WO2017164832A1 - Composite-based raw material, a brake lining and its production method - Google Patents
Composite-based raw material, a brake lining and its production method Download PDFInfo
- Publication number
- WO2017164832A1 WO2017164832A1 PCT/TR2017/050114 TR2017050114W WO2017164832A1 WO 2017164832 A1 WO2017164832 A1 WO 2017164832A1 TR 2017050114 W TR2017050114 W TR 2017050114W WO 2017164832 A1 WO2017164832 A1 WO 2017164832A1
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- WIPO (PCT)
- Prior art keywords
- raw material
- product
- weight
- predetermined temperature
- fly ash
- Prior art date
Links
- 239000002994 raw material Substances 0.000 title claims abstract description 37
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 16
- 239000002131 composite material Substances 0.000 title description 7
- 239000010881 fly ash Substances 0.000 claims abstract description 31
- 239000012467 final product Substances 0.000 claims abstract description 26
- 239000000047 product Substances 0.000 claims description 24
- 238000000034 method Methods 0.000 claims description 14
- 244000226021 Anacardium occidentale Species 0.000 claims description 12
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 12
- 239000004760 aramid Substances 0.000 claims description 12
- 229920003235 aromatic polyamide Polymers 0.000 claims description 12
- 235000020226 cashew nut Nutrition 0.000 claims description 12
- NJLLQSBAHIKGKF-UHFFFAOYSA-N dipotassium dioxido(oxo)titanium Chemical compound [K+].[K+].[O-][Ti]([O-])=O NJLLQSBAHIKGKF-UHFFFAOYSA-N 0.000 claims description 12
- 239000010439 graphite Substances 0.000 claims description 12
- 229910002804 graphite Inorganic materials 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 12
- 239000002006 petroleum coke Substances 0.000 claims description 12
- 229920001568 phenolic resin Polymers 0.000 claims description 12
- 239000005011 phenolic resin Substances 0.000 claims description 12
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 11
- 239000000428 dust Substances 0.000 claims description 11
- 229910052959 stibnite Inorganic materials 0.000 claims description 11
- YPMOSINXXHVZIL-UHFFFAOYSA-N sulfanylideneantimony Chemical compound [Sb]=S YPMOSINXXHVZIL-UHFFFAOYSA-N 0.000 claims description 10
- 238000003825 pressing Methods 0.000 claims description 5
- 230000005484 gravity Effects 0.000 claims description 4
- 239000000203 mixture Substances 0.000 claims description 4
- 238000000465 moulding Methods 0.000 claims description 3
- 239000010680 novolac-type phenolic resin Substances 0.000 claims 2
- 239000000843 powder Substances 0.000 claims 1
- 239000002440 industrial waste Substances 0.000 abstract description 3
- 239000000945 filler Substances 0.000 description 6
- 230000002787 reinforcement Effects 0.000 description 4
- 239000011230 binding agent Substances 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000011148 porous material Substances 0.000 description 3
- 210000002268 wool Anatomy 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- 229920003986 novolac Polymers 0.000 description 2
- 239000012779 reinforcing material Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 229910001369 Brass Inorganic materials 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 229910052787 antimony Inorganic materials 0.000 description 1
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- 239000000920 calcium hydroxide Substances 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000002783 friction material Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 239000011490 mineral wool Substances 0.000 description 1
- 229910052961 molybdenite Inorganic materials 0.000 description 1
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 description 1
- 229910052982 molybdenum disulfide Inorganic materials 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000010908 plant waste Substances 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 229910052950 sphalerite Inorganic materials 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000010455 vermiculite Substances 0.000 description 1
- 229910052902 vermiculite Inorganic materials 0.000 description 1
- 235000019354 vermiculite Nutrition 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
- 229910052984 zinc sulfide Inorganic materials 0.000 description 1
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
- F16D69/02—Composition of linings ; Methods of manufacturing
- F16D69/025—Compositions based on an organic binder
- F16D69/026—Compositions based on an organic binder containing fibres
Definitions
- This invention relates to a raw material based on fly ash- added composite material, brake lining which is manufactured from this raw material and its production method.
