Abstract: 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.

Abstract: Abrasive articles comprising a cured thermosetting binder and abrasive grains. The binder is prepared with a poly-functional molecule comprising at least two functional groups selected from the group consisting of carboxyl and anhydride, and a crosslinking agent which is selected from the group consisting of a mono(hydroxyalkyl)urea comprising a single urea group, a single hydroxyl group, and at least two carbon atoms disposed between the urea group and the hydroxyl group, and 2-oxazolidone. The abrasive articles comprise bonded, nonwoven or coated abrasive articles.

Abstract: A braking component such as a brake pad, brake rotor, brake drum or clutch disk is comprised of a metal substrate having a friction material laminated on at least a portion of at least one face of the metal substrate, the friction material being a ceramic-metal composite comprised of a metal phase and a ceramic phase dispersed within each other, wherein the ceramic phase is present in an amount of at least about 20% by volume of the ceramic-metal composite. In particular, the braking component is a metal substrate, such as aluminum, having laminated thereto a ceramic-metal composite of a dense boron carbide-aluminum composite having high specific heat and low density.

Abstract: A brake shoe having a metallic support or backbone member with a brake pad formed of at least two portions, each of a separate compound or composition, with each compound pre-selected to effect a separate result for each of the pad portions. The portions are configured, arranged and dimensioned so that each (and all) pad portions have a braking surface in contact with the rim generally simultaneously. The partitioned brake pad is formed of different combinations of multi-rubber or elastomers, not a particular combination, to improve wet and dry braking with one pad or the same pad. The selection of multi-rubber or elastomers could be used to stop squealing and grabbing, while also giving the pad stopping power at the same time; or a different combination could be used in wet and dry conditions, or a combination of compounds may be utilized for different partitions for racing conditions, or the like.

Abstract: A brake component wherein at least a portion of said brake component is a ceramic metal composite (CMC), the CMC having an interconnected ceramic phase and a noncontiguous metal phase dispersed within the interconnected ceramic phase. In particular, a CMC of dense boron carbide-aluminum composite having high specific heat and low density is described.

Abstract: A brake pad assembly is provided having a split backplate design comprising a damping layer disposed between two metal plates which are mechanically fastened together such that the plates are slightly slidable relative to each other to allow independent vibration of the two plates. The two metal plates are provided with a ratio of the thickness of the plate farther from the friction material to the plate closer to the friction material of at least 1.50. The damping layer is formed of a non-compressible, non-metal, heat-resistant material such as glass fiber cloth, mineral fiber cloth, ceramic fiber cloth, aramid fiber cloth, or graphite fiber cloth, and preferably has a low coefficient of friction. The plates are mechanically fastened together by rivets, pins or the like.

Abstract: A disk pad type brake comprises a rotor disk provided with a carbon-carbon composite material (a) as a friction member, and at least one pad provided with a carbon-carbon composite material (b) as a friction member, wherein the difference in thermal conductivity between the materials (a) and (b) is 30 to 450 W/m.multidot.K in the radial direction; and a multi-disk type brake comprises at least one rotor disk provided with a carbon-carbon composite material (c) as a friction member, and at least one stator disk provided with a carbon-carbon composite material (d) as a friction member, wherein the difference in thermal conductivity between the materials (c) and (d) is 30 to 450 W/m.multidot.K in the radial direction.

Abstract: A method and apparatus for producing an arcuate brake shoe from a first strip of material which is to provide a web of the shoe and has a plurality of projections extending from one edge and a second strip which has a plurality of corresponding openings to receive the projections and which is to provide the platform of the shoe. The two strips are secured together with projections and openings engaged and formed into an arcuate shape by passage through a roller arrangement.

Abstract: This invention relates to metal and ceramic matrix composite brake rotors comprising an interconnected matrix embedding at least one filler material. In the case of metal matrix composite materials, the at least one filler material comprises at least about 26% by volume of the brake rotor for most applications, and at least about 20% by volume for applications involving passenger cars and trucks. In a preferred embodiment of the present invention, the metal matrix composite brake rotor comprises an interconnected metal matrix containing at least about 28% by volume of a particulate filler material and more preferably at least about 30% by volume. Moreover, the composite rotors of the present invention exhibit a maximum operating temperature of at least about 900.degree. F. and preferably at least about 950.degree. F. and even more preferably at least about 975.degree. F. and higher.

Abstract: A fiber reinforcing mat is used proximate a through hole in an automotive structural element in order to reinforce the element in the area approximate the through hole. The fiber reinforcing mat is comprised of a warp having a plurality of radially extending loops and a weft which is woven through the loops in a spiral fashion. Since the weft is configured as a spiral, weft material is more dense in the area close to the through hole than in the area distal of the through hole. Consequently, the stiffness of the structural element decreases gradually in radial directions away from the through hole.

