GB2241246A - Non-asbestos type friction material - Google Patents

Non-asbestos type friction material Download PDF

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Publication number
GB2241246A
GB2241246A GB9103409A GB9103409A GB2241246A GB 2241246 A GB2241246 A GB 2241246A GB 9103409 A GB9103409 A GB 9103409A GB 9103409 A GB9103409 A GB 9103409A GB 2241246 A GB2241246 A GB 2241246A
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United Kingdom
Prior art keywords
fiber
friction material
asbestos
friction
carbon fiber
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
GB9103409A
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GB9103409D0 (en
GB2241246B (en
Inventor
Mitsuru Kobayashi
Takeo Nagata
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.)
Nisshinbo Holdings Inc
Original Assignee
Nisshinbo Industries Inc
Nisshin Spinning Co 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 Nisshinbo Industries Inc, Nisshin Spinning Co Ltd filed Critical Nisshinbo Industries Inc
Publication of GB9103409D0 publication Critical patent/GB9103409D0/en
Publication of GB2241246A publication Critical patent/GB2241246A/en
Application granted granted Critical
Publication of GB2241246B publication Critical patent/GB2241246B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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    • 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
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00Materials not provided for elsewhere
    • C09K3/14Anti-slip materials; Abrasives
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00Manufacture of articles or shaped materials containing macromolecular substances
    • 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

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

Abstract

The present invention relates to a non-asbestos type friction material for use as a brake pad, brake lining, clutch facing, etc. for vehicles, industrial machinery, etc. The material comprises non-asbestos reinforcing fibre, resin binder and friction- controlling agent, the reinforcing fibre including carbon fibre derived from polyacrylonitrile, in particular carbon fibre having a specific gravity of 1.60-1.74. <IMAGE>

