Abstract: Paper base friction material in the form of a porous, flexible interfelted fibrous sheet comprised of a mixture of 25 to 65 percent cellulose fibers, 5 to 20 percent carbon fibers, 5 to 20 percent flame-resistant organic fibers, fillers, and an oil resistant elastomeric sizing. The friction material also includes a synthetic resin binder which may be incorporated during preparation of the sheet or subsequently. In use, the paper base friction material is bonded to a supporting member, preferably metal, whereby it is useful as a friction element particularly in oil, such as in automotive automatic transmissions.

Abstract: A laminated friction member, such as a clutch facing comprising a friction element comprising aramid fibers and a reinforcing element formed of non-aramid fibers, the elements being impregnated with and bonded together by means of heat-curable cement.

Abstract: A composite friction element suitable for the manufacture of railroad brake shoes of the composition type is prepared from a mixture of a curable rubber binder having distributed therethrough a plurality of fillers and a reinforcing fiber, at least one of the fillers having an oil absorption value of at least 30 and the fiber being formed from an aramid polymer.

Abstract: Composition railroad friction materials having low wear rates are characterized by the use of synthetic fiber and by the absence of lead and asbestos. These friction materials are particularly suitable for use in railroad brake shoes and contain, by approximate weight, 0.5-11% non-asbestos fiber, of which at least 0.5% is synthetic fiber, 66-81% filler and 14-21% organic binder.

Abstract: The present invention relates to composite friction assemblies and to methods of making the assemblies. The assemblies include at least one friction member and a support member. The friction member is formed from a mixture of thermosettable phenol-aldehyde resin and filler material under conditions less than those which would thermoset the resin component. The preformed friction member is joined to the support member by molding a mixture of phenol-aldehyde resin and filler material in a mold cavity which utilizes a face of the preformed friction member as a portion thereof. The molding conditions are such that the resin component of the members are commonly cured, or thermoset, to produce a composite friction assembly.

Abstract: The invention concerns a composition for a friction material, e.g. for a clutch facing, of the type containing a fibrous reinforcement, a binder and various additives.The composition contains a thermoset binder, the binder making up 15 to 40% by volume of the material.The fibrous reinforcement is a mixture of inorganic and organic fibres which makes up about 70 to 33% by volume of the material. The inorganic fibre is selected from metal fibres, glass fibre, mineral wools, silica fibres and ceramic fibres. The organic fibre can be wood pulp, jute, sisal, cotton.

Abstract: A method of manufacturing a clutch facing including the steps of mixing graphite and phenolic resin to form a graphite mixture, soaking an asbestos fiber string within the mixture, removing the soaked string such that phenolic resin content of between 14-24 weight percents and graphite content of between 1-8 weight percents for every 100 weight percents is produced and bonding the string to the clutch facing such that the Rockwell hardness of the clutch facing is between 20-60 on the Moh scale.

Abstract: A combined friction modifier and reinforcing agent and friction materials containing it are disclosed in which the combined modifier and reinforcing agent comprises a substantially amorphous, unstable, finely divided glass convertible in response to heat generated by the friction material during use to a devitrified, crystallized, friable state which separates from the amorphous, unstable glass in a substantially non-smearing particulate form.

Abstract: A disc brake pad comprises an organic friction material layer and an organic backplate layer. Both layers are formed of pulverulent materials compacted into "green" preforms at a pressure of 80-150 bars, which are then placed in a mold where heat and pressure are applied to create the integral disc brake pad. Both layers use the same resin and they may even be of identical composition.

Abstract: A friction segmented brake disk has a plurality of arcual segments which are rigidly fastened together by a tongue extending from at least one end portion of the segment and is received by an adjacent segment recess and fastened thereto by at least two fastening members. The tongue, recess, and fastening members all reside by the periphery of each arcual segment, substantially beyond the swept area of each segment to avoid the thermal expansion and contraction forces inherent to the swept area. In another embodiment, a rigid friction brake disk contains a plurality of arcual segments which have a slot in each end portion thereof. A clip engages the slots and is connected thereto by a fastening member. Similarly, the clip, slot and fastening members will reside on the periphery of each arcual segment, substantially beyond or outside the swept area of each segment, and thereby also minimizes thermal expansion and contraction forces inherent to the swept area.

