Friction Materials Made With Resins Containing Polar Functional Groups

Abstract

A friction material that has a base material impregnated with at least one resin having at least one type of functional group that interacts with the additives in the lubricant. In the preferred embodiment, the resin is a hydroxyl or aldehyde modified phenolic. The heat of absorption, or the interaction energy, of the modified resins to friction modifier additives are larger than the heat of absorption of non-modified phenolic resins when compared to the same friction modifier additives or similar mimic compounds.

Description

TECHNICAL FIELD

The present invention relates to friction materials made with resins possessing at least one functional group that can interact with the lubricant. Such groups have an affinity towards the polar or aromatic components in the automatic transmission fluid and interact with these components to affect the lubricant film composition and structure. The degree of interaction can be quantified through the measurement of the heat-of-adsorption of a probe molecule, representative of the fluid components, and the resin.

BACKGROUND ART

New and advanced automatic transmission systems, having continuous slip torque converters and shifting clutches are being developed by the automotive industry. The development of these new systems is driven by the need to improve fuel efficiency. Therefore, the friction material technology must be also developed to meet the increasing. requirements of these advanced systems.

In particular, as the clutch interfaces are reduced in size to reduce weight, the friction material must be able to perform in environments more severe than found in current transmissions. In this environment, the apply pressure generally must be increased to maintain torque capacity, thus increasing the energy density within the friction interface and concomitantly the interface temperature. Newer transmissions are therefore also being designed to run hotter, stressing both the friction element and the transmission fluid. This change in the interface environment can lead to early degradation of the friction modifier system contained in the lubricant, thus reducing the available concentration for adsorption onto the friction surfaces. In addition changes to the transmission designs have lead to systems that are more sensitive to increases in friction with decreased speed (negative μ-v slope).

Phenolic resins are used as an economic impregnant in friction materials for clutch and brake applications. Phenolics impart strength and rigidity to the friction material and, in wet systems, are inert to the lubricant environment. However, these resins have various limitations, most notably when used in sufficient concentration to impart strength the material may become too rigid or brittle for the application. In some high-energy friction materials the phenolic is also the least thermally stable component. Over the years many modifications have been made to phenolic resins to address these limitations including the modification of the phenolic resin with such moieties as tung oil, linseed oil, cashew nut shell oil, melamine, epoxy, various rubbers, metals, boron, refractory oxides and recently nano particles.¹ In some instances the phenolic may be replaced with another thermosetting impregnating resin. The advantages stated in all these patents and other publications deal with improvements to the resin's mechanical properties or its thermal durability.

However, phenolic resins have one other limitation that is widely recognized but not addressed in any prior art; phenolic resins exhibit little surface activity. Incorporation of phenolic resin into the friction composite, while necessary, reduces the interaction between the lubricant and the non-resin components of the friction material. As the resin level is increased, the friction characteristics, in particular the negative μ-v slope, worsen. To overcome this limitation we have invented resins that incorporate at least one functional group to increase the surface activity of the phenolic resin and enhance frictional performance. At present there is no prior art that suggests that phenolic resin having at least one functional group can be used to provide an improved product.

SUMMARY OF THE INVENTION

The present invention relates to friction material made with resins possessing at least one functional group. The functional group may be polar, ionic, electron rich or electron deficient moieties, but must possess an affinity to the additives in the lubricant. Such currently available, new or modified resins provide active sites for the adsorption of lubricant friction modifiers. This adsorption impacts the friction modifier surface-to-solution equilibrium, and correspondingly the μ-v slope and the coefficient of friction. The adsorption of friction modifiers is accompanied by the release of energy, termed the interaction energy or heat-of-adsorption, and can be measured directly to quantify the degree of the adsorption. The degree of adsorption relates directly to the affinity of the resin to the additives in the lubricant. Such heats-of-adsorption are measured utilizing a device such as a flow-microcalorimeter (FMC).² This technique is well established.³

Friction material made with resins modified according to this invention exhibits a stronger interaction, or higher heats-of-adsorption, with lubricant additives. Similar modification to the resins can allow interaction with metal surfaces also affecting performance.

