Abstract: An aircraft disc stack (1) comprises a plurality of interleaved stator and rotor discs (3,4) keyed respectively to a torque tube (5) and a wheel hub (not shown). The stack (1) further comprises bi-functional friction/load transmitting discs in the form of end stator discs (10,13). These discs (10,13) are subject to uneven loading because the non-friction surfaces (12,15) are in use compressed on areas less than the load bearing areas of the opposing friction faces (11,14). This can lead to premature disc failure and in the past load spreader plates have been used to distribute loading over these areas to minimize the risk of failure. In this invention portions of the load bearing areas of non-friction surfaces (12,15) are toughened ie: material underlying these surfaces is toughened, to increase their resistance to deformation, fracture and/or wear thereby removing the need for additional load spreader plates which were hitherto required.

Abstract: A continuous process for the manufacture of friction units comprises the steps of impregnating a plurality of strands of reinforcing fibers with a phenolic resin having zero to ten percent copper and graphite powders, pulling the impregnated strands of reinforcing fibers through a composite forming die for forming a body having the peripheral configuration of the friction units, and selectively cutting the body into a plurality of the friction units.

Abstract: A method for reducing green roughness of a braking system and a method of manufacturing a brake system includes coating at least one of the components of the brake system with a boundary layer material. The method is applicable to either the pad of a disc brake system or the brake drum lining and/or the brake shoe of a brake drum system. The coating is either a binder, a filler, a boundary layer lubricant or a mixture thereof. The coating hereof is either graphite, molybdenum disulfide and/or a divalent fluoride, either organic or inorganic. Likewise, a thermoset paint such as an alkyd resin, phenolic resin, epoxy resin or the like can be used for the coating material. The coating eliminates uneven transfer of friction material during the brake wear-in period which creates brake torque vibration which, in turn, increases vehicle sensitivity and brake roughness.

Abstract: A friction material and process of forming a friction material embodies a slurry of aramid, acrylic and carbon fibers, together with kaolin clay and aluminum oxide used as fillers in a phenolic resin binder. The matrix formed by the fibers entraps a relatively large quantity of carbon particles. The carbon particles comprise more than forty or fifty percent of the weight of the material. During the process of formation, the slurry is de-watered to reduce moisture content to the order of two percent before the resin binder is cured under heat and pressure.

Abstract: In the case of a friction lining, intended in particular for brake systems and comprising a friction element consisting of asbestos-free friction lining material and an abrasive element consisting of abrasive material with a thermosetting binder on the basis of natural or synthetic resin, it is provided that an abrasive element is incorporated in the friction element which, as wear of the friction lining advances, enables the frictional properties of the surface which presses against the lining to be regenerated at intervals.

Abstract: A continuous process for the manufacture of friction units includes the steps of impregnating a plurality of strands of reinforcing fibers with a phenolic resin having zero to ten percent copper and graphite powders, pulling the impregnated strands of reinforcing fibers through a composite forming die for forming a body having the peripheral configuration of the friction units, and selectively cutting the body into a plurality of the friction units.

Abstract: A brake pad friction lining having, as required by UIC regulations for use on railways in Europe, a coefficient of friction under wet conditions not less than 85% of that under dry conditions, comprising a fibre-reinforced matrix of organic polymeric material which includes non-fibrous particulate material serving as friction or wear modifier or filler. The organic polymeric material employed according to the invention comprises cured high-hysteresis elastomeric material, for example a high-styrene/butadiene rubber, in a proportion by volume of the lining which is high enough to ensure a loss angle of at least 13.degree. therein.

Abstract: A disc brake for a vehicle comprising a disc and pads, the disc being rotatable integrally with wheels and the pads capable of being brought into friction engagement with the disc. The disc comprises a baked carbon fiber reinforced carbon composite comprising dispersed bundles of short carbon fibers impregnated with a reinforcing material of primarily a pitch. The pads comprise a baked carbon fiber reinforced carbon composite comprising dispersed bundles of short carbon fibers impregnated with a reinforcing material of primarily a pyrolytic carbon and a thermosetting resin.

Abstract: The non-asbestos, frictional material composition comprising a fibrous metal, carbon powder manufactured by sintering a mixture of coke and pitch, a hardening agent, a heat-resistant agent, and a filler for stabilizing the composition. The process for manufacturing the composition comprising manufacturing the fibrous metal and carbon powder, inserting the composition in a predetermined mold and molding the composition, and hardening the molded composition for a time.

Abstract: A novel brake friction pad assembly is provided with a backing plate element, and with one or more integrally joined different friction-generating pad, noise-damping pad, and backing pad elements carried by the backing plate element, such friction-generating pad, noise-damping pad, and backing pad elements being molded using specified particulate mixture molding compositions and preferred molding method steps.

