EP0000839B1 - Improvements in or relating to friction materials - Google Patents

Improvements in or relating to friction materials Download PDF

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Publication number
EP0000839B1
EP0000839B1 EP78300258A EP78300258A EP0000839B1 EP 0000839 B1 EP0000839 B1 EP 0000839B1 EP 78300258 A EP78300258 A EP 78300258A EP 78300258 A EP78300258 A EP 78300258A EP 0000839 B1 EP0000839 B1 EP 0000839B1
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EP
European Patent Office
Prior art keywords
friction material
material according
friction
binder
volume
Prior art date
Legal status (The legal status 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 status listed.)
Expired
Application number
EP78300258A
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German (de)
French (fr)
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EP0000839A1 (en
Inventor
John Chester
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Federal Mogul Friction Products Ltd
Original Assignee
Ferodo Ltd
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Publication date
Application filed by Ferodo Ltd filed Critical Ferodo Ltd
Publication of EP0000839A1 publication Critical patent/EP0000839A1/en
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Publication of EP0000839B1 publication Critical patent/EP0000839B1/en
Expired legal-status Critical Current

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/02Composition of linings ; Methods of manufacturing
    • F16D69/025Compositions based on an organic binder
    • F16D69/026Compositions based on an organic binder containing fibres

Definitions

  • This invention relates to friction materials, and more preferably to friction materials of the kind used for brake pads, brake linings, clutch facings and similar uses.
  • Friction materials of this kind are generally composed of a thermoset binder, an inorganic fibrous reinforcement and various fillers and other additives. These compositions are required to withstand severe operating temperatures and pressures under repeated application without failure or deterioration in friction properties and the fibrous reinforcement generally used is asbestos. Numerous proposals have been made of compositions containing other inorganic fibrous reinforcement but such materials have so far found limited commercial acceptance.
  • an asbestos-free friction material composition comprises a thermosetting binder containing phenol-formaldehyde resin, a fibre based reinforcement including steel fibres and other fillers and additives characterised in that:-
  • the steel fibres are fine, e.g. 0.125 mm diam., and with a length in the range 1 to 5 mm.
  • the steel may be mild steel.
  • the fibre-based reinforcement is a mixture of materials, one at least of which is staple steel fibre.
  • Other reinforcing materials which may be included in the mixture in powder form include reinforcing fillers such as mica and wollastonite, and milled glass fibre.
  • the thermoset binder includes a thermoset resin based on a phenol-formaldehyde resin but may also include a heat and chemical resistant vulcanised rubber, such as a nitrile rubber. Preferably a mixture of such materials is used of which the phenol-formaldehyde resin material constitutes at least half.
  • a rubber When a rubber is used it may be incorporated into the friction material in the form of a powder but is preferably incorporated in the form of a solution in a suitable organic solvent and a vulcanising agent such as sulphur is also used.
  • thermoset binder is preferably in the range 20 to 32% by volume of the friction material.
  • various other materials may be included as fillers, friction and wear modifiers etc. the proportions of which can be varied to adjust the friction and other properties of the materials.
  • the preferred additives are particulate fillers, more preferably a mixture of such materials and friction and wear modifying materials.
  • the particulate fillers will' generally be present in an amount between 10 and 50% by volume and may include such fillers as barytes, whiting, silica etc.
  • friction and wear modifiers are carbon, graphite, antimony trisulphide and molybdenum disulphide and metals, in a finely divided form.
  • suitable metals are copper and tin. A mixture of such materials may be used, and the total amount of such materials may be up to 40% by volume.
  • the friction materials of the present invention are particularly suited to be manufactured by a press-molding technique in which all the ingredients of the material are compounded together, the compounded mix disintegrated and (optionally dried) and then moulded into a component such as a brake pad in a die under pressure. The moulded component is then removed from the die and baked to cure the binder.
  • the invention provides friction materials which do not contain asbestos, and yet have comparable properties to asbestos-based friction materials.
  • Example 1 sample disc-brake pads were manufactured according to the formulation given below in Table I. The ingredients were initially compounded together, the nitrile rubber being introduced into the mixture as a powder and the compound was disintegrated and dried.
  • the material was then moulded into pads under pressure in a die and the mouldings baked in an oven to cure the binder.
  • sample pads produced were tested and found to have friction properties comparable to asbestos-containing materials.
  • Sample disc-brake pads were manufactured according to the formulations given below in Table II. The ingredients were initially compounded together, the nitrile rubber being introduced into the mixture as a 15-20% solids content solution in trichloroethylene, and the phenol-formaldehyde resin as a 70% solids content solution in methylated spirits. The compound was disintegrated and dried and then moulded into pads under pressure in a die and the mouldings baked in an oven to cure the binder.
  • Example 2 the reinforcement was a mixture of Steel Fibres and mica (as in Example 1) but in Example 3 the reinforcement was a mixture of the steel fibres and milled E Glass, the latter being a dust composed of very short lengths of milled glass fibre.
  • the binder included equal amounts of rubber and resin.
  • the wear of the material of Example 2 was as good as, or better than, most conventional materials of comparable friction level.
  • the wear of the material of Example 3 was reasonable for the level of friction, although higher than that of the materials of Example 2.
  • Example 2 The assembly shear strength of two pads of each material were measured, the values obtained for Example 2 being 16065 and 14755 KN/m 2 and those for Example 3 being 16134 and 15375 KN/m 2 .

