Method and apparatus for manufacturing friction plate

• US 6,939,427 B1
• Filed: 05/10/2000
• Issued: 09/06/2005
• Est. Priority Date: 05/14/1999
• Status: Expired due to Term

• Current Assignee: Nsk-Warner Kabushiki Kaisha (BorgWarner Incorporated)
• Original Assignee: Nsk-Warner Kabushiki Kaisha (BorgWarner Incorporated)
• Inventors: Takahashi, Rikiya, Anma, Satoru
• Primary Examiner(s): MAYES, MELVIN C
• Application Number:
  US09/568,463
• Time in Patent Office: 1,945 Days
• Field of Search: 156/297, 156/299, 156/256, 156/261, 156/265, 156/538, 156/539, 156/556, 156/510, 156/515, 156/516, 156/517, 156/560, 188/18.A, 188/218.XL
• US Class Current: 156/265
• CPC Class Codes: F16D 13/64 Clutch-plates; Clutch-lamellae brake-plates, brake-lamellae F16D65/12
• CPC Class Codes: F16D 2069/0466 chemical, e.g. using adhesives, vulcanising
• CPC Class Codes: F16D 2069/0491 Tools, machines, processes
• CPC Class Codes: F16D 2250/00 Manufacturing; Assembly
• CPC Class Codes: F16D 69/04 Attachment of linings
• CPC Class Codes: Y10T 156/1077 Applying plural cut laminae to single face of additional lamina
• CPC Class Codes: Y10T 156/1089 of discrete laminae to single face of additional lamina
• CPC Class Codes: Y10T 156/1092 All laminae planar and face to face
• CPC Class Codes: Y10T 156/1322 Severing before bonding or assembling of parts
• CPC Class Codes: Y10T 156/1702 For plural parts or plural areas of single part
• CPC Class Codes: Y10T 156/1754 At least two applied side by side to common base

Abstract

A method for manufacturing a friction plate in which a plurality of frictional material segments are adhered to a substantially annular core plate. The method previously registers the frictional material segments to adhesion positions, and presses the core plate to which adhesive agent is applied and the frictional segments to perform temporary adhesion. Further, an apparatus for manufacturing a friction plate in which a plurality of frictional material segments are adhered to a substantially annular core plate. The apparatus comprises a member for registering the frictional material segments while holding the frictional material segments in a state arranged in the adhesion positions.

Claims

1. A method for manufacturing a friction plate in which a plurality of frictional material segments are adhered in a predetermined arrangement to a substantially annular core plate, said method comprising steps of:

previously registering said frictional material segments in said predetermined arrangement on a rotationally indexable support device, with each said frictional material segment being supported at a periphery thereof by a support portion of said support device disposed radially adjacent to said periphery; and

pressing said frictional material segments and said core plate to which an adhesive agent is applied to perform temporary adhesion of said frictional material segments to said core plate;

wherein said support portion includes a projection which engages a part of said periphery.

2. A method according to claim 1, wherein said frictional material segments are registered by inserting under pressure said frictional material segments to respective windows each having a projection which engages part of said periphery of a frictional material segment inserted therein.

3. A method according to claim 2, said method further comprises steps of advancing said frictional material, punching said advanced frictional material, registering the obtained frictional material segments to adhesion positions, performing said temporary adhesion, and then performing plenary adhesion by heating and pressing at the same time.

4. A method according to claim 1, wherein said registration is performed with respect to one side of said friction plate.

5. A method according to claim 1, said method comprises steps of advancing said frictional material, punching said advanced frictional material, registering the obtained frictional material segments to adhesion positions, performing said temporary adhesion, and then performing plenary adhesion by heating and pressing at the same time.

6. A method according to claim 1, wherein said periphery is a radially outer periphery.

7. A method according to claim 1, wherein said periphery is a radially inner periphery.

8. A method according to claim 1, wherein each frictional material segment is supported at both radially outer and inner peripheries thereof by respective support portions of said support device disposed radially adjacent to said peripheries.