Abstract: An asbestos-free friction material with improved water resistance which is used in automobiles, vehicles, and industrial machinery is disclosed. The friction material comprises a fibrous reinforcing substrate other than asbestos, a binder and a friction wear regulator, the fibrous reinforcing substrate partly containing a fibrillated pulp of an aromatic liquid crystal polyester resin.

Abstract: A disk brake pad assembly includes a rigid metal backing plate, a brake friction lining pad and a damping structure including a viscoelastic material disposed between the backing plate and the friction lining pad and fixed to each. In one embodiment the damping structure is a perforated metal plate having perforations filled with viscoelastic damping material. The damping plate may be provided along its opposite sides with constraining layers. Such a perforated damping structure may be disposed on either side of the backing plate.

Abstract: A noise abating brake shoe assembly having a metal brake shoe and a friction material brake block with an elastomeric sound damping material added as a constituent to the brake block or interposed between the brake block and the brake shoe.

Abstract: The present invention discloses a disc brake for a vehicle having a disc which is rotatable integrally with the wheels and pads which are brought into friction engagement with the disc. The disc is prepared by impregnating a reinforcing material into a carbon fiber reinforced carbon composite obtained by dispersing bundles of multiple single short carbon fibers with primarily a pitch, a combination of a pyrolytic carbon and a pitch or a combination of a pyrolytic carbon and a thermosetting resin, followed by baking; whereas the pads are prepared by impregnating a reinforcing material into a carbon fiber reinforced carbon composite obtained by dispersing bundles of multiple single short carbon fibers with primarily a combination of a pyrolytic carbon and a thermosetting resin or a combination of a pitch and a thermosetting resin, followed by baking.

Abstract: A platelike polycrystalline fiber having a composite phase which consists of potassium hexatitanate crystals and titanium dioxide crystals mixed therewith is prepared by heating a mixture of titanium compound and potassium compound to obtain a melt, cooling the melt to obtain a lump of fibers, treating the lump of fibers in an aqueous acid solution to control the potassium content of the fibers to 1 to 13.5 weight %, and heat-treating the resulting fibers at 900.degree. to 1300.degree. C.The composite fiber is suitable as fibers to be included in friction materials for slide members of automobiles and like brake devices.

Abstract: A sound dampener for a disk brake assembly comprising a composite of vinyl ester and glass. Preferably, the composite is comprised of a region of woven glass sandwiched between a layer of vinyl ester and another layer of vinyl ester in which random strands of glass are embedded. The composite dampens the vibrations induced by the friction associated with the disk brake assembly to eliminate brake squeal. The composite also has low rates of thermal conductivity and thermal expansion which aid in reducing break squeal.

Abstract: A disk-brake pad device includes a carbon-carbon lining pad. The disk-brake pad device attaches the pad to the caliper. At least one pad-positioning surface of the caliper has merging therefrom at least one pad-actuating piston. A first plate element (1) of heat-insulating material, called a screen element, is located against the positioning surface. At least one second element (2) of heat-insulating material, called a spacer element, of adequate thickness, having reduced frontal contacts is located against the first element (1). A carbon-carbon lining pad (3) of high-temperature friction material is located against the second element (2). The first element (1) and/or the second element (2) acts to retain the lining pad (3) and to fix the first element and/or the second element to the caliper.

Abstract: An automotive disc brake assembly comprises a disc rotor made of graphite cast iron with a structure of pearlite, and a brake pad made of organic material. The disc rotor has a first thermal conductivity falling in a range from 0.090 to 0.140 cal/cm.sec..degree.C. The brake pad has second thermal conductivity falling in a range from 0.65 to 3.00 Kcal/mh.degree.C. The second thermal conductivity falls in a range from 0.65 to 0.98 Kcal/mh.degree.C. provided that the second thermal conductivity satisfies the following relationship with the first thermal conductivity:.lambda..sub.R .gtoreq.-0.152.times..lambda..sub.P +0.24where, .lambda..sub.R is first thermal conductivity, and .lambda..sub.P is the second thermal conductivity. The disc brake assembly is successful in improving heat check resistance ability which is substantially influenced by thermal conductivity of the disc rotor and the brake pad.

Abstract: A disc brake vehicles according to this invention is directed to enhancing the coefficient of friction and wear resistance in the friction members, and to reducing the size and weight of the disc brake, in turn, the unspring weight so as to improve operation stability in driving a vehicle. In the disc brake according to the constitution of this invention, either the disc or the brake pads are made of a carbon fiber reinforced ceramic composite consisting of a ceramic matrix reinforced by a carbon fiber.

