Fibrous lining material comprising a primary layer having less fibrillated aramid fibers, carbon fibers, carbon particles and a secondary layer comprising carbon particles

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;

• wherein the fibrous base material comprises, in weight percent, based on the weight of the fibrous base material, about 10 to about 50% less fibrillated aramid fiber;
• about 5 to about 20% carbon particles;
• about 5 to about 20% carbon fibers;
• about 15 to about 35% filler material;
• about 3 to about 10% cotton fibers;
• and about 0.5 to about 5% phenolic novoloid fibers.

A process for producing a non-asbestos friction material comprising mixing a phenolic resin with a silicone resin, impregnating a fibrous base material with the silicone-phenolic resin mixture, the fibrous base material comprising a porous primary layer and a secondary layer;

• the primary layer comprising the primary layer, by weight, based on the primary layer about 10 to about 50% less fibrillated aramid fiber;
• about 5 to about 20% carbon particles;
• about 5 to about 25% carbon fibers;
• about 15 to about 35% filler material;
• about 0 to about 10% cotton fibers;
• and about 0.5 to about 5% phenolic novoloid fibers;
• the porous primary layer having an average pore diameter of about 2.0 to about 15 microns;
• the 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 carbon coated impregnated fibrous base material to cure the phenolic resin and the silicone resin.