Description

1 1 A :; J_:;, "5 IEE, S P E C I F I C A T 1 0 N
Title of the Invention
NON-ASBESTOS TYPE FRICTION MATERIAL Background of the Invention (1) Field of the Invention
The present invention relates to a non-asbestos type friction material as a brake pad, a brake lining, a clutch facing, etc. for vehicles, industrial machinery, etc. more particularly, the present invention relates to a high performance non-asbestos type friction material excellent in strength and friction property and low in damage of brake drum or brake disc rotor, etc.
(2) Prior Art
Many of conventional friction materials use asbestos as a main component. However, a requirement for non-asbestos type friction material having a higher performance than asbestos type is increasing for the following two reasons. One is that the dust unavoidably generated from asbestos was found to be harmful to human health and consequently the use of asbestos is being regulated. The other is that a friction material having a higher performance than asbestos type is being needed as vehicles, etc. are being made to have a higher performance.
Hence, in recent years, a number of proposals have been made on nonasbestos type friction materials., and many of them use, as a base component, an organic fiber such as 1 an aramid fiber, or an inorganic fiber such as glass fiber, carbon fiber, metallic fiber or the like.
However, conventional friction materials using, as a main reinforcing fiber, an aramid fiber, a glass fiber, a carbon fiber or a metallic fiber have had various problems.
These problems are described on the cases where said friction materials are used in brake pads for vehicles, etc. In friction materials using an aramid fiber, the continuous use of brake increases the surface temperature of friction material, causing the thermal decomposition of aramid fiber and resultant reduction in strength and friction coefficient. In friction materials using a glass fiber, there occurs the falling-off of glass fiber at high temperatures, increasing the amount of wear. Friction materials using a metallic fiber such as steel fiber, copper fiber or the like, although they are excellent in anti-wear property, strength, etc., also have problems. That is, as the temperature goes higher, their friction coefficient (i.e.their effect) becomes abnormally high; their volume increases and their thermal conductivity becomes higher, and accordingly, they may invite burning at high temperatures. Further, the friction materials using a glass fiber or a metallic fiber have a fear of damaging or grinding the brake drum or brake disc rotor, etc.
Meanwhile, when a carbon fiber is used as a reinforcing fiber, it is anticipated that owing to the high reinforcing effect and lubricity of the carbon fiber, there can be obtained a friction material excellent in heat resistance and low in damaging or grinding of brake drum or 2 i 1 1 1 brake disc rotor, etc. However, when a carbon fiber is used in such a large amount that the above-mentioned effect can be obtained actually, there occurs abnormal reduction in friction coefficient owing to the high lubricity effect. Such friction materials using a carbon fiber in a large amount find practical applications as a C/C composite only in brakes for high-speed vehicles such as aeroplanes, racing cars and the like; they have been considered to be inapplicable to automobiles, etc. which are often operated at low speeds, because of their very low friction coefficient and higher wear at low speeds.
There were also proposed friction materials using a material other than mentioned above. Many of them, however, are not sufficient in anti-wear property at high teinperatures of 4000C or more as well as in hightemperature properties, or are instable in frictional behavior.
Summary of the Invention
The present invention has been made in order to solve the above-mentioned problems of conventional non-asbestos type friction materials and provide a non-asbestos type friction material which has excellent anti-wear property and stable friction property not only at ordinary use temperatures but also at high temperatures of 4000C or more, which is low in damage of brake drum or brake disc rotor, etc, and which has high strength.
In order to achieve the above object, the present invention provides a non-asbestos type friction material comprising a reinforcing fiber other than asbestos, a binder 3 -1 such as phenolic resin or the like and a friction-controlling agent such as barium sulfate or the like, wherein part of the reinforcing fiber is a polyacrylonitrile-based special carbon fiber.
Detailed Description of the Invention
The present invention is hereinafter described in de- tail.
In the present invention, as the reinforcing fiber other than asbestos, there is used, for example, one fiber selected from organic fibers (e.g. aramid fiber, acrylic fiber. phenolic fiber, polyvinyl alcohol fiber, cellulose fiber), inorganic fibers (e.g. glass fiber, ceramic fiber, carbon fiber) and metallic fibers (e.g. steel fiber, copper fiber, bronze fiber), or their mixture. These fibers are the same as used in conventional fiber materials.
The present invention is characterized in that part of the reinforcing fiber is a polyacrylonitrile (hereinafter referred to as PAW-based special carbon fiber.
The "PAN-based special carbon fiber" used in the present invention refers to a fiber obtained by spinning PAN, subjecting the resulting PAN fiber to a pretreatment (burning at 200-3000C in air) to obtain a flame- retardant oxidized PAN fiber, and carbonizing the fiber in an inert gas at 800-1,OOOOC so that the resulting carbon fiber has a specific gravity of 1.6-1.74.
In the PAN-based carbon fiber, the specific gravity indicates the carbonization degree of the fiber. In the present invention, this PANbased carbon fiber is prefer- 4 ably used in an amount of 0.5-70% by volume based on the total of friction material.
