US2853460A - Binding agent for extrudable brake lining material - Google Patents

Binding agent for extrudable brake lining material Download PDF

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Publication number
US2853460A
US2853460A US501187A US50118755A US2853460A US 2853460 A US2853460 A US 2853460A US 501187 A US501187 A US 501187A US 50118755 A US50118755 A US 50118755A US 2853460 A US2853460 A US 2853460A
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Prior art keywords
brake lining
extrudable
lining material
binding agent
water
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Expired - Lifetime
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US501187A
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Archibald Ian Wilson
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James Hardie and Coy Pty Ltd
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Hardie & Co Pty Ltd J
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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
    • F16D69/021Composition of linings ; Methods of manufacturing containing asbestos
    • F16D69/022Composition of linings ; Methods of manufacturing containing asbestos in the form of fibres
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G16/00Condensation polymers of aldehydes or ketones with monomers not provided for in the groups C08G4/00 - C08G14/00
    • C08G16/02Condensation polymers of aldehydes or ketones with monomers not provided for in the groups C08G4/00 - C08G14/00 of aldehydes
    • C08G16/0293Condensation polymers of aldehydes or ketones with monomers not provided for in the groups C08G4/00 - C08G14/00 of aldehydes with natural products, oils, bitumens, residues
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L61/00Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
    • C08L61/04Condensation polymers of aldehydes or ketones with phenols only
    • C08L61/06Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
    • C08L61/14Modified phenol-aldehyde condensates

Definitions

  • Brake lining materials or mixtures which may be formed extrusively are well known. They invariably consist in a composition of dough-like consistency composed 'the solvent creates a fire or toxic hazard, it is responsible for slow curing rates due to tenacious retention of the solvent in the composition, the extruded articles shrink while drying out, the solvent is expensive in first cost, some of it is inevitably lost during manufacture, and insofar as it is recoverable for re-use such recovery can be achieved only at considerable expense.
  • a binder for an extrudable brake lining material of the kind referred to above consists of an aqueous resin emulsion made from the ingredients (a) to (d) and in the proportion ranges thereof set forth in the following Table A.
  • the proportions of phenol and cashew nut shell liquid in the extreme, may be (d) Water 100% of cashew nut shell liquid and zero percent of phenol; that is, or the cashew nut shell liquid may be used by itself as the resinifying ingredient and still give a serviceable brake linking material.
  • both of these ingredients are used with neither being present in any smaller proportion than one-quarter the amount of the other.
  • the phenol employed may comprise, in addition or instead of ordinary phenol, substituted phenols, cresols, xylenols, or mixtures of any two or more thereof in any proportions.
  • The-cashew nut shell liquid may be raw or it may be thickened, by use of dehydrating agents, in known manner.
  • the raw liquid is first heattrcated in known manner; for example, by preheating to 250300 F. and sending it through a counter 7 water is included due to the use of formalin or other aqueous solution, the amount of water to constitute ingredient (d) above is correspondingly adjusted.
  • the alkaline catalyst is caustic soda or other well known resin catalyst such as caustic potash for example.
  • the catalyst may be previously dissolved in the water of ingredient (d).
  • the ingredients (a) to (d) are simply mixed together, for example, in a slow speed stirrer with, for preference, a trace. of a common anti-foaming agent such as that known as D. C. 200 Fluid.
  • the mixed ingredients are thenheated to the boiling point of the mixture (about 207 F.) and refluxed in a vessel fitted with a stirrer and a reflux condenser open to atmosphere which prevents loss of water during refluxing.
  • the refluxing is carried out at the mentioned boiling temperature and at atmospheric pressure until the desired viscosity of the mixture is reached.
  • the reflux time will depend on the relative proportions of the resinifying material ingredients.
  • the refluxing time may be only a few minutes, where- Table B (a) Phenol 0.7541h01. ('b1)i'Hieiat treated cashew nut shell qu 0.246mo1. (c) Formalln 0.85 mol. (d) Caustic soda 1% of the combined weight of mgre weight of ingredients (a) and (b).
  • a brake lining material (a) Water Although the dominant ingredients of a brake lining material are a fibrous material and a binder as discussed above, usual friction dusts and colouring agents may be added in accordance with known practice. Typical examples of mineral fillers for inclusion in the mix are barytes, magnesium oxide, manganese dioxide, and there are many others. Any selected proportion of a thermosetting resin powder may also be added in accordance with current practice.
  • the fibrous material is preferably chrysotile asbestos fibre treated by usual methods of crushing and blowing to open the fibre bundles and thus facilitate mixing.
  • the asbestos is preferably dried before incorporation with the other ingredients.
  • the lining material composition also includes a curing in such proportion of the agent as will approximately.
  • the lining material ingredients other than the binder emulsion, are first mixed together dry; if necessary, the ingredients are ground together in a hammer mill or the like before blending with the asbestos.
  • the mixed dry materials are then mixed with the binder resin emulsion, for example in a dough mixer type of machine.
  • the finally mixed material is then extruded as brake lining strip which is cut to lining lengths and cured in usual manner, for example by placement in a. curing oven at 400 F. for about'two hours.
  • the binder emulsion is equivalent to 24.0 parts by Weight of anhydrous resin and the water in the mixture will constitute approximately 9.3% or the weight of the mixture.
  • the binder emulsion is equivalent to 18.0 parts by liqui (b) Formaldehydm weight of anhydrous resin and the water in the mixture will constitute approximately 7% of the weight of the mixture.
  • cashew nut shell liquid as being included in molecular proportions, it is not certain whether this ingredient can be assigned molecular weight. However, the proportions of cashew nut-shell liquid are not closely critical, and from experi ment, we have found that if it be assumed to have a molecular weight-of about 288, the purposes aOf the-invention will be served.
  • a water-resin emulsion binder for extrudable, fibrous brake lining materials consisting of (a) A henol and cashew "nutshell liquid mixture wherein the latter is at least one-quarterth ainount of the former (b) A member selected from the group consisting of formaldehyde, p'araform'aldehyd'e and -furfiural 0.6 to 0.95'm0l.
  • a water-resin emulsion binder for extrudable fibrous brake lining materials consisting of (a) Phenol 0.754 m'ol.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)

