WO1993009362A1 - Friction material for a brake pad, having a specified binder content - Google Patents
Friction material for a brake pad, having a specified binder content Download PDFInfo
- Publication number
- WO1993009362A1 WO1993009362A1 PCT/GB1992/001972 GB9201972W WO9309362A1 WO 1993009362 A1 WO1993009362 A1 WO 1993009362A1 GB 9201972 W GB9201972 W GB 9201972W WO 9309362 A1 WO9309362 A1 WO 9309362A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- brake pad
- friction material
- disc brake
- rubber
- binder
- Prior art date
Links
- 239000011230 binding agent Substances 0.000 title claims abstract description 30
- 239000002783 friction material Substances 0.000 title claims abstract description 19
- 229920001971 elastomer Polymers 0.000 claims abstract description 15
- 239000005060 rubber Substances 0.000 claims abstract description 15
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 10
- 239000011236 particulate material Substances 0.000 claims abstract description 6
- 229920005989 resin Polymers 0.000 claims description 10
- 239000011347 resin Substances 0.000 claims description 10
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 5
- 229920000459 Nitrile rubber Polymers 0.000 claims description 4
- 229910000831 Steel Inorganic materials 0.000 claims description 4
- 239000010959 steel Substances 0.000 claims description 4
- 239000004634 thermosetting polymer Substances 0.000 claims description 4
- 239000000203 mixture Substances 0.000 claims description 3
- 239000010455 vermiculite Substances 0.000 claims description 3
- 229910052902 vermiculite Inorganic materials 0.000 claims description 3
- 235000019354 vermiculite Nutrition 0.000 claims description 3
- -1 bromobutyl Chemical group 0.000 claims description 2
- 229920005557 bromobutyl Polymers 0.000 claims description 2
- 229920005556 chlorobutyl Polymers 0.000 claims description 2
- 239000010445 mica Substances 0.000 claims description 2
- 229910052618 mica group Inorganic materials 0.000 claims description 2
- 239000010456 wollastonite Substances 0.000 claims description 2
- 229910052882 wollastonite Inorganic materials 0.000 claims description 2
- 239000000463 material Substances 0.000 abstract description 6
- 239000000835 fiber Substances 0.000 abstract description 3
- 229920001568 phenolic resin Polymers 0.000 description 5
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 3
- 239000000945 filler Substances 0.000 description 3
- 239000004615 ingredient Substances 0.000 description 3
- 239000003607 modifier Substances 0.000 description 3
- 239000005011 phenolic resin Substances 0.000 description 3
- 238000011084 recovery Methods 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 229910001369 Brass Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 239000005864 Sulphur Substances 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- NVWBARWTDVQPJD-UHFFFAOYSA-N antimony(3+);trisulfide Chemical compound [S-2].[S-2].[S-2].[Sb+3].[Sb+3] NVWBARWTDVQPJD-UHFFFAOYSA-N 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920003235 aromatic polyamide Polymers 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 description 1
- 239000002006 petroleum coke Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 239000012255 powdered metal Substances 0.000 description 1
- 239000012763 reinforcing filler Substances 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 239000011135 tin Substances 0.000 description 1
Classifications
-
- 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
Definitions
- This invention relates to brake pads and particularly brake pads of the kind which are used in disc brakes for automotive applications.
- Organic binder materials are in widespread use in the manufacture of brake pads, the common types being phenolic resins or modified phenolic resins with which a proportion of rubber such as SBR or Nitrile rubber is also often used.
- Many published patent specifications mention organic binder materials of this kind for example UK Patent No 1,604,828 discloses non-asbestos brake pads which are made from a friction material containing a thermoset binder making up 20% to 45% by volume of the friction material at least half of which is phenol formaldehyde resin.
- UK Patent No 1,604,839 discloses a friction material for brake pads which contains a thermoset binder making up 20% to 60% by volume of the friction material at least half of the thermoset binder being phenol formaldehyde resin.
- European Patent No 0,184,708 discloses a friction material for automotive uses which contains steel fibres and organic binder, the amount of organic binder being 10% to 35% by volume of the friction material, and all the examples show the use of resin alone at volumes above 20%.
- Binder resin contents expressed as parts by weight or as percentages by weight invariably have a substantial resin content when measured by volume and taking into account material density.
- GB-A-2114586 teaches a preferred binder resin content of only 8% by weight, but in volume terms this is as much as 22% by volume when density is taken into account.
- an apparently minimal thermosetting resin content must be considered in the context of a substantial amount of another binder such as rubber, so that the total organic binder content is again relatively high when determined in terms of volume.
- disc brake pads with advantageous properties may be manufactured using thermosetting resin with or without rubber as a binder, but at very low binder contents when measured by volume.
