US4146527A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method for manufacturing a friction material of the resin mold type
Assignee: Aisin Corp
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Filing: 1977-11-01
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Granted: 1979-03-27
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Expires: 1997-11-01
Abstract
Abstract An improvement is disclosed in the dry method for manufacturing friction materials of the resin mold type, especially brake lining pads, which comprises uniformly mixing graphite particles and a phenolic resin in a liquid form, solidifying the mixture, grinding the solidified mixture, and using the ground material as a binder in forming a friction member of the resin mold type. The binder has a graphite powder content of 2-31 wt.% and a phenolic resin content of 69-98 wt.%. Brake linings of improved wear resistance and fade resistance can be produced using this improved method.
Inventors
- 👤 Yasunobu Yamamoto
- 👤 Ryoichi Tomikawa
- 👤 Kazuo Ueda
- 👤 Makoto Imao
- 👤 Toshio Suzuki
- 👤 Tomio Inoue
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 14:37
CPC Classifications
F; F16; F16D; F16D69/00; F16D69/02; F16D69/025; C; C08; C08K; C08K3/00; C08K3/02; C08K3/04; F16D2200/00; F16D2200/006; F16D2200/0069
Claims Analysis
Total Claims: 13
Claim 1
Independent Claim
131 words
A method of preparing a friction material of high wear resistance and high friction coefficient, which comprises: I. preforming a graphite containing binder by uniformly mixing graphite particles with a liquified form of a phenolic resin, wherein said graphite particles are present in from 3 to 43 wt.%, based on the amount of said phenolic resin taken as 100 wt.%, to obtain a resin-graphite mixture; solidifying said resin-graphite mixture; grinding said solidified resin-graphite mixture to a size sufficient for use as said binder; and thereafter Ii. mixing with said graphite containing binder: ground absestos fibers, copper powder, barium sulfate, and rubber dust to obtain a composition for molding; preforming said composition for molding; compression molding said preform; curing said molded article; and finishing said cured article to obtain said friction material.
Claim 2
Independent Claim
131 words
A method of preparing a friction material of high wear resistance and high friction coefficient, which comprises: I. preforming a graphite containing binder by uniformly mixing graphite particles with a liquified form of a phenolic resin, wherein said graphite particles are present in from 3 to 43 wt.%, based on the amount of said phenolic resin taken as 100 wt.%, to obtain a resin-graphite mixture; solidifying said resin-graphite mixture; grinding said solidified resin-graphite mixture to a size sufficient for use as said binder; and thereafter Ii. mixing with said graphite containing binder: ground absestos fibers, copper powder, barium sulfate, and rubber dust to obtain a composition for molding; preforming said composition for molding; compression molding said preform; curing said molded article; and finishing said cured article to obtain said friction material.
Claim 3
Dependent Claim
14 words
The method of claim 1, wherein said phenolic resin comprises a thermosetting resol resin.
Claim 4
Dependent Claim
13 words
The method of claim 1, wherein said phenolic resin comprises a novolak resin.
Claim 5
Dependent Claim
17 words
The method of claim 3, which further comprises adding a curing agent to said solidified resin-graphite mixture.
Claim 6
Dependent Claim
11 words
The method of claim 4, wherein said curing agent is hexamethylenetetramine.
Claim 7
Dependent Claim
17 words
The method of claim 1, wherein said graphite particles have a particle size smaller than 200 mesh.
Claim 8
Dependent Claim
14 words
The method of claim 6, wherein said particle size is smaller than 500 mesh.
Claim 9
Dependent Claim
27 words
The method of claim 1, wherein said liquified form of a phenolic resin comprises a reaction system in which A-stage or B-stage phenolic resin is being prepared.
Claim 10
Dependent Claim
23 words
The method of claim 1, wherein said liquified form of a phenolic resin comprises a reaction system containing A-stage or B-stage phenolic resin.
Claim 11
Dependent Claim
31 words
The method of claim 1, wherein said liquified form of a phenolic resin is the molten material obtained by concentrating and dehydrating a reaction solution containing A-stage or B-stage phenolic resin.
Claim 12
Dependent Claim
20 words
The method of claim 1, wherein said liquified form of a phenolic resin is remelted A-stage or B-stage phenolic resin.
Claim 13
Dependent Claim
64 words
The method of claim 1, wherein: said binder has a resin:graphite ratio of 95:5 wt.%, said graphite particles are smaller than 500 mesh, 10 wt.% of hexamethylenetetramine is added to the resin-graphite mixture prior to grinding to obtain said binder; and wherein said composition comprises: binder: 15.75 wt.% asbestos fiber: 45 wt.% copper powder: 12 wt.% barium sulfate: 12 wt.% rubber dust: 7.25 wt.%.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1982-03-26 | 1982-09-25 | 1983-03-27 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1986-03-26 | 1986-09-25 | 1987-03-27 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1990-03-26 | 1990-09-25 | 1991-03-27 | $7700.00 | Window Closed / Lapsed |