Patent US2685148A successfully refreshed from Google Patents.
Patent US4438004A successfully refreshed from Google Patents.
US4438004A
Expired / Lapsed
US
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Fused metallic friction materials
Assignee: RAYMARK INDUSTRIES Inc TRUMBULL CT A CORP OF CT
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Filing: 1982-12-06
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Granted: 1984-03-20
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Expires: 2002-12-06
Abstract
Abstract A friction material member particularly useful in high load and temperature applications and a method for making the same are disclosed. The friction material member is made by preparing a mixture of sinterable metal particles, carbonaceous material, friction enhancers and curable polymeric resin; the mixture comprising at least about 50 percent by weight of metal particles and sufficient resin to coat and bond the metal particles, carbonaceous material and friction enhancers. The mixture is molded and the resin cured to form a piece in a solid preformed shape corresponding to the shape of the mold. Thereafter, the preformed piece is heated in a substantially oxygen free atmosphere for a time and at temperatures and pressures sufficient to fuse at least a portion of the metal particles into a sintered metal matrix. The preformed piece may be sintered to a metal backing plate during the heating step, or may be welded, brazed or soldered to the plate after heating. The resulting product may be classified as a hybrid friction material, i.e., being a cross between semi-metallic and sintered full metallic friction materials.
Inventors
- 👤 Paul A. Myers
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 13:03
CPC Classifications
C; C10; C10M; C10M111/00; C10M111/04; B; B22; B22F; B22F1/00; B22F1/10; F; F16; F16D; F16D69/00; F16D69/02; C10M2201/00; C10M2201/04; C10M2201/041; C10M2201/042; C10M2201/05; C10M2201/06; C10M2201/061; C10M2201/062; C10M2201/08; C10M2201/081; C10M2201/082; C10M2201/084; C10M2201/10; C10M2201/102; C10M2201/103; C10M2201/16; C10M2201/18; C10M2209/00; C10M2209/10; C10M2209/101; C10N; C10N2040/00; C10N2040/06; C10N2040/30; C10N2040/32; C10N2040/34; C10N2040/36; C10N2040/38; C10N2040/40; C10N2040/42; C10N2040/44; C10N2040/50; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12014; Y10T428/12028; Y10T428/12042
Claims Analysis
Total Claims: 34
Claim 1
Independent Claim
102 words
A method for making friction material members comprising the steps of: preparing a mixture of sinterable metal particles, carbonaceous material and curable polymeric resin, the mixture comprising at least about 50 percent by weight of sinterable metal particles and sufficient curable polymeric resin to coat and bond the metal particles and carbonaceous material; placing the mixture in a mold; curing the resin to form the mixture into a piece in a solid preformed shape corresponding to the shape of the mold; and thereafter heating the preformed piece sufficiently to carbonize the resin and fuse the metal particles into a sintered metal matrix.
Claim 2
Independent Claim
102 words
A method for making friction material members comprising the steps of: preparing a mixture of sinterable metal particles, carbonaceous material and curable polymeric resin, the mixture comprising at least about 50 percent by weight of sinterable metal particles and sufficient curable polymeric resin to coat and bond the metal particles and carbonaceous material; placing the mixture in a mold; curing the resin to form the mixture into a piece in a solid preformed shape corresponding to the shape of the mold; and thereafter heating the preformed piece sufficiently to carbonize the resin and fuse the metal particles into a sintered metal matrix.
Claim 3
Dependent Claim
19 words
A method for making friction material members according to claim 1, wherein friction enhancers are added to the mixture.
Claim 4
Dependent Claim
41 words
The method of claim 2, wherein the friction enhancers are selected from the following group consisting of alumina, aluminum oxide, chrome oxide, magnesium oxide, lead oxide, barium sulfate, quartz, silicon carbide, clay, mica, wollastonite, ceramic fibers, asbestos fibers and mixtures thereof.
Claim 5
Dependent Claim
33 words
The method of claim 1, wherein the sinterable metal particles are selected from the following group consisting of powdered iron, powdered copper, powdered lead, powdered tin, powdered zinc, steel wool and mixtures thereof.
Claim 6
Dependent Claim
25 words
The method of claim 1, wherein the carbonaceous material is selected from the following group consisting of graphite, coke, coal, carbon black and mixtures thereof.
Claim 7
Dependent Claim
25 words
The method of claim 1, wherein the resin is cured by applying sufficient heat and pressure to the molded mixture to cure the resin therein.
Claim 8
Dependent Claim
12 words
The method of claim 1, wherein the resin is a phenolic resin.
Claim 9
Dependent Claim
22 words
A method of making friction material members according to claim 1, wherein the preformed piece is sintered to a metal backing plate.
Claim 10
Dependent Claim
21 words
The method of claim 8, wherein the preformed piece is sintered to the metal backing plate during the step of heating.
Claim 11
Dependent Claim
12 words
The method of claim 8, wherein the metal backing plate is steel.
Claim 12
Dependent Claim
21 words
The method of claim 10, comprising the further step of copper plating the steel backing plate before sintering the member thereto.
Claim 13
Dependent Claim
30 words
The method of claim 8, wherein the sintering of the member to the metal backing plate develops at least about 400 PSI shear strength between the member and the plate.
Claim 14
Dependent Claim
25 words
A method for making friction material members according to claim 1, comprising the further step of welding the sintered member to a metal backing plate.
Claim 15
Dependent Claim
25 words
A method for making friction material members according to claim 1, comprising the further step of brazing the sintered member to a metal backing plate.
