Patent ID: 8974621
Filing Date: 2015-03-10
Classification: B29C,B29K,B29L,B32B,F16D,Y10T

Abstract:
1. A continuous process for manufacturing composite friction units comprising: selecting a panel of substantially uniform array of predominately glass strands of primary reinforcing fibers, the array of fibers bound together by a process selected from the group consisting of weaving, braiding and stitching, the reinforcing fibers making up about 35% to about 75% by weight of said friction unit; wetting said array of primary reinforcing fibers with a phenolic resin material comprising a wet mixture of friction modifiers including about 5.8% by weight of graphite powder, about 3 to 5% by weight of nut shell flour, about 0.044% wetting agent, about 5% barite, about 3% talc, about 1.9% aluminum oxide and about 0.7% mold release agent; pulling said wetted array of reinforcing fibers in a predetermined uniform distribution and orientation through a composite forming die for forming a body having at least a part of a peripheral configuration of said friction unit; selecting and pulling a substantially rigid panel through said forming die with said panel of primary reinforcing fibers forming a top layer bonded to the substantially rigid panel emerging from the forming die; solidifying said body by curing said resin, wherein said body includes a matrix comprising about 5.8% by weight of graphite powder, about 3 to 5% by weight of nut shell flour, about 0.044% wetting agent, about 5% barite, about 3% talc, about 1.9% aluminum oxide and about 0.7% mold release agent; and selectively cutting said body at least along one path transverse to said strands into a plurality of said friction units, thereby forming a plurality of friction units having a predetermined size and configuration and uniform distribution and alignment of fibers throughout.