- Composite brake linings typically consist of four main components. These are friction additives, fillers, binders and reinforcing materials.
- As the friction additive there can be used graphite, Sb 2 S 3 , MoS 2 , ZnS, petroleum coke, cashew dust.
- As filling materials there can be generally used barium sulfate, mica, vermiculite, calcium carbonate, calcium hydroxide, magnesium oxide and zinc oxide.
- rubber and phenolic resins can be used as binders.
- reinforcement materials there can be used steel fibers, iron dust, copper dust, brass, glass fiber, aramid wool, potassium titanate and rock wool.
- the patent document CN101724378 which is in the prior art, refers to a fly ash-resin based friction material.
- the object of the present invention is to realize the production of raw material in which fly ash, an industrial waste, is used and brake lining which is a product manufactured from this raw material.
- the fly ash one of the waste materials of the thermal power plants, can be used in composite brake lining which is the inventive product.
- fly ash is effectively used as a cost-reducing component.
- raw material and product optimally meet the desired characteristics from a brake lining such as stable friction coefficient, low wear rate, high resistance against cracking and thermal fatigue, minimum sensitivity to corrosive environmental conditions. Manufacturing method conditions (pressure, temperature, etc.) of the product are also determined in this direction.
- A Combination of 35-40% fly ash, 18-20 % phenolic resin, 4-6% aramid wool, 7-9% potassium titanate, 8-10% graphite, 3-5% petroleum coke, 3-5% Sb 2 S 3 (antimony sulphide) and 7-10% cashew dust of the raw material of the invention by weight.
- the fly ash which is used in A or B feedstock mentioned above, contains 29-32% Si0 2 , 15.5-18% Al 2 0 3 , 4.1-6.6% Fe 2 0 3 , 33-35.2% CaO, and 0.75-1.25% S0 3 by weight.
- fly ash used in the abovementioned A or B raw materials contains 29% Si0 2 , 15.5% Al 2 0 3 , 4.1% Fe 2 0 3 , 35.2% CaO and 1.25% S0 3 by weight. These are the most acceptable ratios in terms of desired properties for product or final product brake lining.
- fly ash used in the abovementioned C or D raw materials has 1.308 m 2 /gr surface area, 0.004 cm 3 /gr pore volume, 68 ⁇ particle size and 3.03 gr/cm 3 specific gravity.
- the production method of the inventive product includes following steps.
- the inventive product or final product consists of one of the A or B or D or F or G combinations.
- the inventive is a product or a final product which consists of one of the A or B or D or F or G combinations can be used as brake lining in the preferred applications of the invention.
- Figure 1 Flow chart for production method of the inventive product.
- the inventive raw material consists of 35-40% fly ash, 18-20% phenolic resin, 4-6% aramid pulp, 7-9% potassium titanate, 8-10% graphite, 3-5% petroleum coke, 3-5% Sb 2 S 3 (antimony sulphide) and 7-10% cashew dust by weight.
- the inventive product raw material consists of 35% fly ash, 20% phenolic resin, 6% aramid pulp, 9% potassium titanate, 10% graphite, 5% petroleum coke, 5% Sb 2 S 3 (antimony III sulfur) and 10% cashew dust in weight. These ratios are the most acceptable in terms of desired properties for the brake lining final product.
- Ingredients in fly ash of thermal plant waste are determined with XRF, particle size and distribution are measured by Mastersizer 2000ETM device, specific gravity is measured by Le Chatelier bulb, surface area and pore volume are measured by BET analysis. Performing TG/DTA (thermogravimetric/Differential Analysis) is also for choosing the best fly ash type for the inventive raw material and final product.
- the fly ash which is used in an application of the inventive raw material contains 29-32% Si0 2 , 15.5-18% Al 2 0 3 , 4.1-6.6% Fe 2 0 3 , 33-35.2% Ca Ove 0.75-1.25% S0 3 in weight.