Phenolic resin is used in friction material because of its high thermal stability and low cost. However the resin surface does not adsorb lubricant additives and does not bond well to some friction material components. These problems arise because the phenolic resin is chemically inert and does not interact with other materials or polar compounds. Use of more polar resins such as phenolic resins modified with polar, ionic, electron rich or electron deficient moieties will provide a surface more favorable to bonding and additive adsorption. In addition the increased surface polarity may lead to material that interacts strongly with metal surfaces thus increasing both the dynamic and static coefficients of friction. The resins may be chemically modified either before saturation to maximize the degree of modification or after saturation to concentrate the modifications on the surface of the friction material.

An example of the friction materials covered under this invention is an aldehyde modified phenolic resin. Here the aldehyde groups were bonded directly to the cured resin, after the resin was incorporated into the friction material composite, via the unreacted ortho and para sites on the phenol ring. The density of the aldehyde groups is between 2.5% to 3% of the material weight with a chain length of 6 carbon-carbon bonds. Such modification leads to enhancements in the materials ability to adsorb friction modifiers. In this case the affinity of the final friction material composite was increased 10-fold.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of the Flow-microcalorimeter method of measuring resin affinity to lubricant components.

FIG. 2 shows the reduction in friction material affinity to lubricant components when impregnated with conventional phenolic resin.

FIG. 3 compares the affinity to lubricant components of conventional phenolic resin and the affinity of a resin designed with polar functional groups.

FIG. 4 compares the improvement in affinity to lubricant components of a friction material when the conventional phenolic resin is replaced with a representative resin possessing polar functional groups.

FIG. 5 shows the measured 10-fold increase in the affinity to lubricant components of a frictional material when the conventional phenolic resin is replaced with an aldehyde-modified resin.

FIG. 6 compares the dynamic midpoint coefficient-of-friction of a low energy friction material made with Resin A (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 100 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 7 compares the torque traces showing the coefficient-of-friction variation with time during a shifting engagement of a low energy friction material made with Resin A (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 100 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 8 compares the dynamic midpoint coefficient-of-friction of a moderate energy friction material made with Resin A (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 100 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 9 compares the torque traces showing the coefficient-of-friction variation with time during a shifting engagement of a moderate energy friction material made with Resin A (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 100 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 10 compares the dynamic midpoint coefficient-of-friction of a low energy friction material made with Resin B (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 200 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 11 compares the torque traces showing the coefficient-of-friction variation with time during a shifting engagement of a low energy friction material made with Resin B (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 200 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 12 compares the dynamic midpoint coefficient-of-friction of a moderate energy friction material made with Resin C (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 110 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 13 compares the torque traces showing the coefficient-of-friction variation with time during a shifting engagement of a moderate energy friction material made with Resin C (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 110 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 14 is a graph showing an increase in adsorption and the degree of modification.

DETAILED DESCRIPTION OF THE INVENTION

This invention teaches how polarity and chemical structure of the resin affects μ-v shape and static coefficient. Resin, or modified resin, that contain functional groups possessing affinity towards lubricant additives provide for enhancement of additive interaction with the friction material surface over conventional friction resins. This design of the resin influences the additive adsorption equilibrium in the friction interface and therefore optimizes friction parameters. A convenient method to measure the increased additive affinity is with the use of a FMC.³ A diagram of how the FMC technique operates is shown in FIG. 1. A cured resin is introduced into the sample chamber. A solution of a probe molecule, representative of additives in the lubricant, is then flowed over the resin. If the resin possesses an affinity towards the probe molecule, then heat is evolved as the probe molecule is adsorbed onto the resin surface. The amount of the heat-of-adsorption directly relates to the affinity of the resin to lubricant additives. Details of the theory and operation of the FMC are discussed in the literature.³ In the majority of this work, a 0.2% solution of aminodecane in a nonpolar solvent, such as heptane, was used. However, other concentrations, probe molecules and solvents are acceptable and have been used.

Phenolic resin is known to have negative impact on the coefficient-of-friction characteristics. Unsaturated friction material possesses a high affinity towards lubricant additives. However, once impregnated with phenolic resin, this affinity is drastically reduced. This is illustrated in FIG. 2. FMC measurements show that pure phenolic resin possesses absolutely no affinity towards lubricant additives (zero heat-of-adsorption).

Our concept modifies the phenolic such that it contains active groups by adding to the phenolic resin active resins that promote additive adsorption and consequently improved μ-v character. FIG. 3 compares the heats-of-adsorption of conventional phenolic resin with one of our designed resins containing polar groups. When such resins are incorporated into the friction material, the resulting composite possesses a greater affinity towards lubricant additives than the corresponding composite made with conventional phenolic. A representative example is shown in FIG. 4.

