Composite friction elements and pultrusion method of making

A composite friction unit comprising:

• a three dimensional composite body formed of a substantially uniform array of predominately glass strands of reinforcing fibers making up about 35% to about 75% by weight of said body, the reinforcing fibers formed in at least one fabric array of at least one layer of fibers, the fibers bound together by cross stitching, weaving or braiding, the array of fibers being present in a matrix of phenolic resin material, the fibers distributed throughout said body in a predetermined uniform distribution thereby forming a friction unit having a predetermined size and configuration and uniform distribution and alignment of fibers throughout;
• and
• wherein said matrix contains the following materials in the indicated percentages by weight:
• about 0.044% wetting agent, about 5% barite, about 5% Copper, about 3% walnut flour, about 3% talc, about 5.8% graphite, about 4.4% zirconium, about 1.9% aluminum oxide and about 0.7% mold release agent.

A friction unit formed of composite material, comprising:

• a three dimensional composite body formed of a substantially uniform array of predominately glass strands of reinforcing fibers making up between about 35% to about 50% by weight of said body, the reinforcing fibers formed in at least one fabric array of at least one layer of fibers, the fibers bound together in a woven structure, wherein the fibers are under tension in a matrix comprising a mixture of phenolic resin and resorcinol resin and the fibers are distributed throughout said body in a predetermined uniform distribution thereby forming a friction unit having a predetermined size and configuration and uniform distribution and alignment of fibers throughout;
• wherein said friction unit has a friction surface parallel to the primary fibers;
• and
• wherein the matrix comprises about 5 to 10% by weight of graphite powder, about 5 to 10% by weight of copper powder, about 3 to 5% by weight of nut shell flour and one to ten percent by weight of each one of barite, aluminum oxide, zirconium, talc and up to about one percent of mold release and wetting agent.

A friction unit formed of composite material, comprising:

• a three dimensional composite body formed of a substantially uniform array of predominately glass strands of reinforcing fibers making up between about 35% to about 50% by weight of said body, the reinforcing fibers formed in a fabric array with the fibers bound together in a woven structure, said array formed of at least two woven panels wherein fibers of each panel extend into the other panel, the fibers being present under tension in a matrix comprising a mixture of phenolic resin and resorcinol resin, the reinforcing fibers distributed throughout said body in a predetermined uniform distribution thereby forming a friction unit having a predetermined size and configuration with uniform distribution and alignment of fibers throughout;
• wherein said friction unit formed with a friction surface parallel to the primary fibers;
• and
• wherein the matrix comprises about 0.044% by weight wetting agent, about 5% by weight barite, about 5% by weight Copper, about 3% by weight walnut flour, about 3% by weight talc, about 5.8% by weight graphite, about 4.4% by weight zirconium, about 1.9% by weight aluminum oxide and about 0.7% by weight mold release agent.

A friction unit formed of composite material, comprising:

• a three dimensional composite body formed of a substantially uniform array of predominately glass strands of reinforcing fibers making up between about 35% to about 50% by weight of said body, the reinforcing fibers formed in at least one fabric array of at least one layer of fibers, the fibers bound together in a woven structure, wherein the fibers are under tension in a matrix comprising a mixture of phenolic resin and resorcinol resin and the fibers are distributed throughout said body in a predetermined uniform distribution thereby forming a friction unit having a predetermined size and configuration and uniform distribution and alignment of fibers throughout;
• wherein said friction unit has a friction surface parallel to the primary fibers;
• and
• wherein the matrix comprises about 5 to 10% by weight of graphite powder, about 3 to 5% by weight of nut shell flour and one to ten percent by weight of each one of barite, aluminum oxide, talc up to about one percent of mold release and wetting agent.