EP0000841B1 - Improvements in or relating to friction materials - Google Patents

Improvements in or relating to friction materials Download PDF

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Publication number
EP0000841B1
EP0000841B1 EP78300260A EP78300260A EP0000841B1 EP 0000841 B1 EP0000841 B1 EP 0000841B1 EP 78300260 A EP78300260 A EP 78300260A EP 78300260 A EP78300260 A EP 78300260A EP 0000841 B1 EP0000841 B1 EP 0000841B1
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EP
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Prior art keywords
friction material
friction
material according
composition
volume
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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.)
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Application number
EP78300260A
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German (de)
French (fr)
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EP0000841A1 (en
Inventor
John Chester
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Federal Mogul Friction Products Ltd
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Ferodo Ltd
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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
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00Use of ingredients characterised by shape
    • C08K7/02Fibres or whiskers
    • C08K7/04Fibres or whiskers inorganic
    • C08K7/06Elements

Definitions

  • This invention relates to friction materials, and more particularly 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, and asbestos fibre reinforcement and various fillers and other additives and are used against cast iron brake discs, drums etc.
  • French Patent Specification No. 1,575,746 describes a friction material containing steel wool, but this material is for use against steel counter members, as in railway brake blocks, and is formulated from materials those function includes embrittlement of the steel so that it will break up at the surface of the brake block.
  • Proposals have also been made of compositions containing non-asbestos inorganic fibrous reinforcement for brake pads and linings of automotive types but such materials have so far had limited commercial acceptance.
  • a friction material suitable for moulded brake pads or linings comprises a thermoset binder a steel fibre reinforcement, and other fillers and additives and is characterised in that the composition consists of, in combination,
  • the inert mineral filler is present in an amount between 10 and 35 per cent by volume, and is most important from a cost point of view when comparing these materials, since asbestos is a cheap raw material being replaced by relatively expensive man-made fibre. Hence it is necessary to find a friction material having satisfactory properties but able to carry a loading of cheap filler material.
  • the fibrous reinforcement consists of fine steel fibres having a length of the order of 1 to 5mm, preferably having a diameter of the order of 0.125mm.
  • the steel may be a mild steel.
  • the fibrous reinforcement preferably constitutes at least 9% by volume of the friction material.
  • the thermoset binder includes a thermoset resin based on a phenol-formaldehyde material but may also include a heat and chemical resistant vulcanized rubber, such as a nitrile rubber.
  • a mixture of such materials is used in which the phenol-formaldehyde resin material is preferably the major constituent i.e. more than 50% of said mixture.
  • a rubber When a rubber is used it may be incorporated into the friction material in the form of a solution in an organic solvent such as trichloroethylene, or in the form of a powder, and a vulcanizing agent such as sulphur can be also used.
  • friction materials It is usual in the manufacture of friction materials to include various other material as friction and wear modifiers the proportions of which can be varied to adjust to the friction and other properties of the materials.
  • friction and wear modifiers are carbon, graphite, antimony trisulphide and molybdenum disulphide and metals in a finely divided form.
  • suitable metals are copper, brass and tin. A mixture of such materials may be used, and the total amount of such materials may be up to 40 per cent by volume.
  • the invention provides friction materials which contain no asbestos and yet which have friction properties comparable to conventional asbestos-reinforced materials.
  • Sample disc brake pads were made using the formulation given below in Table I. The ingredients were compounded together the nitrile rubber being introduced as a powder and the resulting dry mix was disintegrated and press-moulded in a die into the shape of disc-brake pads. The mouldings so produced were baked in an oven to cure the binder.
  • sample disc-brake pads were tested and their friction properties found to be comparable to materials containing asbestos as the fibre reinforcement.
  • This example illustrates a formulation with a higher loading of steel fibres.
  • Disc brake pads were manufactured to the formulation given below in Table II by the same method as used in Example 1 except that the nitrile rubber in the present example was introduced as a 16% (by weight) solution in trichloroethylene.
  • This example illustrates the use of lower binder content and higher loading of inert filler (Barytes).
  • the assembly shear strengths measured were 15237 and 13031 kN/m 2.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)