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Description

  • This invention relates to friction materials, and more preferably to friction materials of the kind used for brake pads, brake linings, clutch facings and similar uses.
  • Friction materials of this kind are generally composed of a thermoset binder, an inorganic fibrous reinforcement and various fillers and other additives. These compositions are required to withstand severe operating temperatures and pressures under repeated application without failure or deterioration in friction properties and the fibrous reinforcement generally used is asbestos. Numerous proposals have been made of compositions containing other inorganic fibrous reinforcement but such materials have so far found limited commercial acceptance.
  • According to the present invention an asbestos-free friction material composition comprises a thermosetting binder containing phenol-formaldehyde resin, a fibre based reinforcement including steel fibres and other fillers and additives characterised in that:-
    • a) the thermosetting binder makes up 20% to 60% by volume of the composition at least half of the binder being said phenol-formaldehyde resin,
    • b) the fibre-based reinforcement is a mixture of staple steel fibres and a non-asbestos mineral reinforcing filler in powder form, and makes up 10% to 35% by volume of the composition, said steel fibres having a length in the range of 1 to 5 mm,
    • c) the balance of the composition being friction and wear modifiers and inorganic fillers.
  • The steel fibres are fine, e.g. 0.125 mm diam., and with a length in the range 1 to 5 mm. The steel may be mild steel.
  • The fibre-based reinforcement is a mixture of materials, one at least of which is staple steel fibre. Other reinforcing materials which may be included in the mixture in powder form include reinforcing fillers such as mica and wollastonite, and milled glass fibre.
  • The thermoset binder includes a thermoset resin based on a phenol-formaldehyde resin but may also include a heat and chemical resistant vulcanised rubber, such as a nitrile rubber. Preferably a mixture of such materials is used of which the phenol-formaldehyde resin material constitutes at least half. When a rubber is used it may be incorporated into the friction material in the form of a powder but is preferably incorporated in the form of a solution in a suitable organic solvent and a vulcanising agent such as sulphur is also used.
  • The amount of thermoset binder is preferably in the range 20 to 32% by volume of the friction material.
  • In the manufacture of the friction materials various other materials may be included as fillers, friction and wear modifiers etc. the proportions of which can be varied to adjust the friction and other properties of the materials.
  • In the present case the preferred additives are particulate fillers, more preferably a mixture of such materials and friction and wear modifying materials.
  • The particulate fillers will' generally be present in an amount between 10 and 50% by volume and may include such fillers as barytes, whiting, silica etc.
  • Examples of friction and wear modifiers are carbon, graphite, antimony trisulphide and molybdenum disulphide and metals, in a finely divided form. Examples of suitable metals are copper and tin. A mixture of such materials may be used, and the total amount of such materials may be up to 40% by volume.
  • The friction materials of the present invention are particularly suited to be manufactured by a press-molding technique in which all the ingredients of the material are compounded together, the compounded mix disintegrated and (optionally dried) and then moulded into a component such as a brake pad in a die under pressure. The moulded component is then removed from the die and baked to cure the binder.
  • The invention provides friction materials which do not contain asbestos, and yet have comparable properties to asbestos-based friction materials.
  • The invention will now be illustrated, by way of example only, by means of the following examples.
  • Example 1
  • For Example 1 sample disc-brake pads were manufactured according to the formulation given below in Table I. The ingredients were initially compounded together, the nitrile rubber being introduced into the mixture as a powder and the compound was disintegrated and dried.
  • The material was then moulded into pads under pressure in a die and the mouldings baked in an oven to cure the binder.
    Figure imgb0001
  • In each case the sample pads produced were tested and found to have friction properties comparable to asbestos-containing materials.
  • Examples 2 and 3
  • These Examples illustrate different proportions of binder and reinforcing materials. Sample disc-brake pads were manufactured according to the formulations given below in Table II. The ingredients were initially compounded together, the nitrile rubber being introduced into the mixture as a 15-20% solids content solution in trichloroethylene, and the phenol-formaldehyde resin as a 70% solids content solution in methylated spirits. The compound was disintegrated and dried and then moulded into pads under pressure in a die and the mouldings baked in an oven to cure the binder.
  • In the following table the formulations are expressed in parts by volume.
    Figure imgb0002
  • In Example 2 the reinforcement was a mixture of Steel Fibres and mica (as in Example 1) but in Example 3 the reinforcement was a mixture of the steel fibres and milled E Glass, the latter being a dust composed of very short lengths of milled glass fibre. In Example 3 the binder included equal amounts of rubber and resin.
  • In dynamometer tests of the pads produced the coefficient of friction , of the material of Example 2 varied from 0.26 (cold) to 0.44 (hot) and that of the material of Example 5 varied from 0.30 (cold) to 0.55 (hot).
  • The wear of the material of Example 2 was as good as, or better than, most conventional materials of comparable friction level. The wear of the material of Example 3 was reasonable for the level of friction, although higher than that of the materials of Example 2.
  • The assembly shear strength of two pads of each material were measured, the values obtained for Example 2 being 16065 and 14755 KN/m2 and those for Example 3 being 16134 and 15375 KN/m2.
  • (Assembly Shear Strength = load required to shear material off the backplate area of friction material bonded to the backplate)