- the fly ash which is used in the preferred application of the inventive raw material contains 29% Si0 2 , 15.5% Al 2 0 3 , 4.1% Fe 2 0 3 , 35.2% CaO and 1.25% S0 3 by weight. These ratios are the most acceptable in terms of desired properties for the brake lining final product.
- the fly ash which is used in the preferred application of the invention has 1.308 m 2 /gr surface area, 0.004 cm 3 /gr pore volume, 68 ⁇ particle size and 3.03 gr/cm 3 specific gravity.
- the fly ash which is used in inventive final product can also be used both as reinforcement and filler.
- the effect as filler is ensuring the structural integrity of the final product under thermal and mechanical stress and the effect as reinforcement is increasing the mechanical strength.
- the fenolic resin used in the inventive raw material is novolac type and acts as binder. So it holds brake lining ingredients together.
- Aramid pulp and potassium titanate are used as reinforcement. These increase the mechanical strength too.
- Graphite, petroleum coke, cashew dust and antimony sulphide are used as friction regulator. These ensure that the final product has the proper friction characteristics.
- the final product brake lining has coefficient of friction between 0.25 and 0.55.
- the production method(lOO) of the inventive product is applied according to the following steps.
- pressed material is post cured at 150-160 °C for 3-4 hours.
- the inventive product or final product is used as brake lining in the preferred application of invention.
- the final product obtained from the raw material as a result of the method(lOO) provides features of the brake linings that are currently available on the market like 0.25-0.55 coefficient of friction, 3.83-3.93% mass wear and 4.08-4.26% thick wear (according to SAE J661), 40-50 HRL hardness and 2-3 g/cm 3 density.
- the inventive product or final product consists of 35-40% fly ash, 18-20% phenolic resin, 4- 6% aramid pulp, 7-9% potassium titanate, 8-10% graphite, 3-5% petroleum coke, 3-5% Sb 2 S 3 (antimony sulphide) and 7-10% cashew dust in weight, in an application of the invention.
- the inventive final product in the preferred application of invention consists of 35% fly ash, 20% phenolic resin, 6% aramid pulp, 9% potassium titanate, 10% graphite, 5% petroleum coke, 5% Sb 2 S 3 (antimony sulphide) and 10% cashew dust by weight.
- the inventive brake lining is developed to provide optimum mechanical and physical properties, in particular coefficient of friction and wear properties which are the same in commercial brake linings.
- the inventive final product will be a cost-reductive, environment-friendly and marketable application.
- the inventive method (100) also will be able to allow industrial production of the product.
- the invention is not limited with the applications described above; and a technically qualified person can easily find new applications of the invention. Such applications must be considered as part of the invention protection to be achieved through the Claims.
Landscapes
- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Braking Arrangements (AREA)
Abstract
The invention is about a raw material that is made of fly ash which is an industrial waste, a brake lining as a final-product from this raw material and its production method (100). The inventive final product effectively fulfills the features of a brake lining, having particularly a friction coefficient between 0.25 and 0.55, wear values between 3.83 and 3.93% in weight and 4.08-4.26% in thickness, a hardness around 40-50 HRL and a density around 2-3 g/cm3.
Description
COMPOSITE-BASED RAW MATERIAL, A BRAKE LINING AND ITS PRODUCTION
METHOD
Technical Field of the Invention
This invention relates to a raw material based on fly ash- added composite material, brake lining which is manufactured from this raw material and its production method.
Prior Art
Composite brake linings typically consist of four main components. These are friction additives, fillers, binders and reinforcing materials. As the friction additive, there can be used graphite, Sb2S3, MoS2, ZnS, petroleum coke, cashew dust. As filling materials, there can be generally used barium sulfate, mica, vermiculite, calcium carbonate, calcium hydroxide, magnesium oxide and zinc oxide. In addition, rubber and phenolic resins can be used as binders. As reinforcement materials, there can be used steel fibers, iron dust, copper dust, brass, glass fiber, aramid wool, potassium titanate and rock wool.
