chipping and cracks, and a dimensional change of 1.0 mm or more occurred before and after the test, confirming that there was a practical problem.
The conventional disk brake pad using the steel back plate of Reference Example 1 had no problem in appearance after the test. However, the mass of the steel back plate in the disc brake pad of Reference Example 1 was 250 g, and the mass of the back plate in the disc brake pads of Examples 1 to 3 was 90 g. When one to three disc brake pads are used, the mass of 160 g per disc brake pad can be reduced.
　本発明のバックプレート、ディスクブレーキパッド及びキャリパーアッセンブリは、実用上問題のない耐久性を備えるとともに、軽量であることから、二輪車又は四輪自動車の制動に用いられているバックプレート、ディスクブレーキパッド及びキャリパーアッセンブリとして好適なものである。 The back plate, the disc brake pad, and the caliper assembly of the present invention have durability that is practically no problem, and are light in weight, so that the back plate, the disc brake pad, and the like are used for braking a two-wheeled or four-wheeled vehicle. It is suitable as a caliper assembly.
１…バックプレート
２…摩擦材
３…中間層
４…外周側付根
５…内周側付根
６…外周側付根
７…内周側付根
１１…本体部
１２…第１パッドガイド部
１３…第２パッドガイド部
１４…トルク受部
１５…金属板
２０…キャリパー DESCRIPTION OF SYMBOLS 1 ... Back plate 2 ... Friction material 3 ... Intermediate layer 4 ... Outer peripheral root 5 ... Inner peripheral root 6 ... Outer peripheral root 7 ... Inner peripheral root 11 ... Body part 12 ... First pad guide part 13 ... Second pad Guide part 14: Torque receiving part 15: Metal plate 20: Caliper

Claims (6)

  1. 　ディスクブレーキ用のバックプレートであって、
    　前記バックプレートの本体部の材質が鋼より比重の軽い素材を含有し、
    　前記バックプレートにおけるトルク受部の少なくとも一部に金属板を配置し、
    　前記金属板の材質が鉄及び鉄合金からなる群から選択される少なくとも１種である、バックプレート。     A back plate for a disc brake,
    The material of the main body of the back plate contains a material having a lower specific gravity than steel,
    A metal plate is arranged on at least a part of the torque receiving portion of the back plate,
    A back plate, wherein a material of the metal plate is at least one selected from the group consisting of iron and an iron alloy.
  2. 　前記鋼より比重の軽い素材は、アルミニウム合金、アルミニウム複合材料、マグネシウム合金及び繊維強化樹脂からなる群から選択される少なくとも１種である、請求項１に記載のバックプレート。 The back plate according to claim 1, wherein the material having a lower specific gravity than the steel is at least one selected from the group consisting of an aluminum alloy, an aluminum composite material, a magnesium alloy, and a fiber reinforced resin.
  3. 　前記金属板の厚さは、０．１ｍｍ以上である、請求項１又は２に記載のバックプレート。 The back plate according to claim 1 or 2, wherein the thickness of the metal plate is 0.1 mm or more.
  4. 　パッドガイド部をさらに備える、請求項１～３のいずれか１項に記載のバックプレート。 The back plate according to any one of claims 1 to 3, further comprising a pad guide portion.
  5. 　請求項１～４のいずれか１項に記載のバックプレートと、
    　前記バックプレートの一方の面に摩擦材を備える、ディスクブレーキパッド。     A back plate according to any one of claims 1 to 4,
    A disc brake pad comprising a friction material on one surface of the back plate.
  6. 　請求項５に記載のディスクブレーキパッドと、
    　前記ディスクブレーキパッドを相手材に押さえつけるキャリパーを備える、キャリパーアッセンブリ。     A disc brake pad according to claim 5,
    A caliper assembly comprising a caliper for pressing the disc brake pad against a mating member.
PCT/JP2018/027776 2018-07-24 2018-07-24 Back plate, disc brake pad and caliper assembly WO2020021645A1 (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0592547U (en) * 1992-05-15 1993-12-17 曙ブレーキ工業株式会社 Disc brake pad backing
JP2012211676A (en) * 2011-03-31 2012-11-01 Nippon Brake Kogyo Kk Brake pad
WO2017013619A1 (en) * 2015-07-21 2017-01-26 Itt Italia S.R.L. A vehicle braking unit, brake pad and associated methods

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0592547U (en) * 1992-05-15 1993-12-17 曙ブレーキ工業株式会社 Disc brake pad backing
JP2012211676A (en) * 2011-03-31 2012-11-01 Nippon Brake Kogyo Kk Brake pad
WO2017013619A1 (en) * 2015-07-21 2017-01-26 Itt Italia S.R.L. A vehicle braking unit, brake pad and associated methods

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