PAN-based ordinary carbon fibers are obtained by carbonizing the abovementioned oxidized PAN fiber at high temperatures of 1,000-1,5000C and have a specific gravity of 1.75-1.80.
As the binder, there are used, for example, thermosetting resins such as phenolic resin and the like; as the friction-controlling agent, there are used, for example, cashew dust, barium sulfate, calcium carbonate, etc. These are widely used in conventional friction materials.
As described above, the non-asbestos type friction material of the present invention comprises a PAN-based special carbon fiber as part of the reinforcing fiber. This PAN-based carbon fiber, when used as a reinforcing fiber in a friction material, does not significantly reduce the friction coefficient of the friction material, as compared with a PAN- based ordinary carbon fiber of higher specific gravity. Accordingly, it can be used in a large amount and yet can show excellent effects (e.g. reinforcing effect); moreover, the resulting friction material can exhibit properties at least equal to those of asbestos type friction materials or other non-asbestos type friction materials.
The present invention is hereinafter described in more detail by way of Examples.
1 Examples
Thermex (brand name) (a PAN-based special carbon fiber having a specific gravity of 1.65 manufactured by TOHORAYON CO., LTD.) was uniformly mixed with other components in proportions shown in Table 1, by means of a mixer. The resulting mixture was subjected to compression molding in a mold at a temperature of 1500C at a pressure of 300 kg/cm 2 for 9 minutes to obtain friction materials of Examples A to F. (The numerical f igures in Table 1 are shown by % by volume.) The same operation as above was conducted except that the PAN-based special carbon fiber used in each of Examples A to F was replaced by a PAN-based ordinary carbon fiber having a specific gravity of 1.79, to obtain friction materials of Comparative Examples a to f shown in Table 2.
Further, the same operation as above was conducted except that the PANbased special carbon fiber or PAN-based ordinary carbon fiber, aramid fiber and bronze fiber used in each of Examples A to D and each of Comparative Examples a to d were replaced by asbestos, the same aramid fiber, the same copper fiber, or the same aramid fiber and the same bronze fiber, to obtain friction materials of Comparative Examples 9 to j shown in Table 3.
6 Table 1
Components\Examples A B c D E F PAN-based special carbon fiber 0.5 5 10 25 40 70 Aramid fiber 14.5 10 5 Bronze fiber 10 10 10 10 10 Phenolic resin 15 15 15 15 15 15 Cashew dust 10 10 10 10 10 3 Barium sulfate 31 31 31 31 11 zinc oxide 10 10 10 10 10 Magnesium oxide 5 5 5 5 5 2 Graphite 4 4 4 4 4 Total 100 100 100 100 100 100 Table 2
Components\Comparative Examples a b c d e f PAN-based ordinary carbon fiber 0.5 5 10 25 40 70 Aramid fiber 14.5 10 5 Bronze fiber 10 10 10 10 10 Phenolic resin is 15 15 15 15 15 Cashew dust 10 10 10 10 10 3 Barium sulfate 31 31 31 31 11 Zinc oxide 10 10 10 10 10 Magnesium oxide 5 5 5 5 5 2 Graphite 4 4 4 4 4 Total 100 100 100 100 100 100 7 Table 3
Components\Comparative Examples Asbestos Aramid fiber Bronze fiber Phenolic resin Cashew dust Barium sulfate Zinc oxide Magnesium oxide Graphite Total 9 h 25 is 10 31 10 is 31 4 4 4 4 100 100 100 i 15 10 31 10 j 10 15 10 31 10 5 The friction materials of Examples A to F according to the present invention and the friction materials of Comparative Examples a to j were subjected to a friction test by JASO C406 "Braking Device Dynamometer Test Procedure-Passenger Car". Further, a sample was cut out from each friction material after the above test and subjected to a shear test specified by JASO C444-78 'Thysical Properties of Friction Materials Test Procedure".
In Tables 4 to 6, there are shown the results of the above two tests, i.e. (a) friction coefficients in the fade test when each friction material showed surface temperatures of 1000C, 2000C, 3000C, 4000C and 4500C, (b) the wear amount of each friction material after said test, (c) the 8 A J condition of brake drum or brake disc rotor, etc after said test, and (d) the shear strength of each friction material after said test.
Using three other PAN-based special carbon fibers having specific gravities of i.68, 1.70 and 1.72, there were prepared friction materials in the same manner as above; they were subjected to the same tests; the results were almost the same as in Tables 4 to 6.
As described above, the non-asbestos type friction material of the present invention can be advantageously used as a brake pad, a brake lining, a clutch facing, etc. for vehicles, industrial machinery, etc.
9 Table 4
Items\Examples A B c D E F 1000C 0.43 0.43 0.37 0.27 0.27 0.22 Friction 2000C 0.43 0.42 0.36 0.26 0.26 0.22 3000C 0.40 0.38 0.30 0.25 0.24 0.21 Coefficient 4000C 0.35 0.34 0.28 0.22 0.22 0.20 4500C 0.33 0.33 0.28 0.22 0.21 0.20 Wear amount (mm) 1.0 0.8 0.6 0.3 0.4 0.5 Conditon of Slightly 4Good opposite face poor Shear Strength (Kg/m2) 1.0 1.2 1.2 1.5 1.7 2.0 Table 5
Items\Comparative Examples a b c d e f 1000C 0.43 0.42 0.34 0.26 0.23 0.18 Friction 2 0 OOC 0.42 0.40 0.33 0.25 0.22 0.18 3000C 0.39 0.36 0.28 0.22 0.20 0.15 Coefficient 4000C 0.35 0.32 0.23 0.16 0.17 0.13 4500C 0.32 0.30 0.22 0.14 0.14 0.12 Wear amount (mm) 1.0 0.8 0.7 0.5 0.5 0.7 Conditon of Slightly Good -- opposite face poor Shear Strength (Kg/mm2) 0.9 1.0 0.9 1.1 1.2 1.5 11 Items\Comparative Examples 9 1000C Friction 2000C 3000C 4000C 4500C Coefficient Wear amount (mm) Conditon of opposite face Shear Strength (Kg/mm2) d h 0.50 0.43 0.34 0.27 0.3i 0.32 0.30 0.22 0.25 0.19 0.5 1.8 Slightly poor 0.9 Good 0.4 Table 6 i 0.47 j 0.44 0.45 0.43 0.44 0.40 0.52 0.36 0.60 0.34 1.3 1.2 Poor Slightly poor 1.5 0.9 12 1