Description

  • This invention relates to friction materials, and more particularly 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, and asbestos fibre reinforcement and various fillers and other additives and are used against cast iron brake discs, drums etc. French Patent Specification No. 1,575,746 describes a friction material containing steel wool, but this material is for use against steel counter members, as in railway brake blocks, and is formulated from materials those function includes embrittlement of the steel so that it will break up at the surface of the brake block. Proposals have also been made of compositions containing non-asbestos inorganic fibrous reinforcement for brake pads and linings of automotive types but such materials have so far had limited commercial acceptance.
  • According to the present invention a friction material suitable for moulded brake pads or linings comprises a thermoset binder a steel fibre reinforcement, and other fillers and additives and is characterised in that the composition consists of, in combination,
    • i) a thermoset binder which comprises a phenol-formaldehyde resin and which up 20% to 45% by volume of the composition of which at least half is said resin,
    • ii) as sole fibrous reinforcement staple steel fibre in an amount in the range 5% to 15% by volume of the composition said steel fibres having a length in the range 1 to 5mm,
    • iii) an inert mineral filler not being a metal oxide in an amount in the range 10% to 35% by volume of the composition,
    • iv) the balance of the composition being friction and wear modifiers in an amount up to 40% by volume of the composition.

    By "inert mineral filler" in this specification we mean a particulate filler whose presence does not substantially affect the friction properties of the material and which is an inexpensive mineral such as barytes, whiting or silica. We exclude metal oxides from this class of fillers since they are used for other purposes in friction materials.
  • The inert mineral filler is present in an amount between 10 and 35 per cent by volume, and is most important from a cost point of view when comparing these materials, since asbestos is a cheap raw material being replaced by relatively expensive man-made fibre. Hence it is necessary to find a friction material having satisfactory properties but able to carry a loading of cheap filler material.
  • The fibrous reinforcement consists of fine steel fibres having a length of the order of 1 to 5mm, preferably having a diameter of the order of 0.125mm. The steel may be a mild steel. The fibrous reinforcement preferably constitutes at least 9% by volume of the friction material.
  • The thermoset binder includes a thermoset resin based on a phenol-formaldehyde material but may also include a heat and chemical resistant vulcanized rubber, such as a nitrile rubber. Preferably a mixture of such materials is used in which the phenol-formaldehyde resin material is preferably the major constituent i.e. more than 50% of said mixture. When a rubber is used it may be incorporated into the friction material in the form of a solution in an organic solvent such as trichloroethylene, or in the form of a powder, and a vulcanizing agent such as sulphur can be also used.
  • It is usual in the manufacture of friction materials to include various other material as friction and wear modifiers the proportions of which can be varied to adjust to the friction and other properties of the materials.
  • 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, brass and tin. A mixture of such materials may be used, and the total amount of such materials may be up to 40 per cent by volume.
  • The friction materials of the present invention are particularly suited to be manufactured by a press-moulding 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 contain no asbestos and yet which have friction properties comparable to conventional asbestos-reinforced materials.
  • The invention will now be illustrated by way of example only, by means of the following example.
  • Example 1
  • Sample disc brake pads were made using the formulation given below in Table I. The ingredients were compounded together the nitrile rubber being introduced as a powder and the resulting dry mix was disintegrated and press-moulded in a die into the shape of disc-brake pads. The mouldings so produced were baked in an oven to cure the binder.
    Figure imgb0001
  • The sample disc-brake pads were tested and their friction properties found to be comparable to materials containing asbestos as the fibre reinforcement.
  • Example 2
  • This example illustrates a formulation with a higher loading of steel fibres.
  • Disc brake pads were manufactured to the formulation given below in Table II by the same method as used in Example 1 except that the nitrile rubber in the present example was introduced as a 16% (by weight) solution in trichloroethylene.
    Figure imgb0002
  • In tests, on a dynamometer, of the pads produced the coefficient of friction varied from 0.32 (cold) to 0.44 (hot) and wear was less than that of many conventional asbestos reinforced materials at this level of friction.
  • The assembly shear strength of two pads was measured, the values obtained being 9722 and 9377 KN/m 2
  • Figure imgb0003
  • Example 3
  • This example illustrates the use of lower binder content and higher loading of inert filler (Barytes).
  • Disc brake pads were made by the same method as Example 2 to the formulation given in Table III.
    Figure imgb0004
  • The wear of these pads was similar to those of Example 2 and coefficient of friction varied from 0.27 (cold) to 0.48 (hot).
  • The assembly shear strengths measured were 15237 and 13031 kN/m2.
  • Example 4
  • This example illustrates the use of an even lower binder content at the same loading of barytes.
  • Disc brake pads were made as in Example 2 to the formulation given in Table IV.
    Figure imgb0005
  • The wear of these pads was slightly higher than that of Examples 2 and 3 and the coefficient of friction varied from 0.30 (cold) to 0.40 (hot).
  • The assembly shear strengths measured were 9377 and 7929 KN/m2.