Our modification considers level of treatment (number of active sites needed), structure of the active group (how accessible to interface) and chemical activity of each site. The use of the aldehyde modified resin, referenced previously, increases the affinity of the material to lubricants 10-fold. This data is shown in FIG. 5.

In one aspect, the present invention relates to a friction material comprising a base material impregnated with a resin possessing at least one type of function group. In the preferred embodiments, the resin is comprised of phenolic monomers having at least one function polar group; for example a phenolic resin possesses a high number of surface hydroxyl groups that are bonded directly to phenolic rings via a hydrocarbon chain. The length and structure of the chain and density of the groups can be altered so that the modified resin has sufficient reactive sites on its surface that interact with polar molecules. Examples of modifications covered in this patent are aldehyde, amine, alcohol, ester, ketone, halogenated, acids, acid anhydrides and metal salts. Alkane, alkene, aromatic and branched and crosslinked structures also may be included in the modifications.

In order to achieve the requirements discussed above, many modified resins were prepared and the affinity to lubricant additives measured. In addition friction materials made with these resins were evaluated for friction under conditions similar to those encountered during operation. Commercially available friction materials were used as a control.

The modified resins include an organic compound incorporating one or more high polarity function groups. The polar functional groups include an acid functionality, an alcohol functionality, a ketone functionality, an aldehyde functionality or an ester linkage.

Specific examples of materials classes are as follows:

The acids are polymers containing an acid functionality. They include carboxylic acid, for example, such as those constructed with acrylic acid, methacrylic acid, citraconic, and fumaric acid.

The alcohol are materials such as polyvinyl alcohol.

The ketones include a ketone group that confers water solubility to materials such as vinyl pyrrolidone polymer.

The aldehydes are very similar chemically to ketones, with the doubly bonded oxygen situated at the end of a chain, rather than in the chain. An aldehyde functionality situated on a side chain would enhance solubility of any polymer in aqueous media.

The esters have ester functionality such as for instance polyvinyl acetate.

The acid functionality may be incorporated in the resin by incorporating acid-containing monomers. Useful acid containing monomers include those monomers having carboxylic acid functionality, such as for example acrylic acid, methacrylic acid, itaconic acid, fumaric acid, cirtraconic acid, phosphoethyl methacrylate and the like. A wide variety of monomers or mixture of monomers can be used to make the modified resins. For example, acrylic ester monomers, including methyl acrylate, ethyl acrylate, propyl acrylate, isopropyl acrylate, butyl acrylate, isobutyl acrylate, secondary butyl acrylate, and the like.

The present invention further provides a friction material where the surface of the resin impregnated friction material is available for secondary chemical modifications.

Other ingredients and processing aids known to be useful in both preparing resin blends and in preparing fibrous base materials can be included, and are within the contemplated scope of the present invention.

FIG. 1. An illustration of the Flow-microcalorimeter technique of measuring the resin affinity to lubricant components (heat-of-adsorption).

FIG. 2. The reduction in friction material affinity to lubricant components when impregnated with conventional phenolic resin.

FIG. 3. A comparison of the affinity to lubricant components of conventional phenolic resin to the affinity of a resin designed with polar functional groups.

FIG. 4. A comparison of the improvement in affinity to lubricant components of a friction material when the conventional phenolic resin is replaced with a representative resin possessing polar functional groups.

FIG. 6. Comparison of the dynamic midpoint coefficient-of-friction of a low energy friction material made with Resin A (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 100 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 7. Comparison of the torque traces showing the coefficient-of-friction variation with time during a shifting engagement of a low energy friction material made with Resin A (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 100 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 8. Comparison of the dynamic midpoint coefficient-of-friction of a moderate energy friction material made with Resin A (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 100 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 9. Comparison of the torque traces showing the coefficient-of-friction variation with time during a shifting engagement of a moderate energy friction material made with Resin A (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 100 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 10. Comparison of the dynamic midpoint coefficient-of-friction of a low energy friction material made with Resin B (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 200 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 11. Comparison of the torque traces showing the coefficient-of-friction variation with time during a shifting engagement of a low energy friction material made with Resin B (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 200 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 12. Comparison of the dynamic midpoint coefficient-of-friction of a moderate energy friction material made with Resin C (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 110 mJ/g) to the same friction material made with a conventional phenolic.

