Delphi Technologies, Inc.

Gm Global Technolgoy Operations, Inc.

Robert Anthony Lamport

Thomas H Gardner

Julie Mary Biermann-Weaver

Peter Teh-Kwang Shih

Vinod Kumar Jain

A method of coating disc brake pads to obscure and seal minor surface imperfections, thereby reducing scrap rates. A preform of friction lining material is coated prior to molding and curing the preform and bonding the same to the backing plate to form the brake pad assembly. The preform is coated with an aqueous composition containing a solids mixture of 5&#x2013;50 vol. % resin and 50&#x2013;95 vol. % non-resin solids. Advantageously, the coating composition has a 5&#x2013;30 vol. % solids mixture content, which solids mixture includes 15&#x2013;25 vol. % resin, 0&#x2013;10 vol. % powdered elastomer, 5&#x2013;15 vol. % carbon black, 20&#x2013;50 vol. % inorganic fillers, 5&#x2013;15 vol. % organic fibers and 1&#x2013;10 vol. % inorganic flake material.

Coating method for disc brake pads

Friction materials for clutch, brake shoes and the like are formed of a paper having reduced or eliminated non-functional processing additives. The paper composition includes components selected from a group consisting of aramid pulp, aramid staple, carbon/polyacrylonitrile fibers, glass wool, potassium octatitanate, bronze wool, high surface area filter cake, graphite, amorphous carbon and cyanated phenolic resin. The paper composition may be pre-compounded to a particle size in the range of 60 to 200 mesh. Part molding may be carried out by microwave heating the paper at 250&deg; to 55&deg; F.

Friction facing composition and method of manufacture

A friction material pad comprises a lamination of stacked sheets, each of which has a top edge forming the friction face that is generally parallel to the direction of relative rotation between the friction pad and an opposing rotary member. Each sheet is formed by a wet paper making process and has a plurality of unwoven fibers, platelets, flakes, or the like, more than half of which are oriented within 45.degree. of perpendicularity to the top edge, the sheets being bound together by a resin binder to form a lamination in which the sheet edges progress from inner to outer sheets to form the friction face of the pad, each sheet having the same blend of friction and lubricating particles, fibers and fillers in a resin matrix. Three groups of sheets are heat aged to different densities and have different friction, hardness and stiffness characteristics. These groups of sheets are combined to provide a monolithic friction material pad having different densities in different areas of the pad to provide a pad having generally uniform wear and friction over the friction face and yet having improved noise attenuation. Thus, a pad can be tailored to any specific application by varying the amount and locations of these different groups of sheets.

Method for making a multiple density friction material pad

An improved friction material may be made having reinforcing fibers aligned generally perpendicular to the friction surface of said material by forming a paper of fibrous friction materials such that the fibers in the paper are aligned closely to the longitudinal axis of the paper and then folding or cutting the paper into pleats or strips such that the pleats or strips are bonded together with the edges defining the friction surface of the friction body and the fibers perpendicular to that surface.

Manufacture of friction material using fiber oriented paper

An improved friction material composite is disclosed that contains a fibrous reinforcing constituent, various friction imparting and controlling additives, and a thermosetting resin mixture in which mixture is contained pitch, a polyimide resin, and optionally a phenolic resin. Pitch-polyimide mixtures can be formulated to provide unusually high temperature resistance and strength and the pitch-polyimide-phenolic resin mixtures formulated to provide like properties at moderate cost.

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Centerville, OH, United States of America

Robert Anthony Lamport