GB2113603A - A method of making a friction element - Google Patents

A method of making a friction element Download PDF

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Publication number
GB2113603A
GB2113603A GB08301046A GB8301046A GB2113603A GB 2113603 A GB2113603 A GB 2113603A GB 08301046 A GB08301046 A GB 08301046A GB 8301046 A GB8301046 A GB 8301046A GB 2113603 A GB2113603 A GB 2113603A
Authority
GB
United Kingdom
Prior art keywords
core plate
layer
friction
assembly
mould
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.)
Granted
Application number
GB08301046A
Other versions
GB2113603B (en
GB8301046D0 (en
Inventor
Peter John Clark
Alan Williams
David Noble
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.)
ZF International UK Ltd
Original Assignee
Lucas Industries Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Lucas Industries Ltd filed Critical Lucas Industries Ltd
Priority to GB08301046A priority Critical patent/GB2113603B/en
Publication of GB8301046D0 publication Critical patent/GB8301046D0/en
Publication of GB2113603A publication Critical patent/GB2113603A/en
Application granted granted Critical
Publication of GB2113603B publication Critical patent/GB2113603B/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
    • F16D69/04Attachment of linings
    • F16D69/0408Attachment of linings specially adapted for plane linings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/16Frictional elements, e.g. brake or clutch linings
    • 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
    • F16D69/04Attachment of linings
    • F16D2069/0425Attachment methods or devices
    • F16D2069/0441Mechanical interlocking, e.g. roughened lining carrier, mating profiles on friction material and lining carrier
    • 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
    • F16D69/04Attachment of linings
    • F16D2069/0425Attachment methods or devices
    • F16D2069/045Bonding
    • F16D2069/0466Bonding chemical, e.g. using adhesives, vulcanising
    • F16D2069/0475Bonding chemical, e.g. using adhesives, vulcanising comprising thermal treatment
    • 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
    • F16D69/04Attachment of linings
    • F16D2069/0425Attachment methods or devices
    • F16D2069/0491Tools, machines, processes

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Braking Arrangements (AREA)

Abstract

In a method of making a friction element for a brake or clutch, a layer of particulate friction material containing an unactivated binder is formed in a mould cavity, a core plate is placed in contact with the layer and sufficient pressure applied to cold mould the layer into a homogenous body of friction material and form an assembly of the body and core plate. The assembly is then heated to activate the binder. The lining material may be adhered or keyed to the core plate. Apparatus is also described for carrying out the method having an outer annular die member (6) mounted on a support (7) and urged upwardly by springs (8). A mould cavity (9) is completed by an inner core (10). The member 6 is movable between two levels to define different depths of mould cavity and also to a position in which it no longer defines the mould cavities and thus facilitates removal of the moulded apparatus from the apparatus.