FIG. 13. Comparison of the torque traces showing the coefficient-of-friction variation with time during a shifting engagement of a moderate energy friction material made with Resin C (a phenolic resin modified to contain hydroxyl groups possessing a surface affinity of 110 mJ/g) to the same friction material made with a conventional phenolic.

Base Materials

Various base materials are useful in the friction material of the present invention, including, for example, non-asbestos fibrous base materials comprising, for example, fabric materials, woven and/or nonwoven materials. Suitable fibrous base materials include, for example, fibers and fillers. The fibers can be organic fibers, inorganic fibers and carbon fibers. The organic fibers can be aramid fibers, such as fibrillated and/or nonfibrillated aramid fibers, acrylic fibers, polyester fibers, nylon fibers, polyamide fibers, cotton/cellulose fibers and the like. The fillers can be, for example, silica, diatomaceous earth, graphite, alumina, cashew dust and the like. In particular, silica fillers, such as diatomaceous earth, are useful. However, it is contemplated that other types of fillers are suitable for use in the present invention and that the choice of filler depends on the particular requirements of the friction material.

In other embodiments, the base material can comprise fibrous woven materials, fibrous non-woven materials, and composite materials. Further, examples of the various types of fibrous base materials useful in the present invention are disclosed in many BorgWarner U.S. patents. It should be understood however, that other embodiments of the present invention can include yet different fibrous base materials.

EXAMPLES

The following examples provide further evidence that the friction material of the present invention provides an improvement over conventional friction materials. The test results show the modified resins have a desirable impact on coefficient of friction. The heat-of-absorption for the modified resins are substantial higher than non-modified resins. Various preferred embodiments of the invention are described in the following examples, which however, are not intended to limit the scope of the invention.

Instead of using an unmodified phenolic resin as an impregnant, the present invention provides a friction material impregnated with a phenolic resin possessing functional polar groups into the friction material formulation.

Example 1

Low energy friction material saturated with Resin A: A phenolic resin modified to contain hydroxyl groups possessing a surface affinity (heat-of-adsorption to 0.2% aminodecane) of 100 mJ/g. This resin was incorporated into a friction composite and tested for both friction level and friction μ-v characteristic. The friction characteristics were contrasted against those of the same friction material saturated with a conventional phenolic. Charts of the midpoint dynamic coefficient-of-friction for both materials made with Resin A and the conventional phenolic are shown in FIG. 6. Charts of the torque trace taken from a break-in cycle shows improved >-v characteristic for both materials made with Resin A and the conventional phenolic are shown in FIG. 7. In both cases there was an improvement over the conventional resin system.

Example 2

A moderate energy friction material saturated with Resin A: A phenolic resin modified to contain hydroxyl groups possessing a surface affinity (heat-of-adsorption to 0.2% aminodecane) of 100 mJ/g. This resin was incorporated into a friction composite and tested for both friction level and friction μ-v characteristic. The friction characteristics were contrasted against those of the same friction material saturated with a conventional phenolic. Charts of the midpoint dynamic coefficient-of-friction for both materials made with Resin A and the conventional phenolic are shown in FIG. 8. Charts of the torque trace taken from a break-in cycle shows improved μ-v characteristic for both materials made with Resin A and the conventional phenolic are shown in FIG. 9. In both cases there was an improvement over the conventional resin system.

Example 3

Low energy friction material saturated with Resin B: A phenolic resin modified to contain hydroxyl groups possessing a surface affinity (heat-of-adsorption to 0.2% aminodecane) of 200 mJ/g. This resin was incorporated into a friction composite and tested for both friction level and friction 1-v characteristic. The friction characteristics were contrasted against those of the same friction material saturated with a conventional phenolic. Charts of the midpoint dynamic coefficient-of-friction for both materials made with Resin A and the conventional phenolic are shown in FIG. 10. Charts of the torque trace taken from a break-in cycle shows improved 1-v characteristic for both materials made with Resin A and the conventional phenolic are shown in FIG. 11. In both cases there was an improvement over the conventional resin system.

Example 4

A moderate energy friction material saturated with Resin C: A phenolic resin modified to contain hydroxyl groups possessing a surface affinity (heat-of-adsorption to 0.2% aminodecane) of 110 mJ/g. This resin was incorporated into a friction composite and tested for both friction level and friction μ-v characteristic. The friction characteristics were contrasted against those of the same friction material saturated with a conventional phenolic. Charts of the midpoint dynamic coefficient-of-friction for both materials made with Resin A and the conventional phenolic are shown in FIG. 12. Charts of the torque trace taken from a break-in cycle shows improved μ-v characteristic for both materials made with Resin A and the conventional phenolic are shown in FIG. 13. In both cases there was an improvement over the conventional resin system.