In particular, due to the fact that the fillers and reinforcing materials are expensive, causes the producers to seek for other substances in order to reduce the cost. In other words, this seeking has led to the idea that industrial waste materials can be used in the production of composite brake lining. In this direction, fly ash, a waste of thermal power plants, can be used in raw materials for production of composite brake lining.
Composite brake linings with fly ash in the prior art cannot meet the characteristics such as stable friction coefficient, low wear rate, low sound level, lightness, corrosion resistance and long life performance in an optimum manner according to a classical (fly ash-free) brake lining. Studies carried out by producers in this regard are ongoing.
The patent document CN101724378, which is in the prior art, refers to a fly ash-resin based friction material.
Another patent document US20030055126 in the prior art is related to a brake lining filler material. This filler material contains fly ash in order to reduce cost.
Brief Description of the Invention
The object of the present invention is to realize the production of raw material in which fly ash, an industrial waste, is used and brake lining which is a product manufactured from this raw material.
In this invention, the fly ash, one of the waste materials of the thermal power plants, can be used in composite brake lining which is the inventive product. In the present invention, fly ash is effectively used as a cost-reducing component.
In present invention, raw material and product optimally meet the desired characteristics from a brake lining such as stable friction coefficient, low wear rate, high resistance against cracking and thermal fatigue, minimum sensitivity to corrosive environmental conditions. Manufacturing method conditions (pressure, temperature, etc.) of the product are also determined in this direction.
A: Combination of 35-40% fly ash, 18-20 % phenolic resin, 4-6% aramid wool, 7-9% potassium titanate, 8-10% graphite, 3-5% petroleum coke, 3-5% Sb2S3 (antimony sulphide) and 7-10% cashew dust of the raw material of the invention by weight.
B: Combination of 35% fly ash, 20% phenolic resin, 6% aramid wool, 9% potassium titanate, 10% graphite, 5% petroleum coke, 5% Sb2S3 (antimony sulphide), 10 % cashew dust of the raw material of the invention by weight.
C: Combination of 29-32% Si02, 15.5-18% Al203, 4.1-6.6% Fe203, 33-35.2% CaO, and 0.75- 1.25 % S03 of fly ash by weight.
D: A or B containing C
E: Combination of 29% Si02, 15.5% Al203, 4.1% Fe203, 35.2% CaO and 1.25% S03 of fly ash by weight.
F: A or B containing E
G: A or B or D or F containing Novolak type phenolic resin
In an application of the invention the fly ash, which is used in A or B feedstock mentioned above, contains 29-32% Si02, 15.5-18% Al203, 4.1-6.6% Fe203, 33-35.2% CaO, and 0.75-1.25% S03 by weight.
In the preferred application of the invention, fly ash used in the abovementioned A or B raw materials contains 29% Si02, 15.5% Al203, 4.1% Fe203, 35.2% CaO and 1.25% S03 by weight. These are the most acceptable ratios in terms of desired properties for product or final product brake lining.
In the preferred application of the invention, fly ash used in the abovementioned C or D raw materials has 1.308 m2/gr surface area, 0.004 cm3/gr pore volume, 68 μηη particle size and 3.03 gr/cm3 specific gravity.
The production method of the inventive product includes following steps.
- Homogeneous mixing of one of the A or B or D or F of G combinations
Molding of the mixture
Pressing the raw material at predetermined temperature and pressure
Curing the pressed material at a predetermined temperature for a predetermined period
The inventive product or final product consists of one of the A or B or D or F or G combinations.
The inventive is a product or a final product which consists of one of the A or B or D or F or G combinations can be used as brake lining in the preferred applications of the invention. Explanation of Figures:
Figure 1: Flow chart for production method of the inventive product.
Detailed Description of the Invention
The inventive raw material consists of 35-40% fly ash, 18-20% phenolic resin, 4-6% aramid pulp, 7-9% potassium titanate, 8-10% graphite, 3-5% petroleum coke, 3-5% Sb2S3 (antimony sulphide) and 7-10% cashew dust by weight.