Description

SPECIFICATION A method of making a friction element This invention relates to a method of making a friction element for a brake or clutch, pri marily for motor vehicles, the element being of the type in which a core plate carries, on at least one side thereof, a layer of friction material providing a braking surface.
One conventional method of making a friction element of the aforesaid type consists of forming annular discs of friction material and glueing or bonding them by hot pressing respectively on to opposite sides of the core plate. With this type of process, it is possible for warping of the core plate to occur, either as a result of inaccurate pressure or of heatrelated effects. This results in a lack of parallelism and/or flatness in the braking surfaces of the discs, the correction of which entails expensive machining of the friction surfaces.
One attempt to avoid this problem proposed the moulding on to the core plate under heat and pressure of one or more uncured bodies of friction material containing a curable material, such as a resin. However, the handling of such uncured bodies presents various problems due to their relatively fragile state and can lead to high wastage rates. Moreover, the resin tends to fuse during the hot pressing process before curing takes place and this can result in an unacceptably dense material lacking the porosity desirable in a brake friction material for use with a friction element of the aforesaid type, particularly when the element is intended for use in an oil-immersed brake.
Another conventional method of making a friction element of the aforesaid kind involves sintering powdered friction material onto a core plate. This again entails high temperature pressing techniques and can lead to warping of the core plate.
An object of the present invention is to provide an improved method of making a friction element of the aforesaid type in which the aforesaid problems are minimised or avoided.
According to the present invention, a method of making a friction element comprises forming in a mould cavity a layer of particulate friction material containing an unactivated binder, placing a core plate in contact with said layer over an area of the plate on which a friction lining is to be formed, applying pressure to the core plate and layer sufficient to cold mould the layer into a homogeneous body of friction material and form an assembly of said body and core plate, and heating the assembly to activate said binder.
Preferably, the core plate is provided with a layer of bonding or adhesive agent prior to being placed in contact with the particulate layer, whereby said application of pressure, acts to form said assembly of the body and core plate. Alternatively or#dditionally, the body of friction material may be keyed to the core plate by providing one or more suitable keying formations in the latter.
The heating of the assembly after the moulding operation is preferably effected under light pressure which is sufficient to ensure that the shape of the friction body is maintained but not sufficient significantly to affect the porosity of the friction body.
The particulate material is preferably prepared as a wet mix containing a solvent for the unactivated binder, the latter being preferably in the form of a resin. In this way, the dissolved resin is caused to coat the individual particles and the mix is subsequently heated, prior to the formation of said layer in the mould cavity, to a temperature insufficient to cure the resin in order to dry the mix. The dried particles are predominantly agglomerate particles of mixture rather than of individual constituents, and these may be subsequently pulverised and graded to obtain particles falling within a desired size range.
The wet mix may be prepared either by adding a resin solvent to the dry composition and/or adding a resin solution to the dry mix which may nor may not already contain a quantity of resin.
In a typical practical application of the method of the invention, a second layer of particulate friction material is formed on the opposite surface of the core plate to that contacting the first layer.
From another aspect of the invention, there is provided an apparatus for carrying out the method comprising a die assembly having a mould cavity, means for introducing a quantity of particulate friction material into the cavity, pressure means to apply pressure between the material and a core plate placed in contact with the material to cold mould the layer into a homogenous body of friction material and form an assembly of said body and core plate, and means for heating the moulded assembly.
Preferably, the die assembly includes a member which is movable between two levels, in which it defines respectively the depths of first and second mould cavities for the formation of layers of friction material, one on each side of the core plate.
The member may conveniently be movable, after a moulding operation, to an alternative position in which it no longer defines the mould cavities and thereby facilitates removal of the moulded article from the apparatus.
The invention will now be described, by way of example, with reference to the accompanying drawings in which: Figure 1 is an exploded diagrammatic perspective view of one form of friction element produced by the method of the invention; and Figures 2 to 5 are diagrammatic illustra tions, in various conditions of use, of one form of apparatus for carrying out the method of the invention.
The friction element illustrated in Fig. 1 is of a well known type suitable for inclusion in a tractor brake of the multi-disc type for example. The friction element consists of a core plate 1 of sheet metal, having a central aperture 2 permitting the element to be carried by a shaft, the aperture being provided with internal splines 3 for engagement with complementary external splines on the shaft.
The core plate 1 carries friction linings 4, 5 respectively at either side thereof which provide the braking surfaces of the disc.