Example 5

Resin D, which is a phenolic resin modified to contain polar groups, wherein the polar group is connected to the phenolic backbone polymer with a carbon chain of greater than 10 carbon-carbon units, possessing a surface affinity (heat-of-adsorption to 0.2% aminodecane) of 240 mJ/g. When incorporated into a low energy friction material, the final composite shows almost a 2-fold increase in affinity to lubricant additives (126 mJ/g to 220 mJ/g) when compared with material made with a conventional phenolic.

Example 6

Resin E, which is a phenolic resin modified to contain polar groups, wherein the polar group is connected to the phenolic backbone polymer with a carbon chain of greater than 10 carbon-carbon units, possessing a surface affinity (heat-of-adsorption to 0.2% aminodecane) of 200 mJ/g.

Example 7

Resin F, which is a phenolic resin that was modified to contain aldehyde groups, possessing a surface affinity (heat-of-adsorption to 0.2% aminodecane) of 3400 mJ/g. Here the aldehyde groups were bonded directly to the cured resin, after the resin was incorporated into the friction material composite, via the unreacted ortho and para sites on the phenol ring. The density of the aldehyde groups is between 2.5% to 3% of the material weight with a chain length of 6 carbon-carbon bonds.

Example 8

A commercially available resin that is not a phenolic, though contains some phenolic functionality, and possesses a surface affinity (heat-of-adsorption to 0.2% aminodecane) of 3800 mJ/g.

INDUSTRIAL APPLICABILITY

The present invention is useful as a high energy friction material for use with clutch plates, transmission bands, brake shoes, synchronizer rings, friction disks or system plates. The above descriptions of the preferred and alternative embodiments of the present invention are intended to be illustrative and are not intended to be limiting upon the scope and content of the following claims.

REFERENCES

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• 2. For this work we used a Microscal Model 3 Flow-microcalorimeter.
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Claims

1. A composition useful in friction applications comprising a resin and at least one surface active, functional group wherein the composition when cured has measurable heat-of-adsorption when probed with a polar molecule representative of additives contained in lubricants.

2. A composition according to claim 1 wherein the polar molecule further comprises primary, secondary and tertiary amines, carboxylic acids, ketones, aldehydes, esters, alcohols, glycols and sulfonate with alkyl chains between 3 and 60 carbon atoms.

3. A composition according to claim 1 wherein the heat-of-adsorption is measurable using a standard flow-microcalorimeter when the probe molecule is in a concentration of 0.01 to 10% in a non-polar solvent.

4. A composition according to claim 1 wherein the surface-active functional group is chemically bonded to the resin after the resin is cured.

5. A friction material comprising a base material impregnated with a composition according to claim 1.

6. The friction material of claim 5, wherein the resin comprises at least one type of phenolic resin having at least one type of functional group according to the composition of claim 1.

7. The friction material of claim 6, wherein the phenolic resin is modified with hydroxyl groups.

8. The friction material of claim 6, wherein the phenolic resin resin is modified with aldehyde groups.

9. The friction material of claim 6, wherein the phenolic resin further comprises a high number of surface hydroxyl groups that are bonded directly to phenolic rings via a hydrocarbon chain.

10. The friction material of claim 9, wherein the length of the hydrocarbon chain has a length and density of the groups altered so that the phenolic resin has proper interactions with polar molecules.

11. The friction material of claim 5 wherein the functional group is a reactive site.

12. The friction material of claim 5 wherein the functional group is at least one chemically reactive site.

13. The friction material of claim 5, wherein the functional group is an ionic or polar site.

14. The friction material of claim 5, wherein the function group is at least one organic compound incorporating one or more high polarity functional groups.

15. The friction material of claim 5 wherein the functional group is an acid.

16. The friction material of claim 5 wherein the functional group is an alcohol.

17. The friction material of claim 5 wherein the functional group is a ketone.

18. The friction material of claim 5 wherein the functional group is an aldehyde.

19. The friction material of claim 5 wherein the functional group is an ester.

20. A friction material comprising a base material impregnated with at least one flame retardant material that makes an outer surface of the base material more polar and improves the additive adsorption of the friction material.

21. The friction material of claim