Claims (3)

What is Claimed Is:
1. A non-asbestos type friction material com- prising a reinforcing fiber other than asbestos, a binder such as phenolic resin or the like and a friction-controlling agent such as barium sulfate or the like, wherein part of the reinforcing fiber is a polyacrylonitrile-based special carbon fiber.
2. A non-asbestos type friction material ac- cording to Claim 1, wherein the polyacryloni t rile -based special carbon fiber has a specific gravity of 1.60-1.74.
3. A non-asbestos type friction material ac cording to Claim 1 or 2, wherein the amount of the poly acrylonitrile-based special carbon fiber is 0.5-70% by vol ume based on the total of the friction material.
13 Published 1991 at The Patent Office. Concept House. Cardiff Road. Newport. Gwent NP9 I RH. Further copies may be obtained from Sales Branch. Unit 6. Nine Mile Point. Cw-mfelinfach. Cross Keys. Newport. NP1 7HZ. Printed by Multiplex techniques ltd. St Mary Cray. Kent. Sales Branch. Unit 6. Nine Mile Point. Cw-mfelinfach. Cross Keys. Newport. NP1 7HZ. Printed by Multiplex techniques ltd. St Mary Cray. Kent.
GB9103409A 1990-02-23 1991-02-19 Non-asbestos type friction material Expired - Fee Related GB2241246B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP2043994A JP2838304B2 (en) 1990-02-23 1990-02-23 Non-asbestos friction material

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GB9103409D0 GB9103409D0 (en) 1991-04-03
GB2241246A true GB2241246A (en) 1991-08-28
GB2241246B GB2241246B (en) 1993-03-24

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KR (1) KR0162242B1 (en)
DE (1) DE4105308A1 (en)
GB (1) GB2241246B (en)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0557905A1 (en) * 1992-02-28 1993-09-01 Nisshinbo Industries, Inc. Friction material composition and process for production thereof
EP0647793A1 (en) * 1993-10-06 1995-04-12 Avco Corporation Low cost, asbestos-free friction material
EP0672842A3 (en) * 1994-03-17 1996-05-01 Osaka Gas Co Ltd Method for producing friction material.
WO1998009093A1 (en) * 1996-08-30 1998-03-05 Borg-Warner Automotive, Inc. Carbon deposit friction lining material
US5998307A (en) * 1993-08-04 1999-12-07 Borg-Warner Autotive, Inc. Fibrous lining material comprising a primary layer having less fibrillated aramid fibers and synthetic graphite and a secondary layer comprising carbon particles
US6001750A (en) * 1993-08-04 1999-12-14 Borg-Warner Automotive, Inc. Fibrous lining material comprising a primary layer having less fibrillated aramid fibers, carbon fibers, carbon particles and a secondary layer comprising carbon particles
US7749562B1 (en) 2004-07-26 2010-07-06 Borgwarner Inc. Porous friction material comprising nanoparticles of friction modifying material
US8021744B2 (en) 2004-06-18 2011-09-20 Borgwarner Inc. Fully fibrous structure friction material
US8397889B2 (en) 2008-03-12 2013-03-19 Borgwarner Inc. Frictional device comprising at least one friction plate
US8603614B2 (en) 2004-07-26 2013-12-10 Borgwarner Inc. Porous friction material with nanoparticles of friction modifying material