In order to produce a friction element of the general type illustrated in Fig. 1, the method of the invention may conveniently be carried out using the apparatus illustrated in Figs. 2 to 4 which respectively illustrate different stages of the method.
The moulding apparatus shown in Fig. 2 includes an outer ring 6 mounted on and surrounding an annular support 7, the ring being urged upwardly by resilient means, shown as springs 8, to a position in which, in combination with the support 7, it partially defines an initial mould cavity 9 which is completed by the insertion within the support 7 of an inner lower core 10 resting on an annular support flange 11 carried by the support 7. The first stage in the process is to fill the mould cavity 9 completely with particulate friction material 12 so that the upper surface of the material is flush with the upper surface of the ring 6. It is preferred to fill the mould cavity by a sweep filling technique using one or more arms or blades to sweep material into the cavity and level the upper surface thereof.It would be possible to employ alternative filling techniques which may also include a metering function.
An annular metal core plate 1 3 (Fig. 2) is formed by cutting or stamping from stock sheet material and prepared for use by degreasing with a suitable solvent, and subsequently shot blasted to ensure that all foreign material is removed from its major surfaces.
The plate is then coated with an adhesive material which is preferably a thermosetting adhesive of the nitrile-phenolic type. The adhesive is applied at least over the area to be covered by the friction lining and the core plate is inserted into the apparatus on top of the material 12 filling the mould cavity 9. The outer ring 6 is then raised by an appropriate amount above the core plate and an upper core member 14 inserted within the outer ring to define the inner radial extremity of an upper mould cavity 15, the outer radial extremity of which is defined by the outer ring 6.
This cavity is then filled with particulate material in the same way as the cavity 9.
An annular press tool 16 of suitable dimen scions is then brought into contact with the material in the mould cavity 15 and a cold pressing operation is commenced using á pressure of approximately 2.5 tonnes per square inch of friction material. Typically, the pressure is continued for between 15 and 30 seconds. The press tool is then removed, the outer ring 6 is lowered and the upper core 14 removed, permitting the assembly of core plate and pressed lining material to be lifted from the apparatus.
The next step is curing of the resin so that this becomes fully operative as a binder. Curing is effected by application of heat to the assembly and this is conveniently accomplished by placing the assembly between a pair of metal plates heated to a temperature in the region of 250 C. The plates also apply a light pressure to the assembly, typically about 2 p.s.i., which is sufficient to prevent disintegration of the assembly until curing is effected.
The curing operation is continued for about 15 minutes under the sustained light pressure. It is important that the temperature be raised quickly to heat the resin and enable it to flow and become distributed throughout the material before curing takes place since this optimises the binding action of the resin.
The heating may be carried out completely between the aforesaid plates, or alternatively the friction element may be removed after an initial short heating period and heating completed by passing the plates through a tunnel oven. Heating may alternatively be performed by other means such as induction heating.
Heating of the assembly also cures the adhesive to ensure firm attachment of the lining material to the core plate. After cooling, it may be necessary to machine the lining material to the correct dimensions and oil grooves may also be cut therein, although the latter may alternatively be moulded into the lining by suitable shaping of the dies.
A typical formulation of the composition of the friction lining material is phenolic resin binder and graphite in a ratio of approximately 40:60 by percentage volume. The formulation may also advantageously include fine mineral fillers, such as alumina and silica; metal particles such as copper and zinc; organic particles such as rubber and friction dust; and fibres of materials such as cotton, carbon and steel.
Because of the difficulty of achieving a satisfactory mould fill with a formulation of this kind, particularly when fine particles of 10 microns and less are included, which is often the case with mineral fillers and various fibres, the method of the invention preferably includes a treatment of the formulatid to make it suitable for grading into a narrow particle range of between approximately 200 and 400 microns.
The formulation is treated, before being used for moulding, by forming a wet mix of ingredients including a solution of the resin binder which coats the particles and causes them to agglomerate. Suitable solvents for the resin are methanol, ethanol and acetone.
When the mixture is dried by driving off the solvent, the resulting dry powder may be pulverised and classified to produce particles within the ideal particle size range referred to above. The treatment process is described in more detail in our co-pending Application en titlted "A Method of Making a Particulate Composition".
The method of the invention is seen to provide a convenient and effective method of making a friction element which, because of the cold moulding technique employed and separate heating of the assembly after moulding, provides a relatively short press cycle time as compared with conventional hot pressing techniques and also facilitates setting dimensional tolerances of the various parts of the tool since the latter is maintained at ambient temperature. The cold pressing of the lining composition provides good porosity of the moulded lining material, this being enhanced by the wet mixing and grading technique described above which negates any significant variation in batch to batch particle sizes of the constituents.

