Friction material

Patent metadata

Field	Value
Publication number	US-11408476-B2
Application number	US-202016776483-A
Country	US
Kind code	B2
Filing date	Jan 29, 2020
Priority date	Mar 26, 2019
Publication date	Aug 9, 2022
Grant date	Aug 9, 2022

Abstract

A friction material comprises an Fe part which contains Fe as a main component, a coating layer formed on a surface of the Fe part, and a friction part formed on a surface of at least a part of the coating layer, and the coating layer comprises a first coating layer and a second coating layer which have a specific average thickness and a specific component in order from Fe part side, and in the second coating layer, in order of positions at which the thickness is 20%, 40%, 60% and 80% of the second coating layer from the side of the first coating layer to the side opposite thereto, a Cu content increases and a Ni content decreases.

First claim

What is claimed is:

1. A friction material comprising: a Fe part which contains Fe as a main component; a coating layer formed over a surface of the Fe part; and a friction part formed on a surface of at least a part of the coating layer, wherein:
the friction part has a higher coefficient of friction than the Fe part and the coating layer,
the coating layer comprises a first coating layer and a second coating layer in order from Fe part side,
the first coating layer is constituted of an alloy containing Cu, Ni and Fe such that Fe content be not less than 10 atom %,
the second coating layer is constituted of an alloy containing Cu and Ni, or an alloy containing Cu, Ni and Fe such that Fe content be less than 10 atom %,
in the second coating layer, in order of positions at which the thickness is 20%, 40%, 60% and 80% of the second coating layer from the side of the first coating layer to the side opposite thereto, a Cu content increases and a Ni content decreases;
an average thickness of the first coating layer is not less than 1.0 μm and not more than 6.0 μm; and
an average thickness of the second coating layer is not less than 9.5 μm and not more than 24.0 μm.

2. The friction material according to claim 1 , wherein the first coating layer contains not less than 1 atom % and not more than 45 atom % of Cu, not less than 1 atom % and not more than 45 atom % of Ni, and not less than 10 atom % and not more than 95 atom % of Fe.

3. The friction material according to claim 2 , wherein the second coating layer contains not less than 5 atom % and not more than 60 atom % of Cu, not less than 40 atom % and not more than 95 atom % of Ni, and not less than 0 atom % and less than 10 atom % of Fe.

4. The friction material according to claim 3 , wherein, in the second coating layer, from the side of the first coating layer to the side opposite thereto, in three sections comprising a section from the position at which the thickness is 20% of the second coating layer to the position at which the thickness is 40% of the second coating layer, a section from the position at which the thickness is 40% of the second coating layer to the position at which the thickness is 60% of the second coating layer, and a section from the position at which the thickness is 60% of the second coating layer to the position at which the thickness is 80% of the second coating layer, a rate of the Cu content increased and a rate of the Ni content decreased are each within 20 atom %.

5. The friction material according to claim 4 , wherein:
the coating layer comprises a third coating layer formed on a surface of the second coating layer, the surface being opposite to Fe part side,
the third coating layer is constituted of an alloy containing Cu, Ni and Sn, an alloy containing Cu, Ni and Zn, or an alloy containing Cu, Ni, Sn and Zn; and
an average thickness of the third coating layer is not less than 0.1 μm and not more than 5.0 μm.

6. The friction material according to claim 3 , wherein:
the coating layer comprises a third coating layer formed on a surface of the second coating layer, the surface being opposite to Fe part side,
the third coating layer is constituted of an alloy containing Cu, Ni and Sn, an alloy containing Cu, Ni and Zn, or an alloy containing Cu, Ni, Sn and Zn; and
an average thickness of the third coating layer is not less than 0.1 μm and not more than 5.0 μm.

