US5083650A — Friction material having heat-resistant paper sup…

Claim 1

Independent Claim 99 words

A friction member which is especially useful as a friction facing member in a transmission, said friction member comprising: (a) a uniform density heat resistant paper; (b) a first layer of thermoset polymeric binder coated over and at least partially impregnated into one major surface of the paper; (c) granular carbon friction particles uniformly distributed over and partially embedded in the exposed surface of the first layer; and (d) a second layer polymeric binder as defined in (b) over the first layer and the partially embedded granular carbon friction particles which coats without obscuring the granular carbon friction particles.

Claim 2

Dependent Claim 99 words

A friction member which is especially useful as a friction facing member in a transmission, said friction member comprising: (a) a uniform density heat resistant paper; (b) a first layer of thermoset polymeric binder coated over and at least partially impregnated into one major surface of the paper; (c) granular carbon friction particles uniformly distributed over and partially embedded in the exposed surface of the first layer; and (d) a second layer polymeric binder as defined in (b) over the first layer and the partially embedded granular carbon friction particles which coats without obscuring the granular carbon friction particles.

Claim 3

Dependent Claim 18 words

The friction member of claim 1 wherein said paper has a weight 40 to 60 g/m 2 .

Claim 4

Dependent Claim 20 words

The friction member of claim 1 wherein said heat resistant paper is formed substantially of resin bonded aramid staple fibers.

Claim 5

Dependent Claim 19 words

The friction member of claim 3 wherein said aramid staple fibers have a length between 0.6 and 2 cm.

Claim 6

Dependent Claim 13 words

The friction member of claim 3 wherein said resin is an acrylate resin.

Claim 7

Dependent Claim 15 words

The friction member of claim 1 wherein said thermoset polymer is an acid-catalyzed phenolic resin.

Claim 8

Dependent Claim 20 words

The friction member of claim 1 wherein said first layer of thermoset polymeric binder is filled with carbon filler particles.

Claim 9

Dependent Claim 19 words

The friction member of claim 7 wherein said carbon filler particles are of a size less than 50 μm.

Claim 10

Dependent Claim 44 words

The friction member of claim 1 wherein at least 85% by weight of said carbon friction particles have an average particle size which exceeds about 40 μm and no more than about 10% by weight have an average particle size which exceeds 250 μm.

Claim 11

Dependent Claim 44 words

The friction member of claim 1 wherein at least 85% by weight of said carbon friction particles have an average particle size which exceeds about 40 μm and no more than about 10% by weight have an average particle size which exceeds 350 μm.

Claim 12

Dependent Claim 153 words

Method of making a friction member, said method comprising the steps of: (a) applying a coating of a liquid coating composition comprising thermosettable binder material filled with carbon filler particles to one major surface of a continuous length of uniform density, heat resistant paper under viscosity conditions which cause the coating composition to coat and impregnate the coated surface of the paper; (b) supporting the coated paper on a movable carrier; (c) applying a uniform layer of granular carbon friction particles over the coating of step (a) while the coating is sufficiently uncured so that at least some of the granular carbon friction particles become partially embedded into the coating; (d) at least partially curing the coating after application of the granular carbon friction particles; (e) applying a coating of a coating composition as defined in (a) over the partially cured coating; and (f) curing the coatings until the binder material is thermoset.

Claim 13

Dependent Claim 153 words

Method of making a friction member, said method comprising the steps of: (a) applying a coating of a liquid coating composition comprising thermosettable binder material filled with carbon filler particles to one major surface of a continuous length of uniform density, heat resistant paper under viscosity conditions which cause the coating composition to coat and impregnate the coated surface of the paper; (b) supporting the coated paper on a movable carrier; (c) applying a uniform layer of granular carbon friction particles over the coating of step (a) while the coating is sufficiently uncured so that at least some of the granular carbon friction particles become partially embedded into the coating; (d) at least partially curing the coating after application of the granular carbon friction particles; (e) applying a coating of a coating composition as defined in (a) over the partially cured coating; and (f) curing the coatings until the binder material is thermoset.

Claim 14

Dependent Claim 102 words

A transmission which includes a friction facing member to transmit torque to another member by contact therewith, said friction facing member comprising: (a) a uniform density heat resistant paper; (b) a first layer of thermoset polymeric binder coated over and at least partially impregnated into one major surface of the paper; (c) granular carbon friction particles uniformly distributed over and partially embedded in the exposed surface of the first layer; and (d) a second layer polymeric binder as defined in (b) over the first layer and the partially embedded granular carbon friction particles which coats without obscuring the granular carbon friction particles.

Claim 15

Dependent Claim 102 words

A transmission which includes a friction facing member to transmit torque to another member by contact therewith, said friction facing member comprising: (a) a uniform density heat resistant paper; (b) a first layer of thermoset polymeric binder coated over and at least partially impregnated into one major surface of the paper; (c) granular carbon friction particles uniformly distributed over and partially embedded in the exposed surface of the first layer; and (d) a second layer polymeric binder as defined in (b) over the first layer and the partially embedded granular carbon friction particles which coats without obscuring the granular carbon friction particles.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1995-01-27	1995-07-29	1996-01-28	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1999-01-27	1999-07-29	2000-01-28	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2003-01-27	2003-07-29	2004-01-28	$7700.00	Window Closed / Lapsed

Friction material having heat-resistant paper support bearing resin-bonded carbon particles

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