Abstract: A friction pad for a disc brake comprising a stationary pad which is fixed on a backing plate, and a rotatable pad which is rotatably attached to the backing plate, wherein the rotatable pad is rotatable along an axis which is perpendicular to the backing plate.

Abstract: A multimaterial disk for high-energy braking comprises an assembly of various flanges. They comprise, in succession, a central flange and on either side of the central flange thermal barriers and outer flanges made up of a substrate faced on one side with a ceramic or cermet type facing.

Abstract: In a method of making a carbon fibre preform such as for use in the manufacture of a friction disc a compressible body of carbon fibre or carbon fibre precursor material is acted upon by compressing means to compress the body to a required thickness and then operated upon by means such as a barbed needle-punch needle for a stitching thread which penetrates substantially the whole thickness of the body whereby the compressed preform may be removed from action by the compressing means in a free-standing and compressed state. If the method uses carbon fibre precursor material, that is then subjected to carbonization.

Abstract: A friction lining (5) for a device which is cooled with fluid or lubricant and is intended for transferring torque, in particular a friction clutch, synchronizing element or brake, the friction lining being fastened on a carrier body (2) in order to form a friction surface (6) and the torque being transferred to a counter-surface, is constructed from at least two different layers, and in particular from at least one porous substrate (11, 11') which is fastened on the carrier body (2) and which is constructed like a composite material from a cellulose base with synthetic fibers and filler, and from a porous friction layer (12) which is fastened on the substrate (11,11') and is made of synthetic fibers, preferably carbon, which are bonded with a thermoset resin.

Abstract: A brake shoe having a metallic support or backbone member with a brake pad formed of at least two portions, each of a separate compound or composition, with each compound pre-selected to effect a separate result for each of the pad portions. The portions are configured, arranged and dimensioned so that each (and all) pad portions have a braking surface in contact with the rim generally simultaneously. The partitioned brake pad is formed of different combinations of multi-rubber or elastomers, not a particular combination, to improve wet and dry braking with one pad or the same pad. The selection of multi-rubber or elastomers could be used to stop squealing and grabbing, while also giving the pad stopping power at the same time; or a different combination could be used in wet and dry conditions, or a combination of compounds may be utilized for different partitions for racing conditions, or the like.

Abstract: A brake shoe for an elevator safety device comprising a supporting body provided on a vertically moving body and having a front surface thereof facing a guide rail for being pressed toward the guide rail in the event of an emergency stop; the front surface having a plurality of bottomed holes provided therein; and a plurality of ceramic braking members disposed in the holes of the supporting body and each having a top portion thereof protruding from the front surface of the supporting body and each having an outer size smaller than a complementary size of each the hole. In the brake shoe, deformation, fusion, etc. on braking surfaces and breakage of the braking surfaces due to shocks during operation can be prevented, thereby achieving an improvement in safety and reliability. Further, an elevator speed can be increased and a device size can be reduced.

Abstract: A tread brake shoe for a railroad wheel has a cross-section with a bidirectional laminate structure, which includes a core element of a high-friction material for contacting the wheel tread and, at least one low-friction element positioned on the high-friction material sidewall for contact with the wheel flange and to inhibit wheel flange contact with the high friction material.

Abstract: Disclosed is a friction pad of a disc brake for a vehicle. The friction pad has a lining, which contacts the brake disc with friction and is formed of a carbon composite material, and a coating layer formed of glass or a heat resistant resin on the back surface and side surfaces of the lining. The carbon composite layer is preferably a carbon-carbon composite or a glass-impregnated carbon material. Borosilicate glass is suitable as the glass.

Abstract: A tread brake shoe for a railroad wheel has a cross-section with a bidirectional laminate structure, which includes a core element of a high-friction material for contacting the wheel tread and, at least one low-friction element positioned on the high-friction material sidewall for contact with the wheel flange and to inhibit wheel flange contact with the high friction material.

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 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 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 wear-resistant composite structure which is especially suitable for use in the formation of sealing components, brake linings, electrical motor brushes, bearings, and like products, is disclosed. This composite structure includes as its primary component vitreous carbon in a continuous phase, and strengthening fibers interspersed throughout the vitreous carbon in a discontinuous phase. These fibers are individually convoluted in configuration, so as to improve the crack-resistance and other physical properties of the vitreous carbon. A suitable method of forming such wear-resistant composite structure is also disclosed.

Abstract: The friction lining for disk brakes comprises a carrier plate (10) and a block (16) of a compressed friction material secured to the latter, wherein the carrier plate, on the side bearing the block of friction material, is provided with a sinter-fused mounting bed (12) for the block of friction material of individual shaped members (13) forming frictional and positive connections with the block of friction material, in which, prior to the block of friction material is pressed onto the carrier plate (10) with the mounting bed sinter-fused thereupon, a galvanically, thermally or in some other suitable way produced metallic coating (50) is applied to the carrier plate as a corrosion protection.

