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1. WO2020198227 - WET FRICTION MATERIAL PRODUCTION METHODS

Note: Text based on automatic Optical Character Recognition processes. Please use the PDF version for legal matters

[ EN ]

WHAT IS CLAIMED IS:

1. A method of producing a friction material, the method comprising:

mixing silica containing filler particles and a liquid binder to form a binder-filler liquid mixture;

saturating a fibrous base material with the binder-filler liquid mixture to form a saturated fibrous base material; and

curing the saturated fibrous base material at a predetermined temperature for a predetermined time to cure the saturated fibrous base material to form the friction material.

2. The method of claim 1, wherein the silica containing filler particles are present in the friction material in a concentration of 20 to 50 weight % of a total weight of the friction material.

3. The method of claim 1, wherein the saturating step is performed by immersing the fibrous base material into a bath of the binder-filler liquid mixture.

4. The method of claim 1, wherein the silica containing filler particles are present in the binder-fi ller liquid mixture in a concentration of 30 to 60 weight % of a total weight of the binder-filler liquid mixture.

5. The method of claim 1, wherein the binder is a phenolic resin.

6. The method of claim 1, wherein the silica containing filler particles are dialomaceous earth particles.

7. The method of claim 6, wherein the diatomaceous earth particles are amorphous.

8. The method of claim 1 , wherein the saturated fibrous base material has a first surface region and a second surface region opposing the first surface region.

9. The method of claim 8, further comprising applying silica containing filler particles to the first and/or second surface regions of the saturated fibrous base material to form a surface region impregnated saturated fibrous base material.

10. The method of claim 9, further comprising curing the surface region impregnated saturated fibrous base material at a predetermined temperature for a predetermined lime to cure the surface region impregnated saturated fibrous base material to form the friction material having a first concentration of the silica containing filler particles in a first friction material surface region and a second concentration of the silica containing filler particles in a second friction material surface region.