Water slurry process for manufacturing phenolic resin bonded friction materials

A process for producing a friction pad, comprising the steps of:

• mixing a solution of water and from 4-24% by weight of hexamethylenetetramine with a composition of material which includes a dry phenolic resin and hexamethylenetetramine powder to form a slurry;
• communicating said slurry to a mold;
• compressing said slurry in the mold to remove up to 95% of the water in said solution to form a briquette;
• drying said briquette to remove substantially all of said solution and thereby reestablish the dry weight relationship of said phenolic resin and hexamethylenetetramine as in the composition of material;
• and
• curing the briquette at a temperature of up to 600.degree. F. to establish a desired shape and density for the friction pad.

A dustless process for producing organic friction articles comprising the steps of:

• mixing together dry ingredients including a thermosetting phenolic resin containing from 7-15% by weight of hexamethylenetetramine, asbestos and friction modifiers to form a composition of material;
• adding a solution of water and from 13-24% by weight of hexamethylenetetramine to said composition of material to form a slurry;
• communicating a fixed volume of said slurry into a first mold;
• compressing said slurry in said first mold to remove said solution to form a briquette having from 5-10% by weight of water therein;
• drying said briquette through dielectric heating to heat the briquette from the inside to the outside and remove water from the briquette and reestablish substantially the same weight relationship of ingredients therein as in said composition of material;
• and
• compression molding the dried briquette in a second mold to a desired shape and density.

A process for producing a friction pad, comprising the steps of:

• mixing a solution of water and from 13-24% by weight of hexamethylenetetramine with a composition of material which includes a dry phenolic resin and hexamethylenetetramine powder to form a slurry;
• transferring said slurry to a mold;
• compressing said slurry in the mold to remove the solution and form a briquette having from 5-10% by weight of water therein;
• drying said briquette to move additional water and reestablish the dry weight relationship of said phenolic resin and hexamethylenetetramine as in said original composition of material;
• and
• compression molding the briquette at a temperature of up to 600.degree. F. to establish a desired shape and density for the friction pad.