Claims (9)

1. A friction material suitable for moulded brake pads or linings comprises a thermoset binder a steel fibre reinforcement, and other fillers and additives and is characterised in that the composition consists of, in combination,
i) a thermoset binder which comprises a phenol-formaldehyde resin and which makes up 20% to 45% by volume of the composition of which at least half is said resin,
ii) as sole fibrous reinforcement staple steel fibre in an amount in the range 5% to 15% by volume of the composition said steel fibres having a length in the range 1 to 5mm,
iii) an inert mineral filler not being a metal oxide in an amount in the range 10% to 35% by volume of the composition,
iv) the balance of the composition being friction and wear modifiers in an amount up to 40% by volume of the composition.
2. A friction material according to claim 1 in which the steel fibres have a diameter of the order of 0.125 mm.
3. A friction material according to claim 1, or 2, in which not more than 7% by volume (based on total composition) of the friction and wear modifiers is metal.
4. A friction material according to claim 1, 2 or 3, in which the friction and wear modifiers are substantially wholly inorganic.
5. A friction material according to any one of Claims 1 to 4 in which the thermoset binder comprises also a heat and chemical resistant vulcanised rubber.
6. A friction material according to Claim 5 in which said rubber is a nitrile rubber.
7. A friction material according to any one of the preceding claims in which the inert mineral filler is barytes, whiting or silica or a mixture thereof.
8. A friction material according to any one of the preceding claims in which the inert mineral filler makes up between 10 and 30% by volume of the friction material.
9. A friction material according to any one of the preceding claims in which the friction and wear modifiers are selected from carbon, graphite, antimony trisulphide, molybdenum disulphide and copper, brass and tin in finely divided form.
EP78300260A 1977-08-10 1978-08-08 Improvements in or relating to friction materials Expired EP0000841B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB33485/77A GB1604828A (en) 1977-08-10 1977-08-10 Friction materials
GB3348577 1977-08-10

Publications (2)

Publication Number Publication Date
EP0000841A1 EP0000841A1 (en) 1979-02-21
EP0000841B1 true EP0000841B1 (en) 1981-07-29

Family

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Family Applications (1)

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EP78300260A Expired EP0000841B1 (en) 1977-08-10 1978-08-08 Improvements in or relating to friction materials

Country Status (13)

Country Link
US (1) US4226759A (en)
EP (1) EP0000841B1 (en)
JP (1) JPS5434351A (en)
AU (1) AU3875678A (en)
BR (1) BR7805106A (en)
CS (1) CS216921B2 (en)
DD (1) DD138220A5 (en)
DE (1) DE2860882D1 (en)
GB (1) GB1604828A (en)
IN (1) IN148771B (en)
IT (1) IT1157152B (en)
SU (1) SU890983A3 (en)
ZA (1) ZA784380B (en)