Abstract: A disc brake comprising a plurality of alternating stators and rotors each comprising a friction lining at least one of which is constituted by a support and a shoe engaged in the support. Each shoe comprises a first part of larger cross-section and a second part of smaller cross-section extending from the first part and defining therewith a shoulder, the shoe being mounted in a support having an aperture constituted by a first bore of larger diameter extending partly in the depth of the support and a second bore of smaller diameter extending in the remainder of the depth of the respective support so as to define a shoulder against which the shoulder of the shoe can bear. Two adjacent shoes are disposed in respective supports to face in opposite directions in such supports. Furthermore, the shoes in adjacent supports are geometrically identical.

Abstract: A reinforced carbon article which comprises a carbon fiber shape bonded by a carbon binder and having incorporated within said article a friction modifier, e.g., the in situ reaction product of carbon and a boron containing additive which comprises a material selected from the group consisting of boron, boron nitride, boron silicide and refractory metal borides; and a process of making such an article which comprises forming a carbon fiber shape, dispersing a boron containing additive within at least a portion of said carbon fiber shape, impregnating the carbon fiber shape with a carbonizable binder, and heating the shape to carbonize the binder and to form in situ the reaction product of carbon and the boron containing additive.

Abstract: An asbestos free organic base friction material for use as a friction lining of a brake. A combination of fibers selected from a group consisting of steel, cellulose, glass mineral and rayon fibers and a thermosetting resin binder are combined with cashew nut particles, elastomeric modifiers and inorganic modifiers to produce an organic base friction material having a substantial stable coefficient of friction over the normal operating range of the brake.

Abstract: A friction facing for clutches and the like of improved hot burst strength formed of a glass fiber tape disposed in an undulating annular fashion, the undulations being compressed and bonded together by a heat-curable cement system containing rubber, resin and friction modifiers, the rubber being a vulcanizable carboxy nitrile rubber, the resin being a water-soluble, low molecular weight, one-step thermosetting phenol formaldehyde resin, and the friction modifiers being finely divided organic and inorganic particles. In fabricating the friction facings, prior to the application of the heat-curable cement system, there is applied to the glass filaments a precoating comprising rubber, resin and furnace black which is compatible with the cement system and which is applied as an aqueous dispersion.

Abstract: A method of protecting an aluminum braking surface is disclosed. A brake lining associated with the surface is formed of a brake lining material which includes as a part of the composition an additive of sodium fluoride or cryolite. When a brake system composed of the braking surface and the brake lining are subjected to repeated braking actions, the additive of the brake lining reacts with a surface layer of the aluminum braking surface to form a tenacious, wear resistant layer thereon. The additive, upon further braking actions serves to maintain the wear resistant layer as fresh aluminum is exposed during normal wear of the braking surface over its useful life.

Abstract: A system is disclosed for removing squeal or noise from automotive disc brake assemblies. An emulsion of a normally soft polymer together with a cellulosic thickener, an antifreeze compound, a biocide and pigment is coated onto the back side of the outboard pad assembly. When dry the outboard pad assembly is mounted on an automotive disc brake assembly.

Abstract: A disc brake comprising a rotor and a stator wherein the rotor and/or the stator includes a mounting member provided with a friction lining formed at least in part by a plurality of graphite plates, each plate having two flat side faces and a peripheral surface which is perpendicular to the two flat side faces, each plate being received in a recess in a side face of the mounting member, each recess having a flat bottom surface and being of a depth less than the thickness of the plate, the side wall of the recess being parallel to the peripheral surface of the plate and spaced from the peripheral surface of the plate by a distance greater than that necessary to permit thermal expansion and contraction between the mounting member and the plate. The graphite plates of one of the rotor and the stator are formed of polycrystalline graphite and the other of the rotor and the stator is formed and/or has graphite plates formed of structural graphite.