Abstract: A multi-disk braking device for a vehicle, particularly a train equipped with a braking retarder, includes a first set of metallic braking disks and a second set of carbon braking disks. Under normal operation of the train, the braking retarder is used to slow the train to a predetermined relatively slow speed, and the metallic disks are then actuated to complete the stop. If the braking retarder fails, the carbon disks, not used in normal operation, are actuated to bring the train to a slow speed or to a complete stop.

Abstract: A sound dampener for a disk brake assembly comprising a composite of vinyl ester and glass. Preferably, the composite is comprised of a region of woven glass sandwiched between a layer of vinyl ester and another layer of vinyl ester in which random strands of glass are embedded. The composite dampens the vibrations induced by the friction associated with the disk brake assembly to eliminate brake squeal. The composite also has low rates of thermal conductivity and thermal expansion which aid in reducing break squeal.

Abstract: The back and the braking body of the brake shoe are both formed as cast iron elements. The brake shoe, mainly consisting of molded parts, allows a particularly rational manufacture by casting operations or as a composite casting in one and the same casting mold, the casting mold being divided into casting cavities for the back and the braking body by a steel sheet. Cast-in steel reinforcements may be provided as well.

Abstract: A friction material for making brake pads or brake disks is formed by mixing metallic fiber and/or aramid fibers as a main component, a filler material and a binder agent for binding the main component and the filler. The metallic fiber includes at least copper fibers and/or copper alloy fibers. The filler includes one or more inorganic substances having a plane netlike crystal structure. The inorganic substances having the plane netlike crystal structure include mica, talc, vermiculite, aluminum hydroxide, magnesium hydroxide, agalmatolite, kaolin, chlorite, sericite, iron hydroxide, and montmorillonite.

Abstract: A binding agent for molding compositions and molded bodies produced by reacting a low molecular weight lignin from the Organosolv process with phenol in a weight ratio of 1:20 to 3:1 at 100.degree. to 180.degree. C., adjusting the pH to an acidic value and condensing the mixture with 0.2 to 0.9 moles of formaldehyde per mole of phenol at 60.degree. to 120.degree. C. to form the binding agent useful for producing curable molding compositions, high-temperature molding compositions, refractory products, textile fleeces and friction coatings as well as carbon materials.

Abstract: A binding agent for molded bodies and molding compositions produced by prereacting a mixture of 5 to 60% by weight of lignin or a lignin fraction produced by the Organosolv process and 40 to 95% by weight of a phenol novolac resin and subjecting the latter to high shear forces in a kneader or extruder and optionally mixing the same with a curing agent useful in molding compositions and high temperature-stable molded products such as refractory products, friction coatings, textile fleeces and carbon or graphite materials.

Abstract: A multi-layer friction element is disclosed consisting of carbon-carbon composite material comprising a structure layer of so-called "coarse" texture comprising segments of rovings and at least one friction layer of so-called "fine" texture comprising fibre segments. A method also is disclosed for producing the friction element by preparation of a fibrous substrate by introducing segments of roving and/or fibers into a mould preferably by means of a distribution apparatus. Further disclosed is an apparatus for automatically obtaining a fibrous substrate of predetermined texture.

Abstract: A sintered fluorocarbon resin based composite friction material having a high coefficient of friction, greater hardness, good machineability and improved wear resistance. The composite material comprises a homogeneous blend of fluorocarbon resin, aramid and carbon fibers, aluminum oxide and polyester compound. Also provided are process steps required to produce such materials with the desired characteristics of homogeneity, hardness and wear resistance. These steps include a premix together of the fiber components and final sintering at a pressure of about 1600 psi.

Abstract: A blocker-clutch assembly (10) includes an openly porous, pyrolytic carbon composite friction material (74) configured for optimum performance and, therefore, prevention or substantial prevention of nonsynchronous engagement of positive clutch members (12,14) due to premature unblocking of blocker tooth ramps (48-54). The composite friction material is formed to be resilient in direction normal to its friction surface (76c), is cut into segments (76), is positioned and bonded to a frustoconical surface (62) using fixtures 80,82 for preserving the resiliency and with the segments circumferentially spaced apart, and is configured to control engagement force thereon in a range of 150-300 pounds per square inch (100-200 N/cm.sup.2).

Abstract: A dry clutch is prepared from a composite of fiber yarns, including fiberglass fibers and polymer fibers such as polyacrylonitrile fibers, which are blended together and twisted with wire. The yarns are shaped in a disc or other form and are bonded together with a heat curable binder system that includes an elastomer and a resin. The binder system also may contain organic and inorganic friction modifying particles.