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 composite metal material for a friction brake composed of a sliding friction surface metal layer of grey cast iron and a layer of a high strength different metal having a crack transmission resistance. The grey cast iron and high strength different metal are metallurgically bonded together. In this composition metal material, cracks formed in the sliding friction surface metal layer are prevented from spreading by the high strength different metal having a high crack transmission resistance. An intermediate metal layer may be provided if desired.

Abstract: A friction material and carrier plate assembly which may be used in the construction of a driven plate of a friction clutch has a flat, metal, disc-shaped, carrier plate integral with spokes co-planar with the carrier plate and radiating from the outer periphery of the plate. The spokes are adhesively bonded and/or riveted to the bases of recesses in one of the radial friction faces of a one-piece annulus of friction material, that face being proud of the spokes. The assembly is centered on an axis relative to which the annulus and spokes can flex axially.

Abstract: A method of manufacturing a friction article wherein a fiber material (14) having a continuous and substantially uniform three dimensional matrix which is filled with a slurry (24) made up of fillers, friction modifiers, a reinforcing material and a liquid binder. The filled fiber material is conveyed to a dryer (32) where the volatile solution is evaporated leaving the fillers, friction modifiers, reinforcing material and binder. The filled fiber material (14) is thereafter placed in an oven (50) where a compressive force is applied thereto while the binder is cured to define a second matrix which holds the fillers, friction modifiers, and reinforcing material in the three dimensional matrix.

Abstract: A friction material member particularly useful in high load and temperature applications and a method for making the same are disclosed. The friction material member is made by preparing a mixture of sinterable metal particles, carbonaceous material, friction enhancers and curable polymeric resin; the mixture comprising at least about 50 percent by weight of metal particles and sufficient resin to coat and bond the metal particles, carbonaceous material and friction enhancers. The mixture is molded and the resin cured to form a piece in a solid preformed shape corresponding to the shape of the mold. Thereafter, the preformed piece is heated in a substantially oxygen free atmosphere for a time and at temperatures and pressures sufficient to fuse at least a portion of the metal particles into a sintered metal matrix. The preformed piece may be sintered to a metal backing plate during the heating step, or may be welded, brazed or soldered to the plate after heating.

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: A wheel and brake assembly having a plurality of friction members moved by a pressure plate toward a backing plate to affect a brake application. Each friction member has a metallic drive ring coupled to a carbon disc. The carbon disc on a first friction member engages a portion of the drive ring on adjacent friction members to prevent the passage of air to the coupling that could degrade the carbon disc through oxidization.

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: 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: An improved process for preparing a friction particle results when a thermosettable resin is crosslinked in liquid suspension, producing a friction particle which is insoluble, infusible, has good friction stability and good braking fade resistance, and has a narrow particle size range. Also disclosed is a novel polyester friction particle prepared according to the above process or according to a conventional process.

Abstract: A friction disc comprises continuous longitudinally co-extensive generally parallel glass strands wound spirally in the plane of the disc; short, generally parallel glass strands extending normal to the plane of the disc along said spiral; non-ferrous metal chips or wires; and a heat curable cement binding said glass strands and non-ferrous metal chips or wires together. The friction disc is made by forming a glass fabric with warp rovings of continuous parallel glass strands and fill rovings of continuous parallel glass strands; impregnating the fabric with a heat curable cement; winding the glass fabric onto a mandrel to form a spirally wrapped cylinder; slicing the cylinder into disc preforms; and molding the disc preforms under heat and pressure. Either non-ferrous metal wires are included in the fabric or non-ferrous metal chips are deposited on the fabric prior to wrapping the fabric onto the mandrel.

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-like brake or clutch component suitable for being carried in non-rotatable fashion by one of two relatively rotatable members of a brake or clutch and having relatively porous axially protruding spaced sectors for receiving abrasion carried between and integral with spaced spokes of a wheel-like relatively non-porous carrying member of much higher density than said sectors is prepared from a single powdered metal mixture, by placing two different thicknesses of metal powder in portions of a mold for powdered compressing powdered metal portions of greater thickness being joined by portions of lesser thickness and compressing the portions of lesser thickness with a pressure about 40 to 50 or more Tsi and compressing the portions of greater thickness with a lesser pressure of about 5 to 15 or 20 Tsi to produce a preform and then sintering said preform in a reducing or inert atmosphere under a moderate pressure of the order of 200 to 500 Psi and at a temperature of about 1,500.degree. to 1,900.degree. F.

Abstract: A friction plate for use, inter alia in a vehicle disc brake includes a metal backing plate and a plurality of friction pads carried by the backing plate on one major surface thereof. The friction pads are arranged on one major surface in first and second, circular rows which bound respectively first and second concentric, circular annuli. The external diameter of the first annulus is less than the external diameter of the second annulus, but is greater than the internal diameter of the second annulus so that the annuli overlap.