9. A method for manufacturing a friction plate in which a plurality of frictional material segments are adhered to a substantially annular core plate, said method comprising:

advancing a frictional material;

punching said advanced frictional material to obtain the frictional material segments;

previously registering said frictional material segments to adhesion positions;

pressing said frictional material segments and said core plate to which an adhesive agent is applied to perform temporary adhesion; and

performing plenary adhesion by heating and pressing at the same time;

wherein said punching is simultaneously carried out in a plurality of rows, and

wherein said frictional material segments are registered by inserting under pressure said frictional material segments to respective cavities each having a protrusion extending to said corresponding inserted frictional material segment.

10. A method for manufacturing a friction plate having a plurality of frictional material segments adhered in a predetermined arrangement to a substantially annular core plate, said method comprising:

pre-registering the frictional material segments in the predetermined arrangement on a rotationally indexable support device, with each said frictional material segment being supported at a periphery thereof by a support portion of said support device disposed radially adjacent to said periphery; and

attaching the pre-registered frictional material segments to the core plate;

wherein said support portion includes a projection which engages a part of said periphery.

11. A method according to claim 10, wherein the attaching of the pre-registered frictional material segments is a temporary attachment.

12. A method according to claim 11, further comprising permanently adhering the frictional material segments to the core plate.

13. A method according to claim 10, wherein the pre-registering includes inserting the frictional material segments into cavities having respective projections to engage the frictional material segments.

14. A method according to claim 10, wherein the pre-registering and attaching are performed for two sides of the friction plate.

15. A method according to claim 10, comprising:

advancing a frictional material;

punching the frictional material to obtain the frictional material segments; and

permanently adhering the frictional material segments to the core by heating and pressing at the same time.

16. A method according to claim 15, wherein said punching is simultaneously carried out in a plurality of rows.

17. A method according to claim 10, wherein said periphery is a radially outer periphery.

18. A method according to claim 10, wherein said periphery is a radially inner periphery.

19. A method according to claim 10, wherein each frictional material segment is supported at both radially outer and inner peripheries thereof by projections of respective support portions of said support device disposed radially adjacent to said peripheries.

20. A method for manufacturing a friction plate in which a plurality of frictional material segments are adhered in a predetermined arrangement to a substantially annular core plate, said method comprising steps of:

previously registering said frictional material segments in said predetermined arrangement; and

pressing said frictional material segments and said core plate to which an adhesive agent is applied to perform temporary adhesion of said frictional material segments to said core plate;

wherein each said frictional material segment is registered by inserting under pressure said frictional material segment to a cavity in which a protrusion extending to said frictional material segment is provided.

21. A method according to claim 20, said method further comprising steps of advancing said frictional material, punching said advanced frictional material, registering the obtained frictional material segments to adhesion positions, performing said temporary adhesion, and then performing plenary adhesion by heating and pressing at the same time.

22. A method for manufacturing a friction plate having a plurality of frictional material segments adhered in a predetermined arrangement to a substantially annular core plate, said method comprising:

pre-registering the frictional material segments in the predetermined arrangement; and

attaching the pre-registered frictional material segments to the core plate;

wherein the pre-registering includes inserting the frictional material segments into cavities having protrusions to engage the frictional material segments.

23. A method for manufacturing a friction plate having a plurality of frictional material segments adhered in a predetermined arrangement to a substantially annular core plate, said method comprising:

advancing a frictional material;

punching the frictional material to obtain the frictional material segments;

pre-registering the frictional material segments in the predetermined arrangement on a rotationally indexable support device; and

transferring the pre-registered frictional material segments from the support device to the core plate and attaching the frictional material segments to the core plate;

said pre-registering including inserting said frictional material segments into cavities each having a projection to engage a periphery of a frictional material segment inserted therein;

said attaching including permanently adhering the frictional material segments to the core plate by heating and pressing at the same time.