Abstract: A brake fitting comprising a plurality of studs separated from each other by spaces, each stud made of a sintered friction product laterally sheathed by a less fragile sintered metal bead which extends into the spaces between the studs. The fitting further comprises a metal support having a surface on which the studs are fixed, the surface of the metal support being coated by grains of a braze-welding powder which are diffusion bonded thereto. The studs are continuously welded at their base portions to the coated metal support surface.

Abstract: This invention relates to a floating type automotive brake disc having a disc hub and a friction disc combined with a very small clearance therebetween. In the brake disc according to this invention, the friction disc (14) is fixed to the disc hub (10) by a collar (16) inserted through them, a connecting bolt (17) inserted through the collar (16) and a nut (18) to be fitted to the bolt (17). The collar has a annular ridge (16) on the circumference thereof at substantially the middle for defining a clearance between the disc hub (10) and the friction disc (14). The friction disc is supported between the outer lateral side (16b) of the annular ridge (16a) and the head (17a) of the connecting bolt (17). The length of the shaft (16e) protruding from the inner lateral side (16d) of the connecting bolt (17) is greater than the thickness of the disc hub (10).

Abstract: A brake band for the bobbins used on a rigid frame wire strander. The brake band is a substantially non-porous polyester strip or band, preferably made of polyethylene terephthalate (PET). The band is provided with a longitudinal crease for keeping the band centered on the hub of the bobbin with which it is associated.

Abstract: An improved hardened insert and brake shoe adapted for use in bi-directional backstopping clutches is disclosed. The inserts are formed from a base material of high speed alloy tool steel, which is relatively inexpensive and easy to machine. The base material is formed into the desired shape for the insert, then hardened and tempered by conventional processes to achieve a desired hardness. Then, a coating of titanium nitride is applied to the insert by a physical vapor deposition process or a chemical vapor deposition process. The titanium nitride coating provides a very hard surface to the insert, which permits the insert to be used in the backstopping clutch. In an alternative embodiment, the brake shoes are formed in the manner described above, and no inserts are used in the clutch.

Abstract: Disclosed is a resin mold clutch facing integrally heat molded out of a resin mold base member and a reinforcement member. The resin mold base member comprises a matrix composed of a glass fiber and an aromatic polyamide fiber, an inorganic filler, a solid lubricant, and a resin. The reinforcement member comprises a matrix composed of a glass strand or yarn and at least one strand or yarn selected from a group of rayon and an aromatic polyamide strand or yarn and a binder adhered to said matrix, and is shaped in a spirally wound configuration. Thus the weight of the resin mold clutch facing has been reduced, and its friction and anti-wear properties have been improved.

Abstract: An improved hardened insert adapted for use in bi-directional backstopping clutches is disclosed. The inserts are formed from a base material of high speed alloy tool steel, which is relatively inexpensive and easy to machine. The base material is formed into the desired shape for the insert, then hardened and tempered by conventional processes to achieve a desired hardness. Then, a coating of titanium nitride is applied to the insert by a physical vapor deposition process or a chemical vapor deposition process. The titanium nitride coating provides a very hard surface to the insert, which permits the insert to be used in the backstopping clutch.

Abstract: A brake for vehicle wheels which includes a generally stationary brake part and a rotatable brake part adapted for cooperative braking interaction, the generally stationary brake part and rotatable brake part each respectively carrying a layer of friction material, the generally stationary and rotatable brake parts being positioned with the friction material layers in opposing relationship to each other, a hydraulic cylinder and position for forcefully moving the generally stationary brake part toward the rotatable brake part to effect braking therebetween through frictional contact of the friction material layers, the rotatable brake part layer being plastic-bonded organic friction material, and the generally stationary brake part layer being ceramic material.

Abstract: A damping pad for preventing brake squeal includes: a first metal plate with a brake shoe fixed to one surface thereof; a second metal plate; a third metal plate; a first damping layer disposed between the other surface of the first metal plate and one surface of the second metal plate, and composed of viscoelastic material for high temperature use having a maximum loss factor at a temperature of 50.degree. C. to 100.degree. C.; and a second damping layer disposed between the other surface of the second metal plate and one surface of the third metal plate, and composed of viscoelastic material for low temperature use having a maximum loss factor at a temperature of 0.degree. C. to 30.degree. C.

Abstract: A noise abating automotive brake shoe assembly consisting essentially of a mixture of from about 2 to about 30 percent by weight of a discrete, heat-cured, particulate, elastomeric, sound damping material containing cashew nut shell resin, nitrile rubber, resin binder, a fiber selected from a group consisting of metal, glass, mineral rock wool and refractory with the remainder being friction material ingredients.

