Friction material

Patent metadata

Field	Value
Publication number	US-10190649-B2
Application number	US-201415034600-A
Country	US
Kind code	B2
Filing date	Nov 11, 2014
Priority date	Nov 12, 2013
Publication date	Jan 29, 2019
Grant date	Jan 29, 2019

Abstract

This friction material contains a fiber base material, a friction modifier and a binder. The content of copper in the friction material is not more than 0.5 mass % in terms of elemental copper, and the content of the binder is at least 10 mass %. Furthermore, the friction material contains calcium hydroxide and zinc, and has a pH of at least 11.7.

First claim

The invention claimed is:

1. A friction material comprising:
a fiber base material;
a friction modifier; and
a binder,
wherein a content of copper is 0.5% by mass or less in terms of copper element,
wherein a content of the binder is 10% by mass or more,
wherein the friction material contains calcium hydroxide and zinc,
wherein the friction material has pH of 113 or more,
wherein a content of the zinc is from 1% by mass to 5% by mass,
wherein the zinc comprises a powder having an average particle diameter in a range of 1 μm to 10 μm,
wherein the calcium hydroxide comprises powder having an average particle diameter in a range of 5 μm to 50 μm,
wherein the fiber base material comprises a bio-soluble inorganic fiber, and
wherein the binder consists of at least one selected from the group consisting of an acrylic rubber-modified phenol resin, a silicone rubber-modified phenol resin, an NBR rubber-modified phenol resin, a cashew-modified phenol resin, an epoxy-modified phenol resin and an alkylbenzene-modified phenol resin.

2. The friction material according to claim 1 , wherein a content of the calcium hydroxide is from 2% by mass to 6% by mass.

3. The friction material according to claim 1 , wherein the bio-soluble inorganic fiber is at least one selected from the group consisting of SiO 2 —CaO—MgO-based fiber, SiO 2 —CaO—MgO—Al 2 O 3 -based fiber and SiO 2 —MgO—SrO-based fiber.

4. A friction material comprising:
a fiber base material;
a friction modifier; and
a binder,
wherein a content of copper is 0.5% by mass or less in terms of copper element,
wherein a content of the binder is 10% by mass or more,
wherein the friction material contains calcium hydroxide and zinc,
wherein the friction material has pH of 11.7 or more,
wherein a content of the zinc is from 1% by mass to 5% by mass,
wherein the zinc comprises a powder having an average particle diameter in a range of 1 μm to 10 μm,
wherein the calcium hydroxide comprises powder having an average particle diameter in a range of 5 μm to 50 μm,
wherein the fiber base material comprises a bio-soluble inorganic fiber,
wherein the binder consists of at least one selected from the group consisting of a straight phenol resin, an acrylic rubber-modified phenol resin, a silicone rubber-modified phenol resin, an NBR rubber-modified phenol resin, a cashew-modified phenol resin, an epoxy-modified phenol resin and an alkylbenzene-modified phenol resin, and
wherein a content of the fiber base material is 10% by mass or more and 50% by mass or less.

5. The friction material according to claim 4 , wherein a content of the calcium hydroxide is from 2% by mass to 6% by mass.

6. The friction material according to claim 4 , wherein the bio-soluble inorganic fiber is at least one selected from the group consisting of SiO 2 —CaO—MgO-based fiber, SiO 2 —CaO—MgO—Al 2 O 3 -based fiber and SiO 2 —MgO—SrO-based Fiber.

7. A friction material comprising:
a fiber base material;
a friction modifier; and
a binder,
wherein a content of copper is 0.5% by mass or less in terms of copper element,
wherein a content of the binder is 10% by mass or more,
wherein the friction material contains calcium hydroxide, zinc, and zirconium silicate,
wherein the friction material has pH of 11.7 or more,
wherein a content of the zinc is from 1% by mass to 5% by mass,
wherein the zinc comprises a powder having an average particle diameter in a range of 1 μm to 10 μm,
wherein the calcium hydroxide comprises powder having an average particle diameter in a range of 5 μm to 50 μm,
wherein the fiber base material comprises a bio-soluble inorganic fiber, and
wherein the binder consists of at least one selected from the group consisting of a straight phenol resin, an acrylic rubber-modified phenol resin, a silicone rubber-modified phenol resin, an NBR rubber-modified phenol resin, a cashew-modified phenol resin, an epoxy-modified phenol resin and an alkylbenzene-modified phenol resin.

8. The friction material according to claim 7 , wherein a content of the calcium hydroxide is from 2% by mass to 6% by mass.

9. The friction material according to claim 7 , wherein the bio-soluble inorganic fiber is at least one selected from the group consisting of SiO 2 —CaO—MgO-based fiber, SiO 2 —CaO—MgO—Al 2 O 3 -based fiber and SiO 2 —MgO—SrO-based fiber.

Assignees

• Akebono Brake Ind

Inventors

• Miyaji Motoyuki
• Shibuya Katsumi
• Watanabe Takayuki

Classifications

• F16D69/026 Primary

  containing fibres · CPC title

• C08K7/02

  Fibres or whiskers · CPC title

• F16D2200/0056

  Elastomers · CPC title

• F16D2200/006

  containing fibres or particles · CPC title

• C08K2003/2206

  of calcium, strontium or barium · CPC title