- an automotive disc brake pad comprises a friction material containing fibres, j particulate materials and an organic binder, wherein the
- binder comprises thermoset resin with or without a proportion of thermoset rubber and the total binder content is from 2% to 9.5% by volume of the friction material.
- organic binder is the sole binder system for the friction material.
- autonomous disc brake pad we mean a pad for a disc brake on a road vehicle such as a car, motor cycle, van or truck.
- thermoset resin is preferably a resin of the phenolic or modified phenolic type, although other resins such as epoxy resins may be used.
- the rubber used is preferably nitrile rubber, although other rubbers may be used as the whole or part of the rubber in the binder, for example • bromobutyl rubber, chlorobutyl rubber.
- the other ingredients of the friction material may be selected from the wide range of available fibres, fillers and friction and wear modifiers.
- possible fibres include metal fibres such as steel, mineral fibres such as glass or basalt, and organic fibres such as aramid.
- the amount of fibre used is not critical but will typically be in the range 0 to 15% by volume.
- the balance of the friction material apart from binders and fibres is of particulate materials.
- the particulate materials are used in the larger sizes of the conventional range of eg 300 ⁇ m to ⁇ OO ⁇ m, and finely divided materials (ie particle sizes below 50 ⁇ m) are to be avoided in order to ensure that there is not too much particle surface area to be wetted out by the binder.
- a friction material was prepared according to the formulation given below in Table 1.
- the dry ingredients including the resin
- the mix was dried and disintegrated and then charged to a pre-forming die where disc brake pad preforms were moulded under a pressure of 7 tons/in 2 .
- Each preform was cured by baking whilst under light pressure in an oven for 2 hours at 240°.
- Disc brake pads made according to Example 1 were tested for friction and wear in machine tests against a cast iron brake disc. Fade and recovery behaviour of the material was tested in a severe sequence which consists of a "fade phase” of 20 successive stops from 130kph, followed by a “recovery phase” of 10 successive stops from 50kph. During the stops from high speed the pad temperature (which is constantly monitored) rises to very high levels and (during the stops from slower speeds) the pad temperature gradually falls again. The results of these tests are given below in tabular form in Table II.
Landscapes
- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Braking Arrangements (AREA)
Abstract
Automotive disc brake pads comprising a friction material which contains particulate material, fibre and binder. The binder is substantially all thermoset rubber and makes up only 2 % to 9.5 % by volume of the material.
Description
FRICTION MATERIAL FOR A BRAKE PAD, HAVING A SPECIFIED BINDER CONTENT
This invention relates to brake pads and particularly brake pads of the kind which are used in disc brakes for automotive applications.
Organic binder materials are in widespread use in the manufacture of brake pads, the common types being phenolic resins or modified phenolic resins with which a proportion of rubber such as SBR or Nitrile rubber is also often used. Many published patent specifications mention organic binder materials of this kind, for example UK Patent No 1,604,828 discloses non-asbestos brake pads which are made from a friction material containing a thermoset binder making up 20% to 45% by volume of the friction material at least half of which is phenol formaldehyde resin. UK Patent No 1,604,839 discloses a friction material for brake pads which contains a thermoset binder making up 20%
to 60% by volume of the friction material at least half of the thermoset binder being phenol formaldehyde resin. European Patent No 0,184,708 discloses a friction material for automotive uses which contains steel fibres and organic binder, the amount of organic binder being 10% to 35% by volume of the friction material, and all the examples show the use of resin alone at volumes above 20%.
This is typical of the prior art. Binder resin contents expressed as parts by weight or as percentages by weight invariably have a substantial resin content when measured by volume and taking into account material density. Thus in another example, GB-A-2114586 teaches a preferred binder resin content of only 8% by weight, but in volume terms this is as much as 22% by volume when density is taken into account. In some instances, an apparently minimal thermosetting resin content must be considered in the context of a substantial amount of another binder such as rubber, so that the total organic binder content is again relatively high when determined in terms of volume.
We have now found that disc brake pads with advantageous properties may be manufactured using thermosetting resin with or without rubber as a binder, but at very low binder contents when measured by volume.
Thus according to the invention an automotive disc brake
pad comprises a friction material containing fibres, j particulate materials and an organic binder, wherein the
:. binder comprises thermoset resin with or without a proportion of thermoset rubber and the total binder content is from 2% to 9.5% by volume of the friction material.
It will be understood that in this present context, the organic binder is the sole binder system for the friction material.
In this specification by "automotive" disc brake pad we mean a pad for a disc brake on a road vehicle such as a car, motor cycle, van or truck.