Claims (11)

1. An asbestos-free friction material comprising a thermosetting binder containing phenol- formaldehyde resin, a fibre based reinforcement including steel fibres, and other fillers and additives characterised in that:-
a) the thermosetting binder makes up 20% to 60% by volume of the composition, at least half of the binder being said phenol-formaldehyde resin,
b) the fibre based reinforcement is a mixture of staple steel fibres and a non-asbestos mineral reinforcing filler in powder form, and makes up 10% to 35% by volume of the composition, said steel fibres having a length in the range 1 to 5 mm,
c) the balance of the composition being friction and wear modifiers and inorganic fillers.
2. A friction material according to Claim 2 in which the steel is mild steel.
3. A friction material according to Claim 1 or 2 in which the reinforcing filler includes mica.
4. A friction material according to Claim 3 in which said reinforcing filler is mica.
5. A friction material according to Claim 1 or 2 in which the reinforcing filler is wollastonite.
6. A friction material according to any one of the preceding claims which includes as a binder a heat and chemical resistant vulcanized rubber.
7. A friction material according to Claim 6 in which said rubber is a nitrile rubber.
8. A friction material according to any one of the preceding claims which the amount of thermoset binder is in the range 20 to 32% by volume of the material.
9. A friction material according to any one of the preceding claims which includes one or more particulate fillers in an amount between 10 and 50% by volume.
10. A friction material according to Claim 9 in which said particulate filler comprises barytes, whiting or silica.
11. A friction material according to any preceding claim in which said friction and wear modifiers are selected from carbon, graphite, antimony trisulphide and molybdenum disulphide and brass, copper and tin in finely divided form.
EP78300258A 1977-08-10 1978-08-08 Improvements in or relating to friction materials Expired EP0000839B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB33458/77A GB1604839A (en) 1977-08-10 1977-08-10 Friction materials
GB3345877 1977-08-10

Publications (2)

Publication Number Publication Date
EP0000839A1 EP0000839A1 (en) 1979-02-21
EP0000839B1 true EP0000839B1 (en) 1981-08-05

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Family Applications (1)

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EP78300258A Expired EP0000839B1 (en) 1977-08-10 1978-08-08 Improvements in or relating to friction materials

Country Status (13)

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US (2) US4273699A (en)
EP (1) EP0000839B1 (en)
JP (1) JPS5434349A (en)
AU (1) AU3875478A (en)
BR (1) BR7805104A (en)
CS (1) CS216919B2 (en)
DD (1) DD138076A5 (en)
DE (1) DE2860901D1 (en)
GB (1) GB1604839A (en)
IN (1) IN148770B (en)
IT (1) IT1156900B (en)
SU (1) SU837328A3 (en)
ZA (1) ZA784379B (en)