In the preferred application of the invention, the inventive product raw material consists of 35% fly ash, 20% phenolic resin, 6% aramid pulp, 9% potassium titanate, 10% graphite, 5% petroleum coke, 5% Sb2S3 (antimony III sulfur) and 10% cashew dust in weight. These ratios are the most acceptable in terms of desired properties for the brake lining final product. Ingredients in fly ash of thermal plant waste are determined with XRF, particle size and distribution are measured by Mastersizer 2000E™ device, specific gravity is measured by Le Chatelier bulb, surface area and pore volume are measured by BET analysis. Performing TG/DTA (thermogravimetric/Differential Analysis) is also for choosing the best fly ash type for the inventive raw material and final product.
The fly ash which is used in an application of the inventive raw material contains 29-32% Si02, 15.5-18% Al203, 4.1-6.6% Fe203, 33-35.2% Ca Ove 0.75-1.25% S03 in weight. The fly ash which is used in the preferred application of the inventive raw material contains 29% Si02, 15.5% Al203, 4.1% Fe203, 35.2% CaO and 1.25% S03 by weight. These ratios are the most acceptable in terms of desired properties for the brake lining final product. The fly ash which is used in the preferred application of the invention has 1.308 m2/gr surface area, 0.004 cm3/gr pore volume, 68 μηη particle size and 3.03 gr/cm3 specific gravity.
The fly ash which is used in inventive final product can also be used both as reinforcement and filler. The effect as filler is ensuring the structural integrity of the final product under thermal and mechanical stress and the effect as reinforcement is increasing the mechanical strength.
The fenolic resin used in the inventive raw material is novolac type and acts as binder. So it holds brake lining ingredients together.
Aramid pulp and potassium titanate are used as reinforcement. These increase the mechanical strength too.
Graphite, petroleum coke, cashew dust and antimony sulphide are used as friction regulator. These ensure that the final product has the proper friction characteristics. The final product brake lining has coefficient of friction between 0.25 and 0.55.
The production method(lOO) of the inventive product is applied according to the following steps.
Homogeneous mixing of one of the above mentioned raw material combinations components(lOl)
- Molding of the mixture(102)
Pressing the raw material at predetermined temperature and pressure(103) - Curing the pressed material at a predetermined temperature for a predetermined period(104)
In the 101st step of the inventive method(lOO), 35-40% fly ash, 18-20% phenolic resin, 4-6% aramid pulp, 7-9% potassium titanate, 8-10% graphite, 3-5% petroleum coke, 3-5% Sb2S3 (antimony sulphide) and 7-10% cashew dust in weight are mixed.
In the 101st step of preferred application of the inventive method(lOO) 35% fly ash, 20% phenolic resin, 6% aramid pulp, 9% potassium titanate, 10% graphite, 5% petroleum coke, 5% Sb2S3 (antimony sulphide) and 10% cashew dust in weight are mixed.
In the 103rd step of the inventive method(lOO), the raw material pressed at 125-150 °C temperature and 25-35 MPa pressure.
In the 103rd step of preferred application of the inventive method(lOO) the raw material pressed at 150 °C temperature and 25 MPa pressure. These temperature and pressure values are the values that give the most suitable results in terms of desired characteristics of the final product brake.
In the 104th step of an application of the inventive method(lOO), pressed material is post cured at 150-160 °C for 3-4 hours.
In the 104th step of preferred application of the inventive method(lOO) pressed material is post cured at 160 °C for 3 hours. These temperature and time values are the values that give the most suitable results in terms of desired characteristics of the final product brake.
The inventive product or final product is used as brake lining in the preferred application of invention.
The final product obtained from the raw material as a result of the method(lOO) provides features of the brake linings that are currently available on the market like 0.25-0.55 coefficient of friction, 3.83-3.93% mass wear and 4.08-4.26% thick wear (according to SAE J661), 40-50 HRL hardness and 2-3 g/cm3 density.
The inventive product or final product consists of 35-40% fly ash, 18-20% phenolic resin, 4- 6% aramid pulp, 7-9% potassium titanate, 8-10% graphite, 3-5% petroleum coke, 3-5% Sb2S3 (antimony sulphide) and 7-10% cashew dust in weight, in an application of the invention.
