Friction material

• US 10,458,500 B2
• Filed: 12/02/2014
• Issued: 10/29/2019
• Est. Priority Date: 12/24/2013
• Status: Active Grant

• Current Assignee: Nisshinbo Brake Incorporated (Nisshinbo Holdings Incorporated)
• Original Assignee: Nisshinbo Brake Incorporated (Nisshinbo Holdings Incorporated)
• Inventors: Yaguchi, Mitsuaki, Kaji, Shinya
• Primary Examiner(s): Lee, Doris L
• Application Number:
  US15/186,385
• Publication Number:
  US 20160356332A1
• Time in Patent Office: 1,792 Days
• Field of Search: 523156, 192107, 264 3733
• CPC Class Codes: C08K 3/042 Graphene or derivatives, e.g. graphene oxides
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 3/30 Sulfur-, selenium- or tellurium-containing compounds
• CPC Class Codes: C08K 3/32 Phosphorus-containing compounds
• CPC Class Codes: C08K 7/06 Elements
• CPC Class Codes: C08L 2205/02 containing two or more polymers of the same C08L -group
• CPC Class Codes: C08L 2205/06 having improved processability or containing aids for moulding methods
• CPC Class Codes: C08L 61/06 of aldehydes with phenols
• CPC Class Codes: C08L 61/14 Modified phenol-aldehyde condensates
• CPC Class Codes: C08L 61/34 Condensation polymers of aldehydes or ketones with monomers covered by at least two of the groups C08L61/04, C08L61/18 and C08L61/20
• CPC Class Codes: C08L 77/10 Polyamides derived from aromatically bound amino and carboxyl groups of amino-carboxylic acids or of polyamines and polycarboxylic acids
• CPC Class Codes: F16D 2200/006 containing fibres or particles
• CPC Class Codes: F16D 2200/0065 Inorganic, e.g. non-asbestos mineral fibres
• CPC Class Codes: F16D 2200/0086 Moulding materials together by application of heat and pressure
• CPC Class Codes: F16D 69/026 containing fibres

Abstract

The present invention provides a friction material for a disc brake pad, which is able to suppress chipping of an edge of the friction material that occurs under the high speed and high load braking conditions and further to suppress the deterioration of the braking effectiveness under the high speed and high load braking conditions while satisfying laws and regulations relating to the required amount of the content of the copper component. A friction material composition that contains 0.5-10 weight % of a resilient graphitic carbon particle relative to the total amount of the friction material composition as a carbon type lubricant and contains the total amount of a copper component contained in the friction material composition is less than 5 weight % relative to the total amount of the friction material composition.

Claims

1. A friction material which is a non-asbestos-organic friction material utilized for a disc brake pad, which is manufactured by forming a non-asbestos organic friction material composition that does not contain a copper component, wherein

said friction material composition contains

4-12 weight % of a binder relative to the total amount of the friction material composition, said binder consists of one or any combination of two or more items selected from the group consisting of a straight phenolic resin, a cashew oil modified phenolic resin, a silicone oil modified phenolic resin, an elastomer modified phenolic resin, an aralkyl modified phenolic resin, an elastomer dispersed phenolic resin, and a fluoropolymer dispersed phenolic resin,

7-35 weight % of a titanate relative to the total amount of the friction material composition,

0.5-10 weight % of a resilient graphitic carbon particle relative to the total amount of the friction material composition as a carbon type lubricant,

1-15 weight % of a ferrous sulfide relative to the total amount of the friction material composition as a metal sulfide type lubricant, and

1-10 weight % of an inorganic friction modifier, said modifier is one or any combination of two or more items selected from the group consisting of an alloy particle mainly containing aluminum, and an alloy fiber mainly containing aluminum relative to the total amount of the friction material composition as an inorganic friction modifier.

2. The friction material according to claim 1, wherein

said alloy particle mainly containing aluminum and said alloy fiber mainly containing aluminum are one or more items selected from the group consisting of an aluminum-zinc type alloy, an aluminum-manganic type alloy, an aluminum-silicon type alloy, an aluminum-magnesium type alloy, an aluminum-magnesium-silicon type alloy, and an aluminum-zinc-magnesium type alloy.