Friction element composition

Claim 2

A FRICTION ELEMENT COMPOSITION, COMPRISING A FRICTION IMPARTING ABRASIVE AGENT, AN INORGANIC FILLER AND A BINDER COMPOSITION CONSISTING ESSENTIALLY OF A NON-HYDROXYALKYLATED HYDROXY AROMATIC HYDROCARBON-ALDEHYDE RESOLE CONTAINING SUBSTANTIALLY NO ETHERIFIED AROMATIC HYDROXY GROUPS AND AT LEAST ABOUT 5 PERCENT BY WEIGHT OF A DIFFERENT ALKYLATED HYDROXY AROMATIC HYDROCARBON-ALDEHYDE RESOLE, WHEREIN THE ALKYLATED GROUPS ARE SUBSTITUTED ON THE AROMATIC RING AND ARE SELECTED FROM THE GROUP CONSISTING OF: A. ALKYL GROUPS OF 1 TO 60 CARBON ATOMS, B. CYCLOALKYL GROUPS OF 5 TO 12 CARBON ATOMS, C. ALKYL, ARYL AND CYCLOALKYL KETONIC GROUPS WHEREIN THE HYDROCARBON PORTON IS AS DEFINED IN (A) AND (B) D. ALKYL, ARYL AND CYCLOALKYL CARBOXYLIC GROUPS WHEREIN THE HYDROCARBON PORTION IS AS DEFINED IN (A) AND (B), E. ARYL GROUPS OF 6 TO 24 CARBON ATOMS, AND F. ARYL SUBSTITUTED ALKYL WHEREIN THE ARYL IS PHENYL, LOWER ALKYL-SUBSTITUTED PHENYL OR HYDROXY SUBSTITUTED PHENYL.

Claim 3

The composition of claim 1 comprising from about 95 to about 60 percent by weight of a non-hydroxyalkylated, non-alkylated resole with from about 5 to about 40 percent by weight of a non-hydroxyalkylated, alkylated resole.

Claim 4

The composition of claim 1 wherein the first said resole is the condensation produce of phenol and formaldehyde in an alkaline medium.

Claim 5

The composition of claim 1 comprising from about 5 to about 95 percent by weight of a B-stage non-hydroxyalkylated alkylated resole with from about 95 to about 5 perceNt by weight of an A-stage, non-hydroxyalklylated, alkylated resole.

Claim 6

A friction element composition comprising about 30 to about 60 weight percent asbestos fiber, up to about 55 weight percent of other fillers and friction imparting abrasive agents and about 15 to about 30 weight percent of a binder composition consisting essentially of a non-hydroxyalkylated hydroxy aromatic hydrocarbon-aldehyde resole containing substantially no etherified aromatic hydroxyl groups and at least about 5 percent of a different alkylated hydroxy aromatic hydrocarbon-aldehyde resole, wherein the alkylated groups are substituted on the aromatic ring and are selected from the group consisting of: a. alkyl groups of 1 to 60 carbon atoms, b. cycloalkyl groups of 5 to 12 carbon atoms, c. alkyl, aryl and cycloalkyl ketonic groups wherein the hydrocarbon portion is as defined in (a) and (b), d. alkyl, aryl and cycloalkyl carboxylic groups wherein the hydrocarbon portion is as defined in (a) and (b), e. aryl groups of 6 to 24 carbon atoms, and f. aryl substituted alkyl wherein the aryl is phenyl, lower alkyl-substituted phenyl or hydroxy substituted phenyl.

Claim 7

A friction element composition comprising about 30 to about 60 weight percent asbestos fiber, up to about 55 weight percent of other fillers and friction imparting abrasive agents and about 15 to about 30 weight percent of a binder composition consisting essentially of a non-hydroxyalkylated hydroxy aromatic hydrocarbon-aldehyde resole containing substantially no etherified aromatic hydroxyl groups and at least about 5 percent of a different alkylated hydroxy aromatic hydrocarbon-aldehyde resole, wherein the alkylated groups are substituted on the aromatic ring and are selected from the group consisting of: a. alkyl groups of 1 to 60 carbon atoms, b. cycloalkyl groups of 5 to 12 carbon atoms, c. alkyl, aryl and cycloalkyl ketonic groups wherein the hydrocarbon portion is as defined in (a) and (b), d. alkyl, aryl and cycloalkyl carboxylic groups wherein the hydrocarbon portion is as defined in (a) and (b), e. aryl groups of 6 to 24 carbon atoms, and f. aryl substituted alkyl wherein the aryl is phenyl, lower alkyl-substituted phenyl or hydroxy substituted phenyl.