Abstract: A friction coupling which utilizes a friction plate composed of high modulus asperities incorporated into a reboundably compressible elastomeric matrix for selective rotational engagement with a relatively noncompressible reaction plate between which is directed a flow of fluid with the asperities hydrodynamically wedging such fluid into a relatively thin load supporting film between the asperities and the reaction plate which film absorbs substantially all of the energy of engagement in the shearing effect of the fluid during relative rotation of the plates.

Abstract: One or both ends of a skateboard has its effective lower surface of the platform brought nearer to the ground than the remainder of the platform by the addition of a block or blocks which comes into contact with the ground when the rider elects to ride the skateboard on only one of the two sets of wheels. The existence and shaping of this block assists the rider to maneuver and control the board and avoids the wear of an irreplaceable part of the board. The block is moulded plate of suitable material attached to the underside of the board the major opposing sides of the plate being elliptical. For control purposes the shape over a 120.degree. central sector of the major side is significant but for wear factor reasons it is extended to 160.degree.. No part of the radius should be less than 15 mm, or more than 110 mm. and the contact periphery should have a rounded shoulder to provide a satisfactory area of initial contact.

Abstract: An anti-oxidation coating, particularly for the exposed peripheral regions of graphite brake discs for aircraft, comprises a layer of silicon on the surface of the graphite, a layer of nickel overlying the silicon layer and a layer of chromium overlying the nickel layer. The silicon layer is suitably formed by flame-spraying followed by arc-melting, and the nickel and chromium layers by electroplating.

Abstract: Resurfaced brake discs comprise a carbon disc and a wide tape of wear resistant material applied to the periphery of the disc, the tape being cut on one or both sides of the disc to allow the tape to be folded over the wearing surface of the disc. The tape is impregnated with a curable resin and heated under pressure to form a strongly adherent friction surface on the disc. Boron-containing or other additives may be added to the tape to improve friction qualities or to increase the oxidation resistance of the surface. Additional resin impregnations and heat treatments may be employed to strengthen the tape surface. The method is not limited to worn brake disc but may also be employed for resurfacing new brake discs as well.

Abstract: A system is disclosed for removing squeal or noise from automotive disc brake assemblies. An emulsion of a normally soft polymer together with a cellulosic thickener, an anti-freeze compound, biocide and pigment is coated onto the back side of the outboard pad assembly. When dry the outboard pad assembly is mounted on an automotive disc brake assembly.

Abstract: A rotatable brake or clutch friction disc formed of a material having characteristic strength weakness in tension and shear modes and provided with an annular metal force transmitting member interposed between the disc and fixed or rotatable portions of the brake or clutch. The annular metal force transmitting member has a plurality of circumferentially spaced apart radially extending key engaging slots or slot engaging keys. The annular metal force transmitting member may be provided with opposite radially extending annular metal shields which slidably engage similar shields on adjacent discs to provide a barrier tending to minimize air flow to and thus oxidation of a heated friction disc.

Abstract: An organic friction pad having iron powder particles added thereto to provide thermal stability when used with a copper rotor to maintain a substantially uniform coefficient of friction up to 550.degree. F.

Abstract: Carbon cloth sheaths impregnated with oxidation inhibiting materials are located between drive slots on the periphery of a carbon friction disc to prevent structural degradation of a band of continuous carbon fibers located in the disc through which a braking torque is uniformly distributed throughout the carbon friction disc during frictional engagement. A metal screen is mated to the carbon cloth by a resin binder. The metal screen carbon cloth sheaths or caps may be held on the disc periphery by locating pins to permit a resin binder bond to be established between each cap and associated arcuate segment of the periphery of the carbon friction disc. Anchor pins which hold a series of metal reinforcing plates in a fixed position with the drive slots extend through the walls of the reinforced carbon caps and the carbon friction disc to reduce the possibility of delamination between the reinforced carbon caps and the periphery.

