US4339021A
Expired / Lapsed
US
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Carbon fiber reinforced carbon friction element and method of making
Assignee: TOLHO BESLON Co Ltd
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Filing: 1980-07-18
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Granted: 1982-07-13
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Expires: 2000-07-18
Abstract
Abstract A friction material comprising a carbon fiber reinforced carbon with an oxidation temperature of at least 800° C. and a crystallinity index of matrix carbon of from 2.3 to 5.0, a process for the production of the same, and a friction element comprising the same.
Inventors
- 👤 Hiroyuki Kosuda
- 👤 Kenji Niijima
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 08:39
CPC Classifications
F; F16; F16D; F16D69/00; F16D69/02; F16D69/023; Y; Y10; Y10S; Y10S428/00; Y10S428/902; Y10T; Y10T428/00; Y10T428/24; Y10T428/24942; Y10T428/24992; Y10T428/29; Y10T428/2913; Y10T428/2916; Y10T428/2918; Y10T428/292; Y10T428/30
Claims Analysis
Total Claims: 31
Claim 1
Independent Claim
197 words
A carbon fiber reinforced carbon friction element containing matrix carbon and, as a reinforcing fiber, at least one carbon fiber, wherein the crystallinity index R of the matrix carbon is from about 2.3 to 5.0, which carbon fiber reinforced carbon friction element contains an antioxidant in an amount of from about 0.02 to 0.5% by weight of the total weight of the carbon fiber reinforced carbon friction element, wherein the oxidation temperature T 0 is at least about 800° C. due to antioxidation processing during the production of the carbon fiber reinforced carbon friction element after the formation of the matrix carbon or after the completion of production thereof by incorporating an antioxidant therein by impregnating a solution of the antioxidant therein, the amount of the antioxidant being sufficient to increase the oxidation temperature T 0 of the carbon fiber reinforced carbon to about 800° C. or more, said matrix carbon being subjected to heat-treatment at a temperature of from about 1200° C. to about 2400° C. at least once during the production of the carbon fiber reinforced friction element to control the R value thereof to be in a range of from about 2.3 to 5.0.
Claim 2
Dependent Claim
197 words
A carbon fiber reinforced carbon friction element containing matrix carbon and, as a reinforcing fiber, at least one carbon fiber, wherein the crystallinity index R of the matrix carbon is from about 2.3 to 5.0, which carbon fiber reinforced carbon friction element contains an antioxidant in an amount of from about 0.02 to 0.5% by weight of the total weight of the carbon fiber reinforced carbon friction element, wherein the oxidation temperature T 0 is at least about 800° C. due to antioxidation processing during the production of the carbon fiber reinforced carbon friction element after the formation of the matrix carbon or after the completion of production thereof by incorporating an antioxidant therein by impregnating a solution of the antioxidant therein, the amount of the antioxidant being sufficient to increase the oxidation temperature T 0 of the carbon fiber reinforced carbon to about 800° C. or more, said matrix carbon being subjected to heat-treatment at a temperature of from about 1200° C. to about 2400° C. at least once during the production of the carbon fiber reinforced friction element to control the R value thereof to be in a range of from about 2.3 to 5.0.
Claim 3
Dependent Claim
32 words
A carbon fiber reinforced carbon friction element as in claim 1, wherein the reinforcing fiber content is from about 20% to 65% by volume based on the total volume of the element.
Claim 4
Dependent Claim
24 words
A carbon fiber reinforced carbon friction element as in claim 1, wherein the antioxidant comprises at least one of phosphorus, boron and compounds thereof.
Claim 5
Dependent Claim
67 words
A carbon fiber reinforced carbon friction element as in claim 1, wherein the production of the carbon fiber reinforced carbon element comprises the steps of impregnating the reinforcing fiber with a carbonizable thermosetting resin, molding, calcining to carbonize the thermosetting resin and impregnating the thus obtained element with a carbonizable resin and carbonizing by calcination to thereby increase the density of the carbon fiber reinforced carbon element.
Claim 6
Dependent Claim
28 words
A carbon fiber reinforced carbon friction element as in claim 4, wherein the carbonizable thermosetting resin is at least one of a phenol resin and a furan resin.
Claim 7
Dependent Claim
38 words
A carbon fiber reinforced carbon friction element as in claim 4, wherein the carbonizable resin used to increase the density is at least one of a phenol resin, a furan resin, a petroleum pitch, coal tar and asphalt.
Claim 8
Dependent Claim
37 words
A carbon fiber reinforced carbon friction element as in claim 1, wherein the production of the carbon fiber reinforced carbon element includes a heat-treatment step at from about 1,300° C. to 2,100° C., in a non-oxidizing atmosphere.
Claim 9
Dependent Claim
54 words
A carbon fiber reinforced carbon friction element as in claim 6, wherein the carbonizable resin is at least one of a phenol resin, a furan resin and coal tar and the production of the carbon fiber reinforced carbon includes a heat-treatment step at from about 1,300° C. to 2,400° C. in a non-oxidixing atmosphere.
Claim 10
Dependent Claim
49 words
A carbon fiber reinforced carbon friction element as in claim 6, wherein the carbonizable resin is at least one of petroleum pitch and asphalt, and the production of the carbon fiber reinforced carbon includes a heat-treatment step at from about 1,200° C. to 2,100° C. in a non-oxidizing atmosphere.
Claim 11
Dependent Claim
36 words
A process for producing a carbon fiber reinforced carbon friction element as in claim 1, wherein the carbon fiber reinforced carbon element comprises a reinforcing fiber having carbon deposited thereon by a chemical vapor deposition method.
