Fibrous lining material comprising a primary layer having less fibrillated aramid fibers and synthetic graphite and a secondary layer comprising carbon particles
AssigneeBorg-Warner Autotive, Inc.
InventorsRobert C. Lam, Marc A. Yesnik, Yih-Fang Chen
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Abstract
The present invention relates to a fibrous base material comprising a primary layer of less fibrillated aramid fibers, synthetic graphite and at least one filler material, and a secondary layer of carbon particles on at least one surface of the fibrous base material for use in a non-asbestos friction material. In certain embodiments, the fibrous base material is impregnated with a phenolic or phenolic-based resin material, including, for example, a mixture of a phenolic resin and a silicone resin to form a friction material having good "break-in" and durability characteristics.
Claims28
A non-asbestos friction material comprising a fibrous base material impregnated with at least one curable resin, the fibrous base material comprising a porous primary layer comprising at least one fibrous material, the porous primary layer having an average pore diameter of about 2.0 to about 15 microns, and a secondary layer comprising carbon particles on at least one surface of the primary layer, the carbon particles being present at about 0.2 to about 20%, by weight, based on the weight of the fibrous base material, the carbon particles covering about 3% to about 90% of the surface area of the primary layer.
A process for producing a non-asbestos friction material comprising coating about 3% to about 90% of the surface area of at least one surface of a porous fibrous base material having an average pore diameter of about 2.5 to about 12 microns with carbon particles, the carbon particles being present at about 0.2 to about 20%, by weight, based on the weight of the fibrous base material impregnating the carbon coated fibrous base material with at least one phenolic resin or modified phenolic resin, and thereafter curing the impregnated carbon coated fibrous base material at a predetermined temperature for a predetermined period of time.
A process for producing a non-asbestos friction material comprising mixing a phenolic resin with a silicone resin, impregnating a fibrous base material with a silicone-phenolic resin mixture, the fibrous base material comprising a porous primary layer comprising at least one fibrous material, the porous primary layer having an average pore diameter of about 2.0 to about 15 microns, and a secondary layer comprising carbon particles on at least one surface of the primary layer, the carbon particles being present at about 0.2 to about 20%, by weight, based on the weight of the fibrous base material, the carbon particles covering about 3% to about 90% of the surface area of the primary layer;
- and thereafter heating the impregnated fibrous base material to cure the phenolic resin and the silicone resin.
Dependencies are inferred from the claim text.