Abstract: A friction member which is suitable for use as a friction facing member in a transmission is provided. the friction member includes a uniform density heat resistant paper, a first layer of thermoset polymeric binder coated over and at least partially impregnated into one major surface of the paper, granular carbon friction particles uniformly distributed over and partially imbedded in the exposed surface of the first layer and a second layer of thermoset binder over the first layer and partially imbedded granular friction particles which coats without obscuring the granular friction particles.

Abstract: An improvement in a torsional coupling in which clutch separator plates (24) are interleaved between clutch friction plates (16) having friction linings (18) on the opposite surfaces thereof to provide an increased coefficient of friction without substantially increasing the wear of the friction lining of the clutch plates during operation of the clutch or brake. The separator plates (24) are formed of a solid ceramic material (24a) or of a steel plate (46) which is coated with a thin layer of the ceramic material (48). Suitable ceramics include silicon nitride, aluminum oxide and zirconium oxide.

Abstract: A friction system comprising at least two frictionally coupled elements produced of refractory composite materials, wherein one of the friction elements is a carbon-carbon composite material whereas the second friction element is a composite material constituted of a fibrous reinforcement in which the fibers are selected from carbon fibers and silicon carbide fibers, and of a two-phased matrix of which the principal phase is constituted by silicon carbide.

Abstract: A friction apparatus which includes a liner having a friction surface. The liner includes a fabric having fluorine fibers. The liner also comprising a resin.

Abstract: A method of manufacturing a brake shoe or pad in which the back plate is zinc plated and a friction material perform is bonded directly to the zinc plated surface.

Abstract: An asbestos-free disc brake pad is provided by employing a cyanate ester-based resin composition as binder. The disc brake pad exhibits consistent braking properties over a wide range of operating temperatures and an improved service life. Also the serious pollution problem due to use of asbestos in the conventional brake pads is removed.

Abstract: Improved friction pads for use with disc brake. The pad has a central main portion and a peripheral portion which are formed of different matrices having different compositions. The matrix of the central main portion contains a hard substance or substances having a specified range of hardness whereas the matrix of the peripheral portion does not contain such hard substances or contains in only a limited smaller amount than the central main portion. This prevents the brake disc from wearing due to friction with the pad and thus avoids uneven abrasion of the brake disc.

Abstract: Disclosed is a method for making a reinforcing element for use in asbestos-free friction materials. According to the method, heterogenous strands are joined together, without twisting them, and subjected to a fluid jet and to a rubber compounding material. At least one of the strands is fed to the multiplying stage at an overfeed rate.

Abstract: A braking system having a disk brake that is mechanically connected to at least one wheel of the vehicle and cooperates with a brake caliper that is actuated by a threaded rod screwed through a threaded connection in a control nut rotatively mounted inside the caliper body, the threaded connection being irreversible by axial forces alone. The brake linings are made of an elastomeric material having a high friction coefficient when the disk is not rotating. This system provides a compact parking brake having a high power and a large remote-indication capacity, and is particularly useful in railroad vehicles.

Abstract: A multiple disc brake assembly having a plurality of interleaved rotor discs and stator discs which are cooperative with a stationary torque tube which has a carbon composite brake pad mounted on its reaction plate in such a manner to prohibit stress concentration due to relative thermal expansion between the non-similar materials of the torque tube and brake pad at the torque reaction points while providing a reaction mechanism to circumferential forces generated by brake friction.

Abstract: A cap clip for a slot in a brake disc wherein a pair of circumferentially spaced cap clips are mounted on the peripheral edges of each circumferential slot. Each cap clip has an arcuate extension that seats into an arcuate recess in the bottom corner of each slot. Each cap clip also has side portions that functionally engage the annular sides of the brake disc and also may have a top portion and a front portion that seat on the periphery of the brake disc and the side wall of the slot respectively. The pair of cap clips in each slot are not interconnected but are separately retained in their positions in the slots. Such brake disc also may have one retainer located on the periphery of the brake disc between adjacent slots and retained thereon by connection to the clips to reduce oxidation of the brake disc.

Abstract: A brake, clutch, or continuous slip device (12) having a pyrolytic carbon composite friction material (108) directly cooled by water or an ethylene glycol/water solution. Coolant of cooling device (12) may be tapped from a radiator (24) for a prime mover (14). The brake, clutch, or continuous slip device includes a plurality of interdigitated friction discs (74, 76) defining confronting friction surfaces (74b, 76B). One or both confronting friction surfaces have the pyrolytic carbon composite friction material bonded thereon. The material preferably has a bulk density of 0.7 to 1.2 grams/cc.