7. The friction material according to claim 2 , wherein, in the second coating layer, from the side of the first coating layer to the side opposite thereto, in three sections comprising a section from the position at which the thickness is 20% of the second coating layer to the position at which the thickness is 40% of the second coating layer, a section from the position at which the thickness is 40% of the second coating layer to the position at which the thickness is 60% of the second coating layer, and a section from the position at which the thickness is 60% of the second coating layer to the position at which the thickness is 80% of the second coating layer, a rate of the Cu content increased and a rate of the Ni content decreased are each within 20 atom %.

8. The friction material according to claim 7 , wherein:
the coating layer comprises a third coating layer formed on a surface of the second coating layer, the surface being opposite to Fe part side,
the third coating layer is constituted of an alloy containing Cu, Ni and Sn, an alloy containing Cu, Ni and Zn, or an alloy containing Cu, Ni, Sn and Zn; and
an average thickness of the third coating layer is not less than 0.1 μm and not more than 5.0 μm.

9. The friction material according to claim 2 , wherein:
the coating layer comprises a third coating layer formed on a surface of the second coating layer, the surface being opposite to Fe part side,
the third coating layer is constituted of an alloy containing Cu, Ni and Sn, an alloy containing Cu, Ni and Zn, or an alloy containing Cu, Ni, Sn and Zn; and
an average thickness of the third coating layer is not less than 0.1 μm and not more than 5.0 μm.

10. The friction material according to claim 2 , wherein an average thickness of the coating layer is not less than 10.5 μm and less than 30.0 μm.

11. The friction material according to claim 1 , wherein the second coating layer contains not less than 5 atom % and not more than 60 atom % of Cu, not less than 40 atom % and not more than 95 atom % of Ni, and not less than 0 atom % and less than 10 atom % of Fe.

12. The friction material according to claim 11 , wherein, in the second coating layer, from the side of the first coating layer to the side opposite thereto, in three sections comprising a section from the position at which the thickness is 20% of the second coating layer to the position at which the thickness is 40% of the second coating layer, a section from the position at which the thickness is 40% of the second coating layer to the position at which the thickness is 60% of the second coating layer, and a section from the position at which the thickness is 60% of the second coating layer to the position at which the thickness is 80% of the second coating layer, a rate of the Cu content increased and a rate of the Ni content decreased are each within 20 atom %.

13. The friction material according to claim 12 , wherein:
the coating layer comprises a third coating layer formed on a surface of the second coating layer, the surface being opposite to Fe part side,
the third coating layer is constituted of an alloy containing Cu, Ni and Sn, an alloy containing Cu, Ni and Zn, or an alloy containing Cu, Ni, Sn and Zn; and
an average thickness of the third coating layer is not less than 0.1 μm and not more than 5.0 μm.

14. The friction material according to claim 11 , wherein:
the coating layer comprises a third coating layer formed on a surface of the second coating layer, the surface being opposite to Fe part side,
the third coating layer is constituted of an alloy containing Cu, Ni and Sn, an alloy containing Cu, Ni and Zn, or an alloy containing Cu, Ni, Sn and Zn; and
an average thickness of the third coating layer is not less than 0.1 μm and not more than 5.0 μm.

15. The friction material according to claim 11 , wherein an average thickness of the coating layer is not less than 10.5 μm and less than 30.0 μm.

16. The friction material according to claim 1 , wherein, in the second coating layer, from the side of the first coating layer to the side opposite thereto, in three sections comprising a section from the position at which the thickness is 20% of the second coating layer to

Assignees

• Tungaloy Corp

Inventors

• Kamei Mitsuo

Classifications

• F16D69/027 Primary

  Compositions based on metals or inorganic oxides · CPC title

• B32B15/04

  comprising metal as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042)} · CPC title

• C22C19/002

  with copper as the next major constituent · CPC title

• C22C38/08

  containing nickel {(C22C38/105 takes precedence)} · CPC title

• B32B15/01

  all layers being exclusively metallic {(making layered metal workpieces by pressure cladding B23K20/22; making coatings with a metallic material characterised by its composition C23C30/00)} · CPC title