The thermoset resin is preferably a resin of the phenolic or modified phenolic type, although other resins such as epoxy resins may be used.
When rubber is included the rubber used is preferably nitrile rubber, although other rubbers may be used as the whole or part of the rubber in the binder, for example • bromobutyl rubber, chlorobutyl rubber.
'
The other ingredients of the friction material may be selected from the wide range of available fibres, fillers and friction and wear modifiers.
Examples of possible fibres include metal fibres such as steel, mineral fibres such as glass or basalt, and organic fibres such as aramid. The amount of fibre used is not critical but will typically be in the range 0 to 15% by volume.
The balance of the friction material apart from binders and fibres is of particulate materials. The particulate materials used as fillers ;=»nd friction and wear modifiers may be taken from a vast range of possible options. For example alumina, antimony trisulphide, zirconia, crushed coke, graphite, molybdenum disulphide, powdered metals such as copper, tin, brass, reinforcing fillers such as mica, vermiculite, wollastonite, and other fillers such as barytes, silica, calcium carbonate etc. Owing to the very low volumes of the organic binder used in this invention the particulate materials are used in the larger sizes of the conventional range of eg 300μm to βOOμm, and finely divided materials (ie particle sizes below 50μm) are to be avoided in order to ensure that there is not too much particle surface area to be wetted out by the binder.
The invention will be described in more detail, by way of example only, in the following Example.
EXAMPLE 1
A friction material was prepared according to the formulation given below in Table 1. The dry ingredients (including the resin) were pre-blended, then intimately mixed with a solution of binder rubber in trichloreothylene. The mix was dried and disintegrated and then charged to a pre-forming die where disc brake pad preforms were moulded under a pressure of 7 tons/in2. Each preform was cured by baking whilst under light pressure in an oven for 2 hours at 240°.
TABLE 1
EXAMPLE NO 1
Ingredient % Vol
Phenolic Resin 6.00
Nitrile Rubber 3.00
Sulphur 4.29
Steel Fibre 3.00
Vermiculite 30.08
Barytes 17.40
Petroleum Coke 17.00
Friction and Wear Modifiers 22.23
Testing
Disc brake pads made according to Example 1 were tested for friction and wear in machine tests against a cast iron brake disc. Fade and recovery behaviour of the material was tested in a severe sequence which consists of a "fade phase" of 20 successive stops from 130kph, followed by a "recovery phase" of 10 successive stops from 50kph. During the stops from high speed the pad temperature (which is constantly monitored) rises to very high levels and (during the stops from slower speeds) the pad temperature gradually falls again. The results of these tests are given below in tabular form in Table II.
TABLE II
EXAMPLE NO 1
Fade Phase
Max. mean coefficient of friction * 0.38
Min. mean coefficient of friction * 0.34
Initial pad temperature °C 200
Peak pad temperature °C 650
Recovery Phase
Max. mean coefficient of friction * 0.39 Min. mean coefficient of friction * 0.34 Final pad temperature °C 175
* In this Table the expression "mean" coefficient of friction is used to refer to the average value of the coefficient of friction during a single stop, because it is normal to see some variation of the coefficient with time during each stop as the pad temperature rapidly rises.
It can be seen from Table II that the brake pads made according to each Example showed excellent resistance to fade and consistency of friction during both phases of the test.
The wear rates of each pad have been found to be less than is usually seen in current commercially available pads.
Claims
1. An automotive disc brake pad which comprises a friction material containing fibres, particulate materials and an organic binder, wherein the binder comprises thermoset resin with or without a proportion of thermoset rubber and the total binder content is from 2% to 9.5% by volume of the friction material.
2. A disc brake pad according to claim 1 in which the thermoset rubber is selected from nitrile rubber, chlorobutyl rubber and bromobutyl rubber and mixtures thereof.
3. A disc brake pad according to claim 1 or 2 which includes a thermoset rubber and wherein said thermoset resin is a resin of the phenolic or modified phenolic type.
4. A disc brake pad according to claim 1, 2 or 3 in which the friction material further contains fibres in an amount of 0% to 15% by volume.
5. A disc brake pad according to claim 4 in which the fibres are steel fibres.
6. A disc brake pad according to any preceding claim in which the friction material includes mica, vermiculite and/or wollastonite in an amount up to 35% by volume.
