Friction material

Patent metadata

Field	Value
Publication number	US-9677635-B2
Application number	US-201313953235-A
Country	US
Kind code	B2
Filing date	Jul 29, 2013
Priority date	Jul 29, 2013
Publication date	Jun 13, 2017
Grant date	Jun 13, 2017

Abstract

One variation includes a friction material wherein the friction material may be fabricated from fibers, particles, a chemical binder, and a resin bonding agent wherein the particles are aggregated.

First claim

What is claimed is:

1. A product comprising:
friction material comprising:
a plurality of fibers comprising aramid fibers, carbon fibers, and polyvinyl alcohol fibers consisting of vinyl alcohol repeat units;
a plurality of particles comprising graphite particles and diatomaceous earth particles;
a chemical binder comprising at least one of acrylonitrile, acrylate, polyvinyl acetate, or polyvinyl chloride; and
a resin bonding agent,
wherein the percentage weight of the aramid fibers is between 20% and 60% of the friction material,
wherein the percentage weight of the carbon fibers is between 5% and 20% of the friction material,
wherein the percentage weight of the graphite particles is between 5% and 25% of the friction material,
wherein the percentage weight of the diatomaceous earth particles is 5% to 30% of the friction material,
wherein the plurality of particles are aggregated into regions of groups of particles throughout the friction material,
and
wherein the friction material further comprises pores greater than 4 μm accounting for at least 50% of the total pore volume of the friction material.

2. The product of claim 1 , wherein the plurality of fibers further comprise at least one of acrylic, cellulose, glass, mineral polyimide, or rayon.

3. The product of claim 1 , wherein the graphite particles range in size from 20 to 150 mm.

4. The product of claim 1 , wherein the diatomaceous earth particles range in size from 1 to 40 μm.

5. The product of claim 1 , wherein the pores range in size from 5-50 μm.

6. The product of claim 1 , wherein the resin bonding agent comprises at least one of epoxy resin, phenolic resin, modified phenolic resin, or silicone resin.

7. The product of claim 1 , wherein the plurality of particles further comprise at least one of silica particles, carbon particles, carbide particles, ceramic particles, cashew oil particles, rubber particles, nitride particles, nitrile particles, phenolic particles, zeolite particles, or aramid particles.

8. The product of claim 7 , wherein the plurality of particles range in diameter from 10 to 500 μm.

9. The product of claim 7 , wherein the plurality of particles range in diameter from 10 to 150 μm.

10. The product of claim 1 , wherein the groups of particles are a plurality of bonded groups comprising a plurality of particles bonded together, wherein each of the plurality of bonded groups has a diameter ranging from 10-500 μm.

11. The product of claim 10 , wherein each of the plurality of bonded groups has a diameter ranging from 10-150 μm.

12. The product of claim 10 , wherein each of the plurality of bonded groups has an irregular shape.

13. A product comprising:
a friction material comprising:
aramid fibers;
carbon fibers;
polyvinyl alcohol fibers consisting of polyvinyl alcohol repeat units;
graphite particles;
diatomaceous earth particles; and
a chemical binder comprising at least one of acrylonitrile, acrylate, polyvinyl acetate, or polyvinyl chloride,
wherein the percentage weight of the aramid fibers is between 20% and 60% of the friction material,
wherein the percentage weight of the carbon fibers is between 5% and 20% of the friction material,
wherein the percentage weight of the graphite particles is between 5% and 25% of the friction material,
wherein the percentage weight of the diatomaceous earth particles is 5% to 30% of the friction material,
wherein at least one of the graphite particles or the diatomaceous earth particles are aggregated, and
wherein the friction material further comprises pores greater than 4 μm accounting for at least 50% of the total pore volume of the friction material.

14. The product of claim 13 , wherein the diatomaceous earth particles range in size from 1 to 40 μm.

15. The product of claim 13 , wherein the graphite particles range in size from 20 to 150 μm.

16. The product of claim 13 , wherein the pores range in size from 5-50 μm.

17. The product of claim 13 , wherein at least one of the graphite particles or the diatomaceous earth particles are aggregated into regions of groups of particles throughout the friction material.

18. The product of claim 13 , wherein the friction material further comprises a resin bonding agent comprising at least one of epoxy resin, phenolic resin, modified phenolic resin, or silicone resin.

19. The product of claim 13 , wherein the chemical binder further comprises latex.

20. The product of claim 13 , wherein the aggregated particles are arranged into regions of groups of particles which range in diameter from 10 to 500 μm.

21. The product of claim 13 , wherein the friction material further comprises at least one of silica particles, carbon particles, carbide particles, ceramic particles, rubber particles, nitride particles, nitrile particles, phenolic particles, zeolite particles, or aramid particles.

22. The product of claim 13 , wherein the friction material further comprises polyimide fiber.

23. The product of claim 13 , wherein the chemical binder comprises polyvinyl acetate.

24. The product of claim 13 , wherein the chemical binder comprises polyvinyl chloride.

25. The product of claim 13 , wherein the friction material further comprises cellulose fiber.

26. The product of claim 13 , wherein the friction material further comprises glass fiber.

27. The product of claim 13 , wherein the graphite particles or the diatomaceous earth particles are oblong, cubical, or polyhedral shaped.

Assignees

• Borgwarner Inc

Inventors

• Bares Jason
• Lam Robert C

Classifications

• F16D2200/0069

  being characterised by their size · CPC title

• F16D69/026 Primary

  containing fibres · CPC title