Back to results
US 5,688,577 AGranted
Multi-directional friction materials
AssigneeR. K. Carbon Fibers, Ltd.
InventorsW. Novis Smith, Toby Burnham
Life of this patent
Estimating the term…
Abstract
The present invention provides a multi-directional friction material made from unidirectional carbonaceous and/or oxidized PAN based fibers. More particularly, the present invention teaches a multi-layered preform having at least three (3) unidirectional fabric layers oriented at different angles respective to each other to provide a superior heat dissipation properties in a friction material.
Claims20
In an improved multi-layered preform for use as a friction material having carbonaceous and/or oxidized polyacrylonitrile based fibers;
- the improvement comprising at least three stacked unidirectional fabric layers;
- each layer having said fibers unidirectional so that a longitudinal axis of each layer is oriented at an angle of x degrees respective to the longitudinal axis of any other layer;
- wherein x is a whole number greater than zero;
- said angle of x degrees being selected from the group consisting of 22.5, 45.0, 67.5, 90.5, 112.5, 135.0, 157.5 and 180.0;
- said fibers of each layer being substantially symmetrically spaced;
- and said layers being needled together to form said multi-layered preform.
3 more elements
A method of making a multi-layered preform for use as a friction material having unidirectional carbonaceous and/or oxidized polyacrylonitrile based fibers;
- said method comprising the steps of:
- (a) feeding a first group of fibrous tows of said fibers onto a first carrier fabric or a first conveyor belt;
- (b) spreading said first group of fibrous tows until said fibers lay flat and cover said carrier fabric or said conveyor belt;
- (c) feeding a second group of fibrous tows of said fibers onto said carrier fabric or said conveyor belt;
- said second group of fibrous tows being oriented at an angle of x degrees respective to said first group of fibrous tows, wherein x is a whole number greater than zero;
- (d) spreading said second group of fibrous tows until said fibers lay flat and cover a layer below;
- (e) feeding a third group of fibrous tows of said fibers onto said carrier fabric or said conveyor belt;
- said third group of fibrous tows being oriented at an angle of x degrees respective to said second group of fibrous tows, wherein x is a whole number greater than zero;
- (f) spreading said third group of fibrous tows until said fibers lay flat and cover a layer below;
- (g) feeding a preselected number of additional groups of fibrous tows of said fibers onto said carrier fabric or said conveyor belt;
- said additional groups of fibrous tows being oriented at an angle of x degrees respective to any one of said previous groups of fibrous tows, wherein x is a whole number greater than zero;
- (h) spreading each additional group of fibrous tows until said fibers lay flat and cover a layer below;
- (i) needling together said fibrous tow layers to form a multi-layered composite;
- (j) cutting said multi-layered composite into segments;
- (k) feeding a plurality of said multi-layered composite segments onto a second carrier fabric or a second conveyor belt;
- (l) needling together said composite segments to form a multi-layered preform;
- and
- (m) cutting said preform into predetermined sizes.
15 more elements
In an improved multi-layered preform for use as a friction material having carbonaceous and/or oxidized polyacrylonitrile based fibers;
- the improvement comprising at least three stacked unidirectional fabric layers and a plurality of nonwoven fabric layers interspersed between said unidirectional fabric layers;
- said nonwoven fabric layers comprising up to about 25 wt % of a total weight of said multi-layered preform;
- wherein a longitudinal axis of each layer is oriented at an angle of x degrees respective to the longitudinal axis of any other layer;
- wherein x is a whole number greater than zero;
- said fibers of each layer being substantially symmetrically spaced;
- and said layers being needled together to form said multi-layered preform.
3 more elements
A method of making a multi-layered preform for use as a friction material having unidirectional carbonaceous and/or oxidized polyacrylonitrile based fibers;
- said method comprising the steps of:
- (a) feeding a first group of fibrous tows of said fibers onto a first carrier fabric or a first conveyor belt;
- (b) spreading said first group of fibrous tows until said fibers lay flat and cover said carrier fabric or said conveyor belt;
- (c) feeding a second group of fibrous tows of said fibers onto said carrier fabric or said conveyor belt;
- said second group of fibrous tows being oriented at an angle of x degrees respective to said first group of fibrous tows, wherein x is a whole number greater than zero;
- (d) spreading said second group of fibrous tows until said fibers lay flat and cover a layer below;
- (e) feeding a third group of fibrous tows of said fibers onto said carrier fabric or said conveyor belt;
- said third group of fibrous tows being oriented at an angle of x degrees respective to said second group of fibrous tows, wherein x is a whole number greater than zero;
- (f) spreading said third group of fibrous tows until said fibers lay flat and cover a layer below;
- (g) feeding a preselected number of additional groups of fibrous tows of said fibers onto said carrier fabric or said conveyor belt;
- said additional groups of fibrous tows being oriented at an angle of x degrees respective to any one of said previous groups of fibrous tows, wherein x is a whole number greater than zero;
- (h) spreading each additional groups of fibrous tows until said fibers lay flat and cover a layer below;
- (i) feeding a top fabric onto said carrier fabric or said conveyor belt;
- (j) needling together said fibrous tow layers to form a multi-layered composite;
- (k) cutting said multi-layered composite into segments;
- (l) feeding a plurality of said multi-layered composite segments onto a second carrier fabric or a second conveyor belt;
- (m) needling together said composite segments to form a multi-layered preform;
- and
- (n) cutting said preform into predetermined sizes.
16 more elements
Dependencies are inferred from the claim text.