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4243516A1 (en) * 1992-12-22 1994-06-23 Teves Gmbh Alfred Brake pads for disc brakes with aluminum brake discs
DE4340017A1 (en) * 1993-11-24 1995-06-01 Textar Gmbh Friction lining mixture for brake and clutch linings
CA2184342A1 (en) * 1995-09-28 1997-03-29 Robert C. Lam Fibrous lining material comprising a less fibrillated aramid and synthetic graphite
FR2858672B1 (en) * 2003-08-07 2006-10-13 Valeo Materiaux Friction FRICTION TRIM AND METHOD FOR MANUFACTURING SUCH FRICTION TRIM
JP5584392B2 (en) * 2007-12-19 2014-09-03 三菱電機株式会社 Method for manufacturing friction member
DE102017115877A1 (en) 2017-07-14 2019-01-17 Schaeffler Technologies AG & Co. KG friction lining
CN112555308A (en) * 2020-11-13 2021-03-26 安徽清水湖新材料技术有限公司 Friction material with reduced inertia and friction lining

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2027724A (en) * 1978-07-07 1980-02-27 Nisshin Spinning Brake lining material
EP0079544A1 (en) * 1981-11-18 1983-05-25 Raybestos-Manhattan, Inc. Fluoroelastomer composite friction material
JPS62255631A (en) * 1986-04-25 1987-11-07 Toyota Motor Corp Frictional member
JPS63125836A (en) * 1986-11-17 1988-05-30 Akebono Brake Res & Dev Center Ltd Frictional material for brake

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS608536A (en) * 1983-06-27 1985-01-17 Toho Rayon Co Ltd Carbon brake and manufacture thereof

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2027724A (en) * 1978-07-07 1980-02-27 Nisshin Spinning Brake lining material
EP0079544A1 (en) * 1981-11-18 1983-05-25 Raybestos-Manhattan, Inc. Fluoroelastomer composite friction material
JPS62255631A (en) * 1986-04-25 1987-11-07 Toyota Motor Corp Frictional member
JPS63125836A (en) * 1986-11-17 1988-05-30 Akebono Brake Res & Dev Center Ltd Frictional material for brake

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0557905A1 (en) * 1992-02-28 1993-09-01 Nisshinbo Industries, Inc. Friction material composition and process for production thereof
US5998307A (en) * 1993-08-04 1999-12-07 Borg-Warner Autotive, Inc. Fibrous lining material comprising a primary layer having less fibrillated aramid fibers and synthetic graphite and a secondary layer comprising carbon particles
US6001750A (en) * 1993-08-04 1999-12-14 Borg-Warner Automotive, Inc. Fibrous lining material comprising a primary layer having less fibrillated aramid fibers, carbon fibers, carbon particles and a secondary layer comprising carbon particles
US5856244A (en) * 1993-08-04 1999-01-05 Borg-Warner Automotive, Inc. Carbon deposit friction lining material
US5958507A (en) * 1993-08-04 1999-09-28 Borg-Warner Automotive, Inc. Carbon deposit friction lining material
EP0647793A1 (en) * 1993-10-06 1995-04-12 Avco Corporation Low cost, asbestos-free friction material
US5508109A (en) * 1993-10-06 1996-04-16 Avco Corporation Fiber blend for low cost, asbestos free friction material
EP0672842A3 (en) * 1994-03-17 1996-05-01 Osaka Gas Co Ltd Method for producing friction material.
WO1998009093A1 (en) * 1996-08-30 1998-03-05 Borg-Warner Automotive, Inc. Carbon deposit friction lining material
US8021744B2 (en) 2004-06-18 2011-09-20 Borgwarner Inc. Fully fibrous structure friction material
US7749562B1 (en) 2004-07-26 2010-07-06 Borgwarner Inc. Porous friction material comprising nanoparticles of friction modifying material
US8603614B2 (en) 2004-07-26 2013-12-10 Borgwarner Inc. Porous friction material with nanoparticles of friction modifying material
US8397889B2 (en) 2008-03-12 2013-03-19 Borgwarner Inc. Frictional device comprising at least one friction plate

Also Published As

Publication number Publication date
JPH03247628A (en) 1991-11-05
KR0162242B1 (en) 1999-01-15
DE4105308A1 (en) 1991-09-05
JP2838304B2 (en) 1998-12-16
GB9103409D0 (en) 1991-04-03
GB2241246B (en) 1993-03-24
KR910021461A (en) 1991-12-20

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Effective date: 20070219