Description

United States Patent" r Coy. PtyLLimited, Sydney, New South Wales, Australia, a company of New South Wales No Drawing. pplication April 13, 1955 A Serial N0. 501,187
Claims priority, application Australia April 29, 1954 2 Claims. or. 260-293 Brake lining materials or mixtures which may be formed extrusively are well known. They invariably consist in a composition of dough-like consistency composed 'the solvent creates a fire or toxic hazard, it is responsible for slow curing rates due to tenacious retention of the solvent in the composition, the extruded articles shrink while drying out, the solvent is expensive in first cost, some of it is inevitably lost during manufacture, and insofar as it is recoverable for re-use such recovery can be achieved only at considerable expense.
By this invention the foregoing disabilities are remedied by the ability to employ ordinary water as plasticiser. Some of the advantages in using water as plasticiser will be obvious, in that it is clearly extremely inexpensive, it is not worth recovering hence the recovery problem referred to above is eliminated; and, just as clearly, it-is incapable of constituting a fire or toxic risk. Less obvious advantages, revealed by experiment, show that the composition subject hereof requires a very short curing term (compared with that employing a conventional solvent) and moreover drying out of the articles is unaccompanied by appreciable shrinkage.
According to this invention a binder for an extrudable brake lining material of the kind referred to above, consists of an aqueous resin emulsion made from the ingredients (a) to (d) and in the proportion ranges thereof set forth in the following Table A.
Table A Experiment has shown that the proportions of phenol and cashew nut shell liquid, in the extreme, may be (d) Water 100% of cashew nut shell liquid and zero percent of phenol; that is, or the cashew nut shell liquid may be used by itself as the resinifying ingredient and still give a serviceable brake linking material. For preference, however, both of these ingredients are used with neither being present in any smaller proportion than one-quarter the amount of the other.
The phenol employed may comprise, in addition or instead of ordinary phenol, substituted phenols, cresols, xylenols, or mixtures of any two or more thereof in any proportions.
Paterlted Sept. 23, 1958 The-cashew nut shell liquid may be raw or it may be thickened, by use of dehydrating agents, in known manner. For preference, however, the raw liquid is first heattrcated in known manner; for example, by preheating to 250300 F. and sending it through a counter 7 water is included due to the use of formalin or other aqueous solution, the amount of water to constitute ingredient (d) above is correspondingly adjusted.
The alkaline catalyst is caustic soda or other well known resin catalyst such as caustic potash for example. The catalyst may be previously dissolved in the water of ingredient (d).
The ingredients (a) to (d) are simply mixed together, for example, in a slow speed stirrer with, for preference, a trace. of a common anti-foaming agent such as that known as D. C. 200 Fluid. The mixed ingredients are thenheated to the boiling point of the mixture (about 207 F.) and refluxed in a vessel fitted with a stirrer and a reflux condenser open to atmosphere which prevents loss of water during refluxing. The refluxing is carried out at the mentioned boiling temperature and at atmospheric pressure until the desired viscosity of the mixture is reached. The reflux time will depend on the relative proportions of the resinifying material ingredients.
For example, with a high cashew nut shell liquid content the refluxing time may be only a few minutes, where- Table B (a) Phenol 0.7541h01. ('b1)i'Hieiat treated cashew nut shell qu 0.246mo1. (c) Formalln 0.85 mol. (d) Caustic soda 1% of the combined weight of mgre weight of ingredients (a) and (b).