24. A method according to claim 23, wherein said punching is simultaneously carried out in a plurality of rows.

25. An apparatus for manufacturing a friction plate in which a plurality of frictional material segments are adhered in a predetermined arrangement to a substantially annular core plate, said apparatus comprising:

a rotationally indexable support device constructed to pre-register and hold said frictional material segments in said predetermined arrangement, with each said frictional material segment being supported at a periphery thereof by a support portion of said support device disposed radially adjacent to said periphery, prior to adhesion of said frictional material segments to said core plate wherein said support portion includes a projection which engages a part of said periphery.

26. An apparatus according to claim 25, wherein said periphery is a radially outer periphery.

27. An apparatus according to claim 25, wherein said periphery is a radially inner periphery.

28. An apparatus according to claim 25, wherein each frictional material segment is supported at both radially outer and inner peripheries thereof by projections of respective support portions of said support device disposed radially adjacent to said peripheries.

29. An apparatus for manufacturing a friction plate in which a plurality of frictional material segments are adhered to a substantially annular core plate, said apparatus comprising:

a member for registering said frictional material segments while holding said frictional material segments in a state arranged in adhesion positions, wherein said member includes a holding rest for placing said frictional material segments, and

a guide which covers the outer periphery of said frictional material segments and slides up and down with respect to said holding rest,

said guide being supported in an advanced position relative to said holding rest by a pressing device, and being retractively movable from said advanced position against a pressing force of said pressing device to expose the frictional material segments on the holding rest for adhesion to the core plate.

30. An apparatus according to claim 29, wherein said guide includes a protrusion extending to said frictional material segment.

31. An apparatus according to claim 29, wherein said pressing device includes a spring.

32. An apparatus according to claim 29,

wherein said guide includes a plurality of windows configured to receive the frictional material segments, each window having a projection disposed to engage a periphery of a frictional material segment received therein.

33. An apparatus for use in manufacturing a friction plate having a plurality of frictional material segments adhered to a substantially annular core plate in a predetermined arrangement, the apparatus comprising:

a mechanism including a rotationally indexable support device and operative to pre-register the frictional material segments in the predetermined arrangement on said support device, with each said frictional material segment being supported at a periphery thereof by a support portion of said support device disposed radially adjacent to said periphery, prior to adhesion of the frictional material segments to the core plate,

wherein the pre-registering mechanism includes a guide having a plurality of windows configured to receive the frictional material segments in the predetermined arrangement, and

wherein the guide includes protrusions extending into each of the windows to engage the frictional material segments.

34. An apparatus according to claim 33, further comprising a mechanism operative to adhere the frictional material segments to the core plate.

35. An apparatus according to claim 34, wherein the adhering mechanism is operative to temporarily adhere the frictional material segments to the core plate.

36. An apparatus according to claim 33, further comprising:

a mechanism operative to temporarily adhere the frictional material segments to the core plate; and

a mechanism operative to permanently adhere the frictional material segments to the core plate.

37. An apparatus according to claim 33, wherein said periphery is a radially outer periphery.

38. An apparatus according to claim 33, wherein said periphery is a radially inner periphery.

39. An apparatus according to claim 33, wherein each frictional material segment is supported at both radially outer and inner peripheries thereof by respective support portions of said support device disposed radially adjacent to said peripheries.

40. An apparatus according to claim 33, wherein said support portion includes a protrusion which engages a part of said periphery.

41. An apparatus for use in manufacturing a friction plate having a plurality of frictional material segments adhered to a substantially annular core plate in a predetermined arrangement, the apparatus comprising:

a mechanism including a rotationally indexable support device and operative to pre-register the frictional material segments in the predetermined arrangement on said support device, with each said frictional material segment being supported at a periphery thereof by a support portion of said support device disposed radially adjacent to said periphery, prior to adhesion of the frictional material segments to the core plate,

wherein the pre-registering mechanism includes a holding rest configured for receiving the frictional material segments and a guide configured to cover the outer periphery of the frictional material segments and slide with respect to the holding rest,

said guide being supported in an advanced position relative to said holding rest by a pressing device, and being retractively movable from said advanced position against a pressing force of said pressing device to expose the frictional material segments on the holding rest for adhesion to the core plate.

