Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Patent
1996-01-17
1999-03-30
Niland, Patrick D.
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
192107M, 523149, 523150, 523152, 523155, 523157, 524 80, 524 81, 524174, 524175, 524178, 524183, 524267, 524268, 524394, 524588, 524589, 524590, 525389, 525393, 525474, C08J 514, C08K 320, C08K 500, C08L 8300
Patent
active
058890815
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
The present invention relates to a binder composition for friction materials, and a friction material.
When used for manufacturing friction materials in the brakes, clutches and the like for various kinds of vehicles such as automobiles, the binder composition of this invention can remarkably improve the fading and abrasion resistances of the friction material.
PRIOR ART
In recent years, there is a strong demand for improving the performance of and reducing the weight of brakes, clutches and other parts of vehicles such as automobiles because of higher power of engines and also an increasing need for decreasing the mass of automotive bodies.
In respect of these automotive parts, it has been long desired to solve or mitigate the technical problems of the fade phenomenon entailing the reduction in coefficient of friction at a high temperature operation and the judder phenomenon involving sharp variation in coefficient of substances which have directly caused the fade phenomenon are gases, tars and the like present as heat decomposition products of cured body of thermosetting resin used as a binder or a friction controlling agent in these automotive parts.
To prevent the generation of such gases and tars, etc., the following have been heretofore proposed: 1) a friction material containing a naphthol resin as a binder (Japanese Unexamined Patent Publication Hei 4-63387), 2) a friction material containing a copna resin as a binder prepared from a condensed polycyclic aromatic compound (such as pitch) crosslinked with methylene linkage (Japanese Unexamined Patent Publication Hei 1-108492), 3) a friction material prepared by molding a mixture of pitch and a cyanic acid ester resin as a binder, followed by semi-carbonization at 250 to 650.degree. C. (Japanese Unexamined Patent Publication Hei 5-215164, and 4) another proposal made from a different viewpoint, i.e. the adsorption of generated decomposition products on the activated carbon incorporated in the friction composition (Japanese Examined Patent Publication Sho 59-18429).
Further proposals are 5) a friction material containing an organopolysiloxane-modified phenol resin as a binder (Japanese Unexamined Patent Publication Sho 61-192711) and 6) a friction material containing a binder having a silicone oligomer incorporated therein (Japanese Unexamined Patent Publication Sho 61-77653).
However, the binders used in 1) and 2) are organic substances and undergo heat decomposition at a temperature of 400 to 500.degree. C. although in a different degree, unavoidably involving the generation of large amounts of gases and tars. The technique 3) can preclude the generation of decomposition products indeed. However, it not only requires a high temperature of 300 to 500.degree. C. for manufacture but also poses the problem of not allowing the use of organic reinforcing fibers which, when fibrillated, facilitate a blend with other constituents, such as aramid fibers currently used as main reinforced fibers for friction materials. The technique 4) has the drawbacks that owing to the use of activated carbon, i.e. a brittle material, the strength and endurance of friction materials are reduced and decomposition products such as tars can not be effectively adsorbed. The technique 5) presents the problem of higher costs being incurred by the modification of phenol resin. The technique 6) can not fully inhibit the decomposition of binder since there occurs the evaporation of silicone oligomer in preference to the decomposition thereof because of the presence of stable silicone oligomer.
DISCLOSURE OF THE INVENTION
A main object of the invention is to provide a binder for friction materials, the binder being easily produced even using conventional equipment, being vaporized in lesser amounts at high temperature operation and being excellent in fading resistance, abrasion resistance, etc.
Directing attention to the foregoing various prior art problems, the inventor of the present invention conducted extensive research, and found that when a mixture of a th
REFERENCES:
patent: 4020226 (1977-04-01), Andrianov
patent: 4369263 (1983-01-01), Matsushima
patent: 4658951 (1987-04-01), Takarada
patent: 5364513 (1994-11-01), Sekhar et al.
patent: 5438113 (1995-08-01), Shimozawa et al.
Kakegawa Hiroya
Wang Xiangsheng
Yasuda Tokugen
Niland Patrick D.
Osaka Gas Company Limited
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