(a) Water Although the dominant ingredients of a brake lining material are a fibrous material and a binder as discussed above, usual friction dusts and colouring agents may be added in accordance with known practice. Typical examples of mineral fillers for inclusion in the mix are barytes, magnesium oxide, manganese dioxide, and there are many others. Any selected proportion of a thermosetting resin powder may also be added in accordance with current practice.
The fibrous material is preferably chrysotile asbestos fibre treated by usual methods of crushing and blowing to open the fibre bundles and thus facilitate mixing. The asbestos is preferably dried before incorporation with the other ingredients.
The lining material composition also includes a curing in such proportion of the agent as will approximately.
exhaust the combining potential of the resin.
The lining material ingredients, other than the binder emulsion, are first mixed together dry; if necessary, the ingredients are ground together in a hammer mill or the like before blending with the asbestos.
The mixed dry materials are then mixed with the binder resin emulsion, for example in a dough mixer type of machine. The finally mixed material is then extruded as brake lining strip which is cut to lining lengths and cured in usual manner, for example by placement in a. curing oven at 400 F. for about'two hours.
Two typical examples of brake lining mixtures using a binderresin emulsion according hereto are as setforth in the following tables C and D.
Table C Parts by weight Asbestos fibre -a----' 51.0 Friction dust 10.0 Mineral fillers are-lndhfifihfin-.. 13.
Hexamine .-.-'-'-a-- 1.5 Binder emulsion according to Table B hereof 4...... 34.25
The binder emulsion is equivalent to 24.0 parts by Weight of anhydrous resin and the water in the mixture will constitute approximately 9.3% or the weight of the mixture.
Table -D Parts -by weight Asbestos fibre -eas e -t a. a 58.2 Mineral fillers e 15.0 Coloring agent 1.0 Hexamine 1.4 Dry powdered thermosetting resin 6.4 Binder emulsion according to Table B hereof 25.5
The binder emulsion is equivalent to 18.0 parts by liqui (b) Formaldehydm weight of anhydrous resin and the water in the mixture will constitute approximately 7% of the weight of the mixture.
Although in the foregoing description, and in the following claims, reference is made to cashew nut shell liquid as being included in molecular proportions, it is not certain whether this ingredient can be assigned molecular weight. However, the proportions of cashew nut-shell liquid are not closely critical, and from experi ment, we have found that if it be assumed to have a molecular weight-of about 288, the purposes aOf the-invention will be served.
I claim:
1. A water-resin emulsion binder for extrudable, fibrous brake lining materials consisting of (a) A henol and cashew "nutshell liquid mixture wherein the latter is at least one-quarterth ainount of the former (b) A member selected from the group consisting of formaldehyde, p'araform'aldehyd'e and -furfiural 0.6 to 0.95'm0l.
1 mol.
(c an alkaline catai stmflfluu. From 0.75% to 1.25%
of the weight of (a). (d) Wate'r n From 2% to 10% of the Weight of (a).
2. A water-resin emulsion binder for extrudable fibrous brake lining materials consisting of (a) Phenol 0.754 m'ol.
(b) Heat treated cashew nut shell 1% of the combined weight of (a) and (e) Wat-eardrumHunt.-- 5 (it the combined rzrbedght of (a) and ('11.) Caustic soda References Cited in the-file of this patent UNITED STATES PATENTS 1 2,215,596 Seebach e Sept. 24, 1940 2,385,374 Rhodes Sept. 25, 1945 2,499,365 De Groote Mar. 7, 1950 2,534,607 Laher et al. Dec. 19, 1950' Cofek Feb. 19, 1952