Abstract: A low wear disk brake assembly has a rotatable body and a fixed axle rotatably supporting the body. A stack of disks having splined portions are aligned alternatingly relative to the axle in the body with each disk characterized by being made from graphite and/or carbon materials such that the disks have flexural strength of greater than 5000 psi and an average interlaminar spacing of crystalline and amorphous carbon of not more than 3.39 angstrom units at 15.degree.C.

Abstract: A two piece brake disc includes an outer ring shaped member and an inner ring shaped member disposed concentrically within and joined to the outer member. One of the members comprises a structural member for mounting the disc with the other member comprising a wear member having one or more frictional surfaces and being replaceable because of the two piece construction. The members are essentially all-carbon composites which may differ chemically from one another such as through use of additives in the structural member to increase its oxidation resistance. The all-carbon composites may include carbon fibers with at least some of the fibers in the structural member being longer and circularly oriented to provide portions of the structural member with added strength.

Abstract: Low abrasion, high strength friction materials are described, containing rubber binder, inorganic filler, fiber, and not more than 1% by volume of lead and lead oxide. Organic fillers and phenolic resins may also be present. The materials find particular use as brake shoes for railroad rolling stock which uses wheels of relatively soft steel.

Abstract: The invention resides in a carbonaceous aircraft brake disk having a reuseable lightweight carbon composite center core to which can be bonded lightweight composite wearing materials to each side. The wearing surface is particularly designed for wear loading applications, and is relatively thin thereby simplifying manufacturing and quality assurance steps. The center core is designed for long life and strength at relatively low cost. A carbon felt layer saturated with an adhesive is located between the center core and the lightweight side wear materials to form an integral disk upon pyrolizing of the adhesive.

Abstract: A disc brake comprising a number of interleaved rotor and stator elements and a brake actuator which is arranged to urge the rotor and stator elements into engagement in order to apply the brake. The engagement surfaces of the rotors and stators are provided with areas of carbon and non-carbon based friction material which are arranged so that the disc brake consists of a number of iron friction pairs and a number of carbon friction pairs, the iron friction pairs being located nearer to an open end of the brake structure so that the friction pairs most likely to be wet are those which perform best when wet.

Abstract: A friction member assembly for a brake or clutch in which a first flat frictional surface is made up of a sheet of pyrolized cloth and carbonaceous filter material laminated to other sheets of a braking member and an opposing second flat frictional surface is made up of the overlapping edges of laminated sheets of pyrolized cloth and carbonaceous filler material extending obliquely from the frictional surface providing improved operation in the wet and dry condition when the first and second frictional surfaces of the assembly are brought into frictional engagement.

Abstract: Fluoroelastomers, including ultra high temperature, thermally stable fluoroelastomers, are bonded to a metal backing member by (a) compounding the fluoroelastomers with CaO, (b) curing the fluoroelastomers in contact with a pretreated surface of the metal member, and (c) postcuring the fluoroelastomers/metal unit at elevated temperatures.

Abstract: A nonmetallic friction member is constructed of a bulk graphite component bonded to a resin impregnated carbon cloth component. The friction member is particularly useful for brake and clutch devices, especially multiple disc-type brakes for aircraft. The member may be in the form of a rotor or stator. If driving slots are provided, the member may be reinforced with resin impregnated carbon cloth at these slots.

Abstract: A carbon brake disc has its torque transmitting formations (keyways or keys) reinforced by filament reinforced carbon inserts which are preferably located, and may be bonded, in cut-out areas of the disc periphery. The formations are formed by a separate series of operations from those used to form the remainder of the friction members such as by application of a filimentary reinforcement of carbonized cloth, textile tape, random textile fibers or boron fibers.

Abstract: Molded articles of carbon or graphite suitable as heat absorbing or friction elements in brakes for jet aircraft are made by coating devolatilized carbon particles with a phenolic resin, especially boronated phenolic resin, reducing the volatile content of the coated carbon to below a critical value, mixing these with a resin coated or uncoated powdered abrasive, molding under critical pressures and temperatures, and then post-curing the resin and carbonizing and optionally graphitizing the product according to a schedule whereby delamination is avoided.