Friction material

Patent metadata

Field	Value
Publication number	US-2020208700-A1
Application number	US-201916725468-A
Country	US
Kind code	A1
Filing date	Dec 23, 2019
Priority date	Dec 28, 2018
Publication date	Jul 2, 2020
Grant date	—

Abstract

A friction material comprising a Fe part; 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 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 %, 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.

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 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 %, 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 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.

4 . The friction material according to claim 1 , wherein:
the second coating layer comprises a lower part and an upper part in order from first coating layer side, the lower part contains not less than 5 atom % and less than 20 atom % of Cu; and the upper part contains not less than 20 atom % and not more than 60 atom % of Cu.

5 . The friction material according to claim 4 , wherein an average thickness of the lower part is not less than 8.0 μm and not more than 20.0 μm, and an average thickness of the upper part is not less than 1.5 μm and not more than 10.0 μm.

6 . The friction material according to claim 4 , wherein the lower part contains not less than 5 atom % and less than 20 atom % of Cu, more than 80 atom % and not more than 95 atom % of Ni, and not less than 0 atom % and less than 10 atom % of Fe.

7 . The friction material according to claim 4 , wherein the upper part contains not less than 20 atom % and not more than 60 atom % of Cu, not less than 40 atom % and not more than 80 atom % of Ni, and not less than 0 atom % and not more than 2 atom % of Fe.

8 . The friction material according to claim 1 , wherein:
the coating layer comprises a third coating layer over 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 8 , wherein the third coating layer contains not less than 30 atom % and not more than 69.5 atom % of Cu, not less than 30 atom % and not more than 69.5 atom % of Ni, and not less than 0.5 atom % not more than 5 atom % of Sn and/or Zn.

10 . The friction material according to claim 1 , 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 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.

12 . The friction material according to claim 2 , wherein:
the second coating layer comprises a lower part and an upper part in order from first coating layer side, the lower part contains not less than 5 atom % and less than 20 atom % of Cu; and the upper part contains not less than 20 atom % and not more than 60 atom % of Cu.

13 . The friction material according to claim 3 , wherein:
the second coating layer comprises a lower part and an upper part in order from first coating layer side, the lower part contains not less than 5 atom % and less than 20 atom % of Cu; and the upper part contains not less than 20 atom % and not more than 60 atom % of Cu.

14 . The friction material according to claim 11 , wherein:
the second coating layer comprises a lower part and an upper part in order from first coating layer side, the lower part contains not less than 5 atom % and less than 20 atom % of Cu; and the upper part contains not less than 20 atom % and not more than 60 atom % of Cu.

15 . The friction material according to claim 5 , wherein the lower part contains not less than 5 atom % and less than 20 atom % of Cu, more than 80 atom % and not more than 95 atom % of Ni, and not less than 0 atom % and less than 10 atom % of Fe.

16 . The friction material according to claim 5 , wherein the upper part contains not less than 20 atom % and not more than 60 atom % of Cu, not less than 40 atom % and not more than 80 atom % of Ni, and not less than 0 atom % and not more than 2 atom % of Fe.

17 . The friction material according to claim 6 , wherein the upper part contains not less than 20 atom % and not more than 60 atom % of Cu, not less than 40 atom % and not more than 80 atom % of Ni, and not less than 0 atom % and not more than 2 atom % of Fe.

18 . The friction material according to claim 15 , wherein the upper part contains not less than 20 atom % and not more than 60 atom % of Cu, not less than 40 atom % and not more than 80 atom % of Ni, and not less than 0 atom % and not more than 2 atom % of Fe.

19 . The friction material according to claim 2 , wherein:
the coating layer comprises a third coating layer over 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.

20 . The friction material according to claim 3 , wherein:
the coating layer comprises a third coating layer over 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.

Assignees

• Tungaloy Corp

Inventors

• Kamei Mitsuo

Classifications

• C25D7/00

  Electroplating characterised by the article coated · CPC title

• C25D5/14

  two or more layers being of nickel or chromium, e.g. duplex or triplex layers · CPC title

• F16D2069/005

  having a layered structure · CPC title

• F16D69/027 Primary

  Compositions based on metals or inorganic oxides · CPC title

• F16D2250/0046

  Coating · CPC title