Method for obtaining a clutch lining, a clutch lining obtained using said method and a clutch disc fitted with one such friction lining

• US 20040089512A1
• Filed: 01/06/2003
• Published: 05/13/2004
• Est. Priority Date: 03/15/2001
• Status: Abandoned Application

• Current Assignee: Valeo Materiaux de Friction Societe PAR Actions Simplifiee
• Original Assignee: Valeo Materiaux de Friction Societe PAR Actions Simplifiee
• Inventors: Boyer, Gerard, Biot, Christian, Marchisseau, Michel
• Application Number:
  US10/275,065
• Publication Number:
  US 20040089512A1
• Time in Patent Office: Days
• US Class Current: 192/107M
• CPC Class Codes: B29C 2045/0027 Gate or gate mark locations
• CPC Class Codes: B29C 45/0005 using fibre reinforcements
• CPC Class Codes: B29C 45/0013 using fillers dispersed in the moulding material, e.g. metal particles
• CPC Class Codes: B29C 45/0046 Details relating to the filling pattern or flow paths or flow characteristics of moulding material in the mould cavity
• CPC Class Codes: B29C 45/1459 Coating annular articles
• CPC Class Codes: B29C 45/561 Injection-compression moulding
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2303/04 Inorganic materials
• CPC Class Codes: B29K 2503/04 Inorganic materials
• CPC Class Codes: B29L 2031/16 Frictional elements, e.g. brake or clutch linings
• CPC Class Codes: B29L 2031/7486 Clutches
• CPC Class Codes: F16D 2069/002 Combination of different friction materials
• CPC Class Codes: F16D 69/02 Composition of linings ; Methods of manufacturing
• CPC Class Codes: F16D 69/026 containing fibres

Abstract

The invention relates to a method for obtaining a clutch lining consisting in: injecting a friction material containing a polyester resin into a mould; the material also contains a polymerisation catalyst, glass fibres, chalk, mica, talc, kaolin, thermoplastic fillers and a mould release agent. The invention also relates to a clutch lining obtained using said method and a clutch disc fitted with one such lining.

Claims

1. A method of obtaining a clutch friction lining by injection, consisting in injecting a friction material into a mould, characterised in that the friction material contains a polyester resin.

2. A method according to claim 1, characterised in that the friction material containing a polyester resin is subjected to compression after it is injected into the mould.

3. A method according to claim 1 or claim 2, characterised in that, after the injection phase, the lining is subjected to a deburring operation.

4. A method according to claim 3, characterised in that burrs removed by the deburring operation are recovered, ground and fed back into the material containing the polyester before it is injected into the injection mould.

5. A method according to any of claims 1 to 4, characterised in that an insert is introduced into the injection mould before the injection operation.

6. A method according to any of claims 1 to 5, wherein the injection is effected via at least one injection point, characterised in that the injection point is situated in the vicinity of the external periphery of the lining to be obtained.

7. A method according to any of claims 1 to 6, characterised in that studs are provided in the mould to produce fixing holes in the lining.

8. A method according to any of claims 1 to 7, characterised in that the material to be injected contains inorganic and/or organic and/or metal fibres from 1 mm to 30 mm long, unsaturated polyester resin, a polymerisation catalyst and more than 0.4% by weight mould release agent.

9. A method according to claim 8, characterised in that the material to be injected contains, by weight:

from 5% to 40% unsaturated polyester resin;

from 0.5% to 2% polyester resin catalyst;

from 0% to 30% heatsetting resins (other than polyester resins), such as melamine resins, or phenolic resins (novolak, resol, CNSL, etc.) or mixed melamine and phenolic resins;

from 0% to 30% organic fibres from 1 mm to 20 mm long, such as acrylic fibres, carbon fibres, polyamide fibres, cellulose fibres;

from 0% to 40% inorganic fibres from 1 mm to 20 mm long, such as glass fibres, rock wool fibres, ceramic fibres, basalt fibres, calcium silicate fibres;

from 0% to 30% metal fibres such as copper fibres, brass fibres, steel fibres, aluminium fibres, zinc fibres, etc.;

from 0% to 15% lubricating fillers such as graphite, antimony trisulphide, talc;

from 0% to 20% conductive powders consisting of metal powders such as powders of copper and its alloys (brass, bronze, etc.), steel, aluminium, etc., or consisting of carbon black, graphite, etc.;

from 0% to 10% abrasive fillers such as silica, various silicates;

from 0% to 15% fillers to improve fluidity during injection and/or to reduce the final density, such as glass microspheres (hollow and/or with high surface porosity), ceramic microspheres, fine sawdust;

from 5% to 15% thermoplastic fillers; and

from 0.5% to 5% internal mould release agents.

10. A method according to claim 8, characterised in that the material to be injected contains, by weight:

16% unsaturated polyester resin;

0.7% polymerisation catalyst;

28% glass fibres 6 mm long;

20% chalk;

10% mica;

5.5% talc;

10% kaolin;

8% thermoplastics fillers; and

1.8% mould release agent.

11. A clutch friction lining characterised in that it is obtained by the method according to any of claims 1 to 10.

12. A friction lining according to claim 11, characterised in that it includes an insert.

13. A friction lining according to claim 12, characterised in that the insert is made of metal.

14. A friction lining according to claim 12, characterised in that the insert is made of a composite material.

15. A friction lining according to any of claims 11 to 14, characterised in that it has moulded-in fixing holes.

16. A friction lining according to any of claims 11 to 15, characterised in that the disposition of the fibres in at least one section (7) of the lining (2) is such that for a population of more than 60% of the fibres (6) each fibre (6) belonging to the aforementioned population is oriented in a space defined by a cone whose characteristics are as follows:

the angle at the apex is 90°

, the axis of symmetry (4) is tangential to the circle (1) centred on the friction lining (2) and passing through the intersection of the fibre (6) concerned with the portion of the section (7) concerned, and the apex is at the intersection of the fibre (6) concerned with the portion of the section (7) concerned.

17. A clutch disc equipped with a friction lining, characterised in that the friction lining is a friction lining according to any of claims 11 to 16.