7. A disc brake pad substantially as described herein in any one of the foregoing Examples.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9123009.4 | 1991-10-30 | ||
| GB919123009A GB9123009D0 (en) | 1991-10-30 | 1991-10-30 | Improvements in or relating to brake pads |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO1993009362A1 true WO1993009362A1 (en) | 1993-05-13 |
Family
ID=10703760
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/GB1992/001972 WO1993009362A1 (en) | 1991-10-30 | 1992-10-28 | Friction material for a brake pad, having a specified binder content |
Country Status (2)
| Country | Link |
|---|---|
| GB (2) | GB9123009D0 (en) |
| WO (1) | WO1993009362A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2003105323A (en) * | 2001-09-27 | 2003-04-09 | Nisshinbo Ind Inc | Nonasbestos friction material |
Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3959194A (en) * | 1972-10-31 | 1976-05-25 | Johns-Manville Corporation | Less abrasive composition railroad brake shoe material |
| EP0000839A1 (en) * | 1977-08-10 | 1979-02-21 | Ferodo Limited | Improvements in or relating to friction materials |
| US4348490A (en) * | 1980-01-30 | 1982-09-07 | Akebono Brake Industry Company, Ltd. | Friction material |
| US4352750A (en) * | 1981-08-03 | 1982-10-05 | Manville Service Corporation | Friction material for railroad brake shoes |
| US4373038A (en) * | 1980-10-16 | 1983-02-08 | Rutgerswerke Aktiengesellschaft | Asbestos-free friction material |
| US4384054A (en) * | 1980-10-09 | 1983-05-17 | Rutgerswerke Aktiengesellschaft | Asbestos-free friction material |
| US4386168A (en) * | 1981-06-10 | 1983-05-31 | Kureha Kagaku Kogyo Kabushiki Kaisha | Organic friction material |
| US4477605A (en) * | 1983-03-21 | 1984-10-16 | Borg-Warner Corporation | Asbestos-free friction materials |
| US4722950A (en) * | 1986-07-07 | 1988-02-02 | Allied Corporation | Friction material |
| WO1992005370A1 (en) * | 1990-09-14 | 1992-04-02 | Ferodo Limited | Improvements in or relating to brake pads |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB983432A (en) * | 1962-04-03 | 1965-02-17 | Sk Wellman Co | Friction material articles and method of making the same |
| DE2934209C2 (en) * | 1979-05-28 | 1982-04-01 | Akebono Brake Industry Co. Ltd., Tokyo | Friction material |
| US4371631A (en) * | 1981-08-03 | 1983-02-01 | Manville Service Corporation | Backing plate composition for brake shoes |
| JPS5834885A (en) * | 1981-08-24 | 1983-03-01 | Akebono Brake Ind Co Ltd | Semimetallic friction material |
| FR2521240B1 (en) * | 1982-02-05 | 1987-03-27 | Valeo | FRICTION LINING, PARTICULARLY FOR BRAKES, CLUTCHES AND OTHER APPLICATIONS |
| JPS59159432A (en) * | 1983-02-28 | 1984-09-10 | Aisin Seiki Co Ltd | Clutch disc |
-
1991
- 1991-10-30 GB GB919123009A patent/GB9123009D0/en active Pending
-
1992
- 1992-10-28 WO PCT/GB1992/001972 patent/WO1993009362A1/en active Application Filing
- 1992-10-29 GB GB9222693A patent/GB2260988A/en not_active Withdrawn
Patent Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3959194A (en) * | 1972-10-31 | 1976-05-25 | Johns-Manville Corporation | Less abrasive composition railroad brake shoe material |
| EP0000839A1 (en) * | 1977-08-10 | 1979-02-21 | Ferodo Limited | Improvements in or relating to friction materials |
| US4348490A (en) * | 1980-01-30 | 1982-09-07 | Akebono Brake Industry Company, Ltd. | Friction material |
| US4384054A (en) * | 1980-10-09 | 1983-05-17 | Rutgerswerke Aktiengesellschaft | Asbestos-free friction material |
| US4373038A (en) * | 1980-10-16 | 1983-02-08 | Rutgerswerke Aktiengesellschaft | Asbestos-free friction material |
| US4386168A (en) * | 1981-06-10 | 1983-05-31 | Kureha Kagaku Kogyo Kabushiki Kaisha | Organic friction material |
| US4352750A (en) * | 1981-08-03 | 1982-10-05 | Manville Service Corporation | Friction material for railroad brake shoes |
| US4477605A (en) * | 1983-03-21 | 1984-10-16 | Borg-Warner Corporation | Asbestos-free friction materials |
| US4722950A (en) * | 1986-07-07 | 1988-02-02 | Allied Corporation | Friction material |
| WO1992005370A1 (en) * | 1990-09-14 | 1992-04-02 | Ferodo Limited | Improvements in or relating to brake pads |
Also Published As
| Publication number | Publication date |
|---|---|
| GB9123009D0 (en) | 1991-12-18 |
| GB2260988A (en) | 1993-05-05 |
| GB9222693D0 (en) | 1992-12-09 |
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