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US4178278A (en) * 1978-03-01 1979-12-11 Johns-Manville Corporation Friction material for railroad service
FR2429066A1 (en) * 1978-06-20 1980-01-18 Roulements Soc Nouvelle PRODUCT, PARTICULARLY FOR THE MANUFACTURE OF FRICTION TRIMS
JPS55157672A (en) * 1979-04-26 1980-12-08 Kureha Chem Ind Co Ltd Organic friction material
AU6662381A (en) * 1980-02-28 1981-09-03 Goodyear Aerospace Corp. Elimination of asbestos in organic-type brake linings
US4373037A (en) * 1981-05-29 1983-02-08 Engelhard Corporation Asbestos-free friction material incorporating attapulgite clay
JPS60139932A (en) * 1983-12-28 1985-07-24 Komatsu Ltd Wet frictional member
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
US4722950A (en) * 1986-07-07 1988-02-02 Allied Corporation Friction material
US5248301A (en) * 1987-12-03 1993-09-28 Medfusion, Inc. Transcutaneous infusion apparatus and methods of manufacture and use
GB9020070D0 (en) * 1990-09-14 1990-10-24 Ferodo Ltd Improvements in or relating to brake pads
US5122550A (en) * 1990-11-21 1992-06-16 Hoechst Celanese Corporation Cellulose ester fibrils: a molding aid for friction materials
DE4039636A1 (en) * 1990-12-12 1992-06-17 Beiersdorf Ag HOT-STIFF ADHESIVE
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
DE4224759C2 (en) * 1992-07-27 2002-04-18 Ina Schaeffler Kg Tensioning system, friction damped for belt or chain drives
JPH06346932A (en) * 1993-06-08 1994-12-20 Akebono Brake Ind Co Ltd Frictional material
US5413194A (en) * 1994-07-25 1995-05-09 Pneumo Abex Corporation Brake friction pad assembly
DE29724077U1 (en) * 1997-06-28 1999-11-11 Daimler Chrysler Ag Brake unit
US6161659A (en) * 1998-09-29 2000-12-19 Inertia Dynamics, Inc. Electromagnetic disk brake with rubber friction disk braking surface
JP2002226834A (en) * 2001-01-30 2002-08-14 Nisshinbo Ind Inc Nonasbestos friction material
JP2003113253A (en) * 2001-07-30 2003-04-18 Nisshinbo Ind Inc Non-asbestos-based friction material
MD86Y (en) * 2006-10-04 2009-09-30 Владимир КЛЕЙМЕНОВ Composition of friction material
MD20060243A (en) * 2006-10-04 2008-06-30 Владимир КЛЕЙМЕНОВ Composition of friction material

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3007890A (en) * 1959-05-07 1961-11-07 Chrysler Corp Friction elements and method of making the same
FR1575746A (en) * 1968-04-26 1969-07-25
DE1780271A1 (en) * 1968-08-23 1971-12-30 Jurid Werke Gmbh Brake pad for vehicle disc brakes
US4051097A (en) * 1972-01-31 1977-09-27 The Bendix Corporation Carbon metallic friction composition
US3835118A (en) * 1973-05-14 1974-09-10 Bendix Corp Sponge iron friction material
US4119591A (en) * 1977-07-05 1978-10-10 The Bendix Corporation Friction material reinforced with steel and cellulose fibers

Also Published As

Publication number Publication date
IT1157152B (en) 1987-02-11
CS216921B2 (en) 1982-12-31
EP0000841A1 (en) 1979-02-21
IT7850667A0 (en) 1978-08-09
BR7805106A (en) 1979-04-24
US4226759A (en) 1980-10-07
AU3875678A (en) 1980-02-14
GB1604828A (en) 1981-12-16
DD138220A5 (en) 1979-10-17
ZA784380B (en) 1979-07-25
IN148771B (en) 1981-06-06
SU890983A3 (en) 1981-12-15
JPS5434351A (en) 1979-03-13
DE2860882D1 (en) 1981-10-29

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