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US4178278A (en) * 1978-03-01 1979-12-11 Johns-Manville Corporation Friction material for railroad service
US4175070A (en) * 1978-06-02 1979-11-20 The Bendix Corporation High carbon friction material
AU6662381A (en) * 1980-02-28 1981-09-03 Goodyear Aerospace Corp. Elimination of asbestos in organic-type brake linings
JPS579330A (en) * 1980-06-19 1982-01-18 Uchiyama Mfg Corp Core material of clutch friction plate
EP0050377B1 (en) * 1980-10-16 1985-10-02 Rütgerswerke Aktiengesellschaft Asbest-free friction material
US4373037A (en) * 1981-05-29 1983-02-08 Engelhard Corporation Asbestos-free friction material incorporating attapulgite clay
NL193609C (en) * 1981-12-30 2000-04-04 Bekaert Sa Nv Composite strand for processing as granulate in plastic products and method for manufacturing a plastic mixing granulate.
FR2521240B1 (en) * 1982-02-05 1987-03-27 Valeo FRICTION LINING, PARTICULARLY FOR BRAKES, CLUTCHES AND OTHER APPLICATIONS
US4474905A (en) * 1982-09-30 1984-10-02 General Technology Applications, Inc. Freeze blending of reactive liquids and solids
BE900821A (en) * 1983-10-14 1985-02-01 Rogers Corp PHENOLIC COMPOSITION STABLE TO HEAT.
US4659758A (en) * 1983-10-14 1987-04-21 Rogers Corporation Heat stable phenolic composition
GB8405645D0 (en) * 1984-03-03 1984-04-04 Ferodo Ltd Friction materials
US4775705A (en) * 1984-10-20 1988-10-04 T&N Plc Friction materials and their manufacture
GB8426601D0 (en) * 1984-10-20 1984-11-28 Nuturn Corp Friction materials
JPS61115987A (en) * 1984-11-12 1986-06-03 Sumitomo Electric Ind Ltd Friction material using steel fiber
US4722950A (en) * 1986-07-07 1988-02-02 Allied Corporation Friction material
GB8806600D0 (en) * 1988-03-19 1988-04-20 Lucas Ind Plc Friction materials
JPH02146327A (en) * 1988-11-29 1990-06-05 Akebono Brake Res & Dev Center Ltd Friction material
CA2024478C (en) * 1989-09-01 1997-05-20 Mitsuhiko Nakagawa Friction material and method of manufacturing such material
US5268398A (en) * 1989-09-01 1993-12-07 Sumitomo Electric Industries, Ltd. Friction material and method of manufacturing such material
GB9020070D0 (en) * 1990-09-14 1990-10-24 Ferodo Ltd Improvements in or relating to brake pads
JP2813060B2 (en) * 1990-11-28 1998-10-22 株式会社曙ブレーキ中央技術研究所 Non-asbestos friction material
JPH055091A (en) * 1991-02-08 1993-01-14 Akebono Brake Res & Dev Center Ltd Frictional material
AT411765B (en) * 1991-03-20 2004-05-25 Hoerbiger & Co FRICTION MATERIAL PRODUCED BY SINTER
DE4119515C1 (en) * 1991-06-13 1992-12-10 Textar Gmbh, 5090 Leverkusen, De
GB9123009D0 (en) * 1991-10-30 1991-12-18 Ferodo Ltd Improvements in or relating to brake pads
GB2268502B (en) * 1992-07-03 1995-11-01 Ferodo Ltd Improved friction materials
JP3421364B2 (en) * 1992-07-14 2003-06-30 曙ブレーキ工業株式会社 Friction material
US5622785A (en) * 1994-01-31 1997-04-22 Performance Friction Corporation Coating for a brake pad, a method of reducing brake pad noise, and a brake pad
JP2002226834A (en) * 2001-01-30 2002-08-14 Nisshinbo Ind Inc Nonasbestos friction material
GB2517951A (en) 2013-09-05 2015-03-11 Imp Innovations Ltd A substrate and a method of manufacturing a substrate

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FR1363324A (en) 1963-04-30 1964-06-12 Brake linings comprising an improved phenolic resin and method of manufacture thereof
US3355272A (en) * 1964-11-24 1967-11-28 Union Carbide Corp Abrasive compositions and structures thereof comprising a thermosetting resin and a thermoplastic polyarylene polyether
FR1575746A (en) 1968-04-26 1969-07-25
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CA928227A (en) 1969-02-14 1973-06-12 R. Johnson Howard Friction lining composition
US4051097A (en) * 1972-01-31 1977-09-27 The Bendix Corporation Carbon metallic friction composition
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US3956545A (en) * 1972-05-10 1976-05-11 Johns-Manville Corporation Glass fiber friction element
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Also Published As

Publication number Publication date
IT7850665A0 (en) 1978-08-09
IN148770B (en) 1981-06-06
JPS5434349A (en) 1979-03-13
DE2860901D1 (en) 1981-11-05
BR7805104A (en) 1979-04-24
CS216919B2 (en) 1982-12-31
SU837328A3 (en) 1981-06-07
GB1604839A (en) 1981-12-16
US4273699A (en) 1981-06-16
ZA784379B (en) 1979-07-25
AU3875478A (en) 1980-02-14
EP0000839A1 (en) 1979-02-21
US4310452A (en) 1982-01-12
DD138076A5 (en) 1979-10-10
IT1156900B (en) 1987-02-04

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