Claims (18)

1. A method of making a friction element comprising forming in a mould cavity a layer of particulate friction material containing an unactivated binder, placing a core plate in contact with said layer over an area of the plate on which a friction lining is to be formed, applying pressure to the core plate and layer sufficient to cold mould the layer into a homogeneous body of friction material and form an assembly of said body and core plate, and heating the assembly to activate said binder.
2. A method according to Claim 1 wherein the core plate is povided with a layer of bonding or adhesive agent prior to being placed in contact with the particulate layer, whereby said application of pressure, acts to form said assembly of the body and core plate.
3. A method according to Claim 2 wherein the body of friction material is additionally keyed to the core plate by providing one or more suitable keying formations in the latter.
4. A method according to Claim 1 wherein said body is keyed to the core plate by providing one or more suitable keying formations in the latter.
5. A method according to any one of the preceding claims wherein the heating of the assembly after the moulding operation is effected under light pressure which is sufficient to ensure that the shape of the friction body is maintained but not sufficient significantly to affect the porosity of the friction body.
6. A method according to any one of the preceding claims wherein the particulate material is prepared as a wet mix containing a solvent for the unactivated binder.
7. A method according to Claim 6 wherein the binder is a resin.
8. A method according to Claim 7 wherein the mix is heated, prior to the formation of said layer in the mould cavity, to a temperature insufficient to cure the resin, in order to dry the mix.
9. A method according to any one of Claims 6 to 8 wherein the wet mix is prepared either by adding a resin solvent to the dry composition and/or adding a resin solution to the dry mix which may or may not already contain a quantity of resin.
10. A method according to any one of the preceding claims wherein a second layer of particulate friction material is formed on the opposite surface of the core plate to that contacting the first layer.
11. A method according to any one of the preceding claims wherein the formation of said layer in the mould cavity is effected by a sweep filling technique.
12. A method of making a friction element substantially as hereinbefore described.
13. Apparatus for carrying out the method of any one of Claims 1 to 12 comprising a die assembly having a mould cavity, means for introducing a quantity of particulate friction material into the cavity, pressure means to apply pressure between the material and a core plate placed in contact with the material to cold mould the layer into a homogeneous body of friction material and form an assembly of said body and core plate, and means for heating the moulded assembly.
14. Apparatus according to Claim 13 wherein the die assembly includes a member which is movable between two levels, in which it defines respectively the depths of first and second mould cavities for the formation of layers of friction material, one on each side of the core plate.
15. Apparatus according to Claim 14 wherein the member is movable, after a moulding operation, to an alternative position in which it no longer defines the mould cavities and thereby facilitates removal of the moulded article from the apparatus.
16. Apparatus according to Claim 15 wherein said member is urged by force-applying means away from said alternative position.
17. Apparatus for carrying out the method of any one of Claims 1 to 12 substantially as hereinbefore described with reference to Figs.
2 to 5 of the accompanying drawings.
18. A friction element produced by carrying out the method of any one of Claims 1 to 12.
GB08301046A 1982-01-22 1983-01-14 A method of making a friction element Expired GB2113603B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB08301046A GB2113603B (en) 1982-01-22 1983-01-14 A method of making a friction element

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8201798 1982-01-22
GB08301046A GB2113603B (en) 1982-01-22 1983-01-14 A method of making a friction element

Publications (3)

Publication Number Publication Date
GB8301046D0 GB8301046D0 (en) 1983-02-16
GB2113603A true GB2113603A (en) 1983-08-10
GB2113603B GB2113603B (en) 1985-10-16

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0353481A2 (en) * 1988-07-22 1990-02-07 Automotive Products Plc Method and apparatus for the assembly of friction components
WO1990003526A1 (en) * 1988-09-27 1990-04-05 Automotive Products Plc Bonding apparatus
WO1990003525A1 (en) * 1988-09-27 1990-04-05 Automotive Products Plc Bonding apparatus
WO1997019277A1 (en) * 1995-11-21 1997-05-29 Frimatec Ingenieurgesellschaft Mbh Process for producing friction linings
CN105881893A (en) * 2016-05-26 2016-08-24 安徽贵达汽车部件有限公司 Brake pad pressing device with reserved riveting hole

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0353481A3 (en) * 1988-07-22 1991-11-06 Automotive Products Plc Method and apparatus for the assembly of friction components
EP0353481A2 (en) * 1988-07-22 1990-02-07 Automotive Products Plc Method and apparatus for the assembly of friction components
GB2244764A (en) * 1988-09-27 1991-12-11 Automotive Products Plc Bonding apparatus
EP0365159A1 (en) * 1988-09-27 1990-04-25 Automotive Products Plc Bonding apparatus
GB2239062A (en) * 1988-09-27 1991-06-19 Automotive Products Plc Bonding apparatus
WO1990003525A1 (en) * 1988-09-27 1990-04-05 Automotive Products Plc Bonding apparatus
WO1990003526A1 (en) * 1988-09-27 1990-04-05 Automotive Products Plc Bonding apparatus
GB2239062B (en) * 1988-09-27 1992-06-10 Automotive Products Plc Method and apparatus for bonding friction facings to a carrier plate
GB2244764B (en) * 1988-09-27 1992-09-02 Automotive Products Plc Bonding apparatus
US5250144A (en) * 1988-09-27 1993-10-05 Automotive Products Plc Bonding apparatus
WO1997019277A1 (en) * 1995-11-21 1997-05-29 Frimatec Ingenieurgesellschaft Mbh Process for producing friction linings
CN105881893A (en) * 2016-05-26 2016-08-24 安徽贵达汽车部件有限公司 Brake pad pressing device with reserved riveting hole
CN105881893B (en) * 2016-05-26 2018-08-07 安徽贵达汽车部件有限公司 A kind of brake block preforming device being reserved with riveted holes

Also Published As

Publication number Publication date
GB2113603B (en) 1985-10-16
GB8301046D0 (en) 1983-02-16

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