Claim 12
Dependent Claim
37 words
A carbon fiber reinforced carbon friction element as in claim 10, wherein the deposition of carbon on the reinforcing fiber includes a heat-treatment step conducted at from about 1,200° C. to 2,100° C. in a non-oxidizing atmosphere.
Claim 13
Dependent Claim
45 words
A carbon fiber reinforced carbon friction element as in claim 1, wherein the production steps comprise impregnating the reinforcing fiber with a carbonizable thermosetting resin, molding, calcining to carbonize the resin, and increasing the density of the calcined product by a chemical vapor deposition method.
Claim 14
Dependent Claim
35 words
A carbon fiber reinforced carbon friction element as in claim 1, wherein the production of the carbon fiber reinforced carbon includes a heat-treatment at from about 1,200° C. to 2,100° C. in a non-oxidizing atmosphere.
Claim 15
Dependent Claim
43 words
A carbon fiber reinforced carbon friction element as in claim 4, 10 or 12, wherein the production of the carbon fiber reinforced carbon element includes a heat-treatment step whereby R is controlled to from about 2.3 to 5.0 after the first carbonization step.
Claim 16
Dependent Claim
28 words
A carbon fiber reinforced carbon friction element as in claim 1, wherein the friction element is a brake for an aircraft, an automobile, a train or a motorcycle.
Claim 17
Dependent Claim
24 words
A carbon fiber reinforced carbon friction element as in claim 1, wherein the friction element is a pantograph of a train run by electricity.
Claim 18
Dependent Claim
28 words
A carbon fiber reinforced carbon friction element as in claim 14, wherein the step of increasing the density is carried out before the heat-treatment and anti-oxidation processing steps.
Claim 19
Dependent Claim
28 words
A carbon fiber reinforced carbon friction element as in claim 14, wherein the step of increasing the density is carried out between the heat-treatment and anti-oxidation processing steps.
Claim 20
Dependent Claim
28 words
A carbon fiber reinforced carbon friction element as in claim 14, wherein the step of increasing the density is carried out after the heat-treatment and anti-oxidation processing steps.
Claim 21
Dependent Claim
31 words
A carbon fiber reinforced carbon friction element as in claim 1, wherein the reinforcing fiber content is from 25% to 50% by volume based on the total volume of the element.
Claim 22
Dependent Claim
42 words
A carbon fiber reinforced carbon friction element as in claim 3, comprising an additional antioxidant selected from the group consisting of ZnO, CuSO 4 , AlCl 3 , Al(NO 3 ) 3 , Ca(OH) 2 , CaCl 2 and CaCO 3 .
Claim 23
Dependent Claim
22 words
A carbon fiber reinforced carbon friction element as in claim 1, wherein the crystallinity index R is from about 2.5 to 4.5.
Claim 24
Dependent Claim
23 words
A carbon fiber reinforced carbon friction element as in claim 1, wherein the oxidation temperature T 0 is at least about 850° C.
Claim 25
Dependent Claim
35 words
A carbon fiber reinforced carbon friction element as in claim 3, wherein the phosphorus or boron compounds are selected from the group consisting of boric acid, phosphoric acid metal salts thereof and phosphoric acid esters.
Claim 26
Dependent Claim
34 words
A carbon fiber reinforced carbon friction element as in claim 3, wherein the phosphorus or boron compounds are selected from the group consisting of calcium and zinc salts of boric acid and phosphoric acid.
Claim 27
Dependent Claim
21 words
A carbon fiber reinforced carbon friction element as in claim 3, wherein a phosphorus compound is used which is trimethyl phosphate.
Claim 28
Dependent Claim
20 words
A carbon fiber reinforced carbon friction element as in claim 3, wherein said phosphorus or said phosphorus compound is used.
Claim 29
Dependent Claim
20 words
A carbon fiber reinforced carbon friction element as in claim 3, wherein said boron or said boron compound is used.
Claim 30
Dependent Claim
131 words
A process for producing a carbon fiber reinforced carbon friction element containing matrix carbon, and, as a reinforcing fiber at least one carbon fiber, wherein the matrix carbon is heat-treated at such a temperature that the crystallinity index R of the matrix carbon is from about 2.3-5.0 and antioxidation processing is carried out during the production of the carbon fiber reinforced carbon after the formation of the matrix carbon, or after the completion thereof, by incorporating an antioxidant by impregnating a solution of the antioxidant therein in an amount of from about 0.02 to 0.5% by weight of the total weight of the carbon fiber reinforced friction element, which amount is effective to increase the oxidation temperature T 0 of the carbon fiber reinforced carbon to about 800° C. or more.
Claim 31
Dependent Claim
131 words
A process for producing a carbon fiber reinforced carbon friction element containing matrix carbon, and, as a reinforcing fiber at least one carbon fiber, wherein the matrix carbon is heat-treated at such a temperature that the crystallinity index R of the matrix carbon is from about 2.3-5.0 and antioxidation processing is carried out during the production of the carbon fiber reinforced carbon after the formation of the matrix carbon, or after the completion thereof, by incorporating an antioxidant by impregnating a solution of the antioxidant therein in an amount of from about 0.02 to 0.5% by weight of the total weight of the carbon fiber reinforced friction element, which amount is effective to increase the oxidation temperature T 0 of the carbon fiber reinforced carbon to about 800° C. or more.
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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) | 1985-07-12 | 1986-01-11 | 1986-07-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1989-07-12 | 1990-01-11 | 1990-07-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1993-07-12 | 1994-01-11 | 1994-07-13 | $7700.00 | Window Closed / Lapsed |