Claim 16
Dependent Claim
25 words
A method for making friction material members according to claim 1, comprising the further step of soldering the sintered member to a metal backing plate.
Claim 17
Independent Claim
129 words
A method for making friction material members comprising the steps of: preparing a mixture comprising at least about 60 percent by weight of sinterable metal powders, from about 5 to about 30 percent by weight of carbonaceous material, and from zero to about 15 percent by weight of friction enhancers; adding sufficient curable polymeric resin to coat and bond the metal powders, carbonaceous material and friction enhancers; placing the mixture in a mold; curing the resin to form the mixture into a piece in a solid preformed shape corresponding to the shape of the mold; and thereafter heating the preformed piece in a substantially oxygen free atmosphere for a time and at a temperature sufficient to carbonize the resin and fuse the metal powders into a sintered metal matrix.
Claim 18
Independent Claim
129 words
A method for making friction material members comprising the steps of: preparing a mixture comprising at least about 60 percent by weight of sinterable metal powders, from about 5 to about 30 percent by weight of carbonaceous material, and from zero to about 15 percent by weight of friction enhancers; adding sufficient curable polymeric resin to coat and bond the metal powders, carbonaceous material and friction enhancers; placing the mixture in a mold; curing the resin to form the mixture into a piece in a solid preformed shape corresponding to the shape of the mold; and thereafter heating the preformed piece in a substantially oxygen free atmosphere for a time and at a temperature sufficient to carbonize the resin and fuse the metal powders into a sintered metal matrix.
Claim 19
Independent Claim
117 words
A method for making friction material members comprising the steps of: preparing a mixture of sinterable metal powders, metal fibers, carbonaceous material, friction enhancers and curable polymeric resin, the mixture comprising at least about 50 percent by weight of metal powders and metal fibers, and from about 4 to about 15 percent by weight of curable polymeric resin; placing the mixture in a mold; curing the resin to form the mixture into a piece in a solid preformed shape corresponding to the shape of the mold; and thereafter heating the preformed piece under temperature and compressive pressure conditions to precondition the member to temperature and compressive pressure conditions anticipated during subsequent use of the friction material member.
Claim 20
Independent Claim
117 words
A method for making friction material members comprising the steps of: preparing a mixture of sinterable metal powders, metal fibers, carbonaceous material, friction enhancers and curable polymeric resin, the mixture comprising at least about 50 percent by weight of metal powders and metal fibers, and from about 4 to about 15 percent by weight of curable polymeric resin; placing the mixture in a mold; curing the resin to form the mixture into a piece in a solid preformed shape corresponding to the shape of the mold; and thereafter heating the preformed piece under temperature and compressive pressure conditions to precondition the member to temperature and compressive pressure conditions anticipated during subsequent use of the friction material member.
Claim 21
Dependent Claim
51 words
A method for making a friction material member according to claim 17, wherein the heating step comprises heating the preformed piece in a substantially oxygen free atmosphere for a time and at a temperature sufficient to carbonize the resin and fuse the metal powders and fibers into a sintered metal matrix.
Claim 22
Dependent Claim
35 words
A method for making friction material members according to claim 17, wherein the heating step comprises heating one surface of the preformed piece to fuse the metal powders and fibers proximate to the one surface.
Claim 23
Dependent Claim
8 words
The product of the process of claim 1.
Claim 24
Dependent Claim
45 words
A friction material member comprising: a sintered metal matrix, at least one surface of said metal matrix having carbonaceous material and friction enhancers substantially uniformly distributed therein, said metal matrix comprising from about 50 to about 80 percent by weight of the friction material member.
Claim 25
Dependent Claim
45 words
A friction material member comprising: a sintered metal matrix, at least one surface of said metal matrix having carbonaceous material and friction enhancers substantially uniformly distributed therein, said metal matrix comprising from about 50 to about 80 percent by weight of the friction material member.
Claim 26
Dependent Claim
19 words
A friction material member as in claim 21, further comprising a metal backing plate sintered to said metal matrix.
Claim 27
Dependent Claim
15 words
A friction material member as in claim 22, wherein said metal backing plate is steel.
Claim 28
Dependent Claim
17 words
A friction material member as in claim 22, wherein said metal backing plate is copper plated steel.
Claim 29
Dependent Claim
24 words
A friction material member as in claim 22, wherein the shear strength between said matrix and said plate is at least about 400 PSI.
Claim 30
Dependent Claim
19 words
A friction material member as in claim 21, further comprising a metal backing plate welded to said metal matrix.
Claim 31
Dependent Claim
19 words
A friction material member as in claim 21, further comprising a metal backing plate brazed to said metal matrix.
Claim 32
Dependent Claim
19 words
A friction material member as in claim 21, further comprising a metal backing plate soldered to said metal matrix.
Claim 33
Dependent Claim
55 words
A friction material member comprising a substantially uniform mixture of metal particles, carbonaceous material and friction enhancers; said metal particles comprising at least about 50 percent by weight of said mixture; said mixture bonded together by a polymeric resin; wherein on at least one surface of the friction material, said metal particles are fused together.
Claim 34
Dependent Claim
55 words
A friction material member comprising a substantially uniform mixture of metal particles, carbonaceous material and friction enhancers; said metal particles comprising at least about 50 percent by weight of said mixture; said mixture bonded together by a polymeric resin; wherein on at least one surface of the friction material, said metal particles are fused together.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-03-20 | 1987-09-19 | 1988-03-20 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-03-20 | 1991-09-19 | 1992-03-20 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-03-20 | 1995-09-19 | 1996-03-20 | $7700.00 | Window Closed / Lapsed |