The inventive final product in the preferred application of invention consists of 35% fly ash, 20% phenolic resin, 6% aramid pulp, 9% potassium titanate, 10% graphite, 5% petroleum coke, 5% Sb2S3 (antimony sulphide) and 10% cashew dust by weight. The inventive brake lining is developed to provide optimum mechanical and physical properties, in particular coefficient of friction and wear properties which are the same in commercial brake linings.
Industrial Applicability
The inventive final product will be a cost-reductive, environment-friendly and marketable application. The inventive method (100) also will be able to allow industrial production of the product.
The invention is not limited with the applications described above; and a technically qualified person can easily find new applications of the invention. Such applications must be considered as part of the invention protection to be achieved through the Claims.
Claims
1- A raw material or final product which is characterized by being composed of 35-40% fly ash, 18-20% phenolic resin, 4-6% aramid, 7-9% potassium titanate, 8-10% graphite, 3-5% petroleum coke, 3-5% Sb2S3 (antimony sulphide) and 7-10% cashew dust by weight.
2- A raw material or final product which is characterized by being composed of 35% fly ash, 20% phenolic resin, 6% aramid, 9% potassium titanate, 10% graphite, 5% petroleum coke, 5% Sb2S3 (antimony sulphide) and 10% cashew powder by weight.
3- A raw material or final product which is characterized by having a fly ash composed of 29-32% Si02, 15.5-18% AI203, 4.1-6.6% Fe203, 33-35.2% CaO and 0.75-1.25% S03 by weight, as described in Claim 1 or 2.
4- A raw material or final product which is characterized by having a fly ash composed of 29% Si02, 15.5% AI203, 4.1% Fe203, 35.2% CaO and 1.25% S03 by weight, as described in Claim 1 or 2.
5- A raw material or final product which is characterized by including Novolac type phenolic resin as described in Claim 3.
6- A raw material or final product which is characterized by including Novolac type phenolic resin as described in Claim 4.
7- A raw material or final product which is characterized by including a fly ash with around 1.308 m2/gr surface area, 0.004 cm3/gr porosity, 68 μηη grain size and 3.03 gr/cm3 specific gravity, as described in Claim 1 or 2 or 5 or 6.
8- A production method which is characterized by including the following steps (100):
Homogeneous mixing of a raw material composition in any of the Claims above (101)
- Molding of the mixture (102)
Pressing the raw material at a predetermined temperature and pressure (103) Curing the pressed material at a predetermined temperature for a predetermined period(104).
9- A production method (100) which is characterized by having 125-150°C predetermined temperature and 25-35 MPa predetermined pressure, as described in Claim 8, at the step "Pressing the raw material at a predetermined temperature and pressure (103)".
10- A production method (100) which is characterized by having 150°C predetermined temperature and 25 MPa predetermined pressure, as described in Claim 8, at the step "Pressing the raw material at a predetermined temperature and pressure (103)".
11- A production method (100) which is characterized by having 150-160°C predetermined temperature and 3-4 hours as predetermined period, as described in
Claim 9 or 10, at the step "Curing the pressed material at a predetermined temperature for a predetermined period (104)".
12- A production method (100) which is characterized by having 160°C predetermined temperature and 3 hours as predetermined period, as described in Claim 9 or 10, at the step "Curing the pressed material at a predetermined temperature for a predetermined period (104)".
13- A product that is produced with a method described in Claim 8 or 9 or 10 or 11 or 12 (100) and that features a friction coefficient between 0.25 and 0.55, wear values between 3.83 and 3.93% in weight and 4.08-4.26% in thickness, a hardness around 40-50HRL and a density around 2-3 g/cm3.
14- A product that can be used as brake lining, as described in Claim 13.
15- A product -as described in Claim 1 or 2 or 5 or 6- that is produced with a method described in Claim 8 or 9 or 10 or 11 or 12 (100) and that features a friction coefficient between 0.25 and 0.55, wear values between 3.83 and 3.93% in weight and 4.08-4.26% in thickness, a hardness around 40-50 HRL and a density around 2-3 g/cm3.