42. An apparatus according to claim 41, wherein the guide has a plurality of windows configured to receive the frictional material segments in the predetermined arrangement.

43. An apparatus according to claim 42, wherein the guide includes protrusions extending into each of the windows to engage the frictional material segments.

44. An apparatus for use in manufacturing a friction plate having a plurality of frictional material segments adhered to a substantially annular core plate in a predetermined arrangement, the apparatus comprising:

a mechanism operative to pre-register the frictional material segments in the predetermined arrangement prior to adhesion of the frictional material segments to the core plate,

wherein the pre-registering mechanism includes a holding rest configured for receiving the frictional material segments and a guide configured to cover the outer periphery of the frictional material segments and slide with respect to the holding rest,

said guide being supported in an advanced position relative to said holding rest by a support mechanism constructed to allow retractile movement of said guide from said advanced position to expose the frictional material segments on the holding rest for adhesion to the core plate.

45. An apparatus according to claim 44,

wherein said guide includes a plurality of windows configured to receive the frictional material segments, each window having a protrusion disposed to engage a periphery of a frictional material segment received therein.

46. An apparatus for manufacturing a friction plate in which a plurality of frictional material segments are adhered to a substantially annular core plate, said apparatus comprising:

a member for registering said frictional material segments while holding said frictional material segments in a state arranged in adhesion positions, wherein said member includes a holding rest for placing said frictional material segments, and

a guide which covers the outer periphery of said frictional material segments and slides up and down with respect to said holding rest,

wherein a portion of a partition portion extending in the radial direction of said guide is recessed.

47. An apparatus for use in manufacturing a friction plate having a plurality of frictional material segments adhered to a substantially annular core plate in a predetermined arrangement, the apparatus comprising:

a mechanism operative to pre-register the frictional material segments in the predetermined arrangement on a rotationally indexable support device prior to mounting and adhesion of the frictional material segments to the core plate,

wherein the pre-registering mechanism includes a guide having a plurality of windows configured to receive the frictional material segments in the predetermined arrangement, and

wherein the guide includes protrusions extending into each of the windows to engage the frictional material segments.

48. A method for manufacturing a friction plate in which a plurality of frictional material segments are adhered in a predetermined arrangement to a substantially annular core plate, said method comprising:

punching a web of frictional material to obtain frictional material segments therefrom, and returning the frictional material segments to the web;

transferring the frictional material segments from the web so as to pre-register the frictional material segments in said predetermined arrangement on a support device; and

attaching the pre-registered frictional material segments to the core plate.

49. A method according to claim 48, wherein said transferring includes effecting relative rotation of the support device and the frictional material segments.

50. A method according to claim 49, wherein said relative rotation includes rotationally indexing the support device to position the support device for receiving the frictional material segments at respective positions on the support device.

51. A method according to claim 50, wherein the web of frictional material is advanced in association with the indexing of the support device.

52. A method according to claim 48, wherein each frictional material segment is supported at a periphery thereof by a support portion of the support device.

53. A method according to claim 52, wherein the support portion includes a protrusion which engages a part of said periphery.

54. A method according to claim 53, wherein said periphery is a radially outer periphery.

55. A method according to claim 53, wherein said periphery is a radially inner periphery.

56. A method according to claim 53, wherein each frictional material segment is supported at both radially outer and inner peripheries thereof by respective protrusions disposed radially adjacent to said peripheries.

57. A method according to claim 52, wherein said transferring includes pressing the frictional material segments into respective windows of the support device.

58. A method according to claim 57, wherein each window has a protrusion that engages the periphery of the respective frictional material segment received in that window.

59. A method according to claim 48, wherein said attaching includes effecting temporary adhesion of the pre-registered frictional material segments to the core plate.

60. A method according to claim 59, wherein said attaching includes, after effecting the temporary adhesion, effecting permanent adhesion of the frictional material segments to the core plate.