Claims (1)

1. A WATER-RESIN EMULSION BINDER FOR EXTRUDABLE, FIBROUS BRAKE LINING MATERIALS CONSISTING OF
US501187A 1954-04-29 1955-04-13 Binding agent for extrudable brake lining material Expired - Lifetime US2853460A (en)

Applications Claiming Priority (3)

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AU1079829X 1954-04-29
AU776490X 1954-04-29
AU2853460X 1954-04-29

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3207717A (en) * 1959-12-21 1965-09-21 Minnesota Mining & Mfg Thermoset copolymers
US4096108A (en) * 1976-05-17 1978-06-20 The Dow Chemical Company Thermosettable resins and frictional materials made therefrom
US6132549A (en) * 1997-02-27 2000-10-17 Borden Chemical, Inc. Wood-product laminated composites
CN103470666A (en) * 2013-09-02 2013-12-25 安徽省中力车辆制动系统制造有限公司 Clean composite ceramic fiber brake pad
CN103267076B (en) * 2013-05-20 2015-10-14 江西元邦摩擦材料有限责任公司 A kind of Nanocomposites modified resin base vehicle brake-holder block

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2078617A (en) * 1934-02-08 1937-04-27 American Brakeblok Corp Friction element and bond therefor
US2215596A (en) * 1935-01-24 1940-09-24 Union Carbide & Carbon Corp Process of preparing resinous compositions
US2385374A (en) * 1942-12-03 1945-09-25 Pennsylvania Coal Products Com Aqueous bonding composition
US2499365A (en) * 1947-03-07 1950-03-07 Petrolite Corp Chemical manufacture
US2534607A (en) * 1948-07-01 1950-12-19 Lasco Brake Products Corp Molded brake lining
US2586150A (en) * 1948-12-31 1952-02-19 Raybestos Manhattan Inc Friction material and method of making same

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2078617A (en) * 1934-02-08 1937-04-27 American Brakeblok Corp Friction element and bond therefor
US2215596A (en) * 1935-01-24 1940-09-24 Union Carbide & Carbon Corp Process of preparing resinous compositions
US2385374A (en) * 1942-12-03 1945-09-25 Pennsylvania Coal Products Com Aqueous bonding composition
US2499365A (en) * 1947-03-07 1950-03-07 Petrolite Corp Chemical manufacture
US2534607A (en) * 1948-07-01 1950-12-19 Lasco Brake Products Corp Molded brake lining
US2586150A (en) * 1948-12-31 1952-02-19 Raybestos Manhattan Inc Friction material and method of making same

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3207717A (en) * 1959-12-21 1965-09-21 Minnesota Mining & Mfg Thermoset copolymers
US4096108A (en) * 1976-05-17 1978-06-20 The Dow Chemical Company Thermosettable resins and frictional materials made therefrom
US6132549A (en) * 1997-02-27 2000-10-17 Borden Chemical, Inc. Wood-product laminated composites
CN103267076B (en) * 2013-05-20 2015-10-14 江西元邦摩擦材料有限责任公司 A kind of Nanocomposites modified resin base vehicle brake-holder block
CN103470666A (en) * 2013-09-02 2013-12-25 安徽省中力车辆制动系统制造有限公司 Clean composite ceramic fiber brake pad

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