16- A product that can be used as brake lining, as described in Claim 15.
17- A product -as described in Claim 3- that is produced with a method described in Claim 8 or 9 or 10 or 11 or 12 (100) and that features a friction coefficient between 0.25 and 0.55, wear values between 3.83 and 3.93% in weight and 4.08-4.26% in thickness, a hardness around 20-50HRL and a density around 2-3 g/cm3.
18- A product that can be used as brake lining, as described in Claim 17.
19- A product -as described in Claim 4- that is produced with a method described in Claim 8 or 9 or 10 or 11 or 12 (100) and that features a friction coefficient between 0.25 and 0.55, wear values between 3.83 and 3.93% in weight and 4.08-4.26% in thickness, a hardness around 20-50HRL and a density around 2-3 g/cm3.
20- A product that can be used as brake lining, as described in Claim 19.
21- A product -as described in Claim 7- that is produced with a method described in Claim 8 or 9 or 10 or 11 or 12 (100) and that features a friction coefficient between 0.25 and 0.55, wear values between 3.83 and 3.93% in weight and 4.08-4.26% in thickness, a hardness around 40-50 HRL and a density around 2-3 g/cm3.
22- A product that can be used as brake lining, as described in Claim 21.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE112017001549.9T DE112017001549T5 (en) | 2016-03-25 | 2017-03-24 | RAW MATERIAL ON COMPOSITE BASE, BRAKE LINING AND ITS MANUFACTURE |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TR2016/03846A TR201603846A1 (en) | 2016-03-25 | 2016-03-25 | A COMPOSITE BASED RAW MATERIAL, A FINAL PRODUCT AND ITS PRODUCTION METHOD |
| TR2016/03846 | 2016-03-25 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2017164832A1 true WO2017164832A1 (en) | 2017-09-28 |
Family
ID=58672655
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/TR2017/050114 WO2017164832A1 (en) | 2016-03-25 | 2017-03-24 | Composite-based raw material, a brake lining and its production method |
Country Status (3)
| Country | Link |
|---|---|
| DE (1) | DE112017001549T5 (en) |
| TR (1) | TR201603846A1 (en) |
| WO (1) | WO2017164832A1 (en) |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20030055126A1 (en) | 2001-09-17 | 2003-03-20 | Jianmei Pan | Brake pad lining filler material |
| US20080121474A1 (en) * | 2006-10-28 | 2008-05-29 | Board Of Trustees Of Southern Illinois University | Friction Materials Comprising Coal Combustion And Coal Gasification Byproducts |
| CN101724378A (en) | 2009-11-26 | 2010-06-09 | 盐城工学院 | Fly ash resin base friction material |
| US20140357758A1 (en) * | 2011-05-21 | 2014-12-04 | Ruiyang Automotive Materials (Xiantao) Co.,ltd | Copper-free friction material composition for brake pads |
-
2016
- 2016-03-25 TR TR2016/03846A patent/TR201603846A1/en unknown
-
2017
- 2017-03-24 WO PCT/TR2017/050114 patent/WO2017164832A1/en active Application Filing
- 2017-03-24 DE DE112017001549.9T patent/DE112017001549T5/en not_active Withdrawn
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20030055126A1 (en) | 2001-09-17 | 2003-03-20 | Jianmei Pan | Brake pad lining filler material |
| US20080121474A1 (en) * | 2006-10-28 | 2008-05-29 | Board Of Trustees Of Southern Illinois University | Friction Materials Comprising Coal Combustion And Coal Gasification Byproducts |
| CN101724378A (en) | 2009-11-26 | 2010-06-09 | 盐城工学院 | Fly ash resin base friction material |
| US20140357758A1 (en) * | 2011-05-21 | 2014-12-04 | Ruiyang Automotive Materials (Xiantao) Co.,ltd | Copper-free friction material composition for brake pads |
Also Published As
| Publication number | Publication date |
|---|---|
| DE112017001549T5 (en) | 2018-12-13 |
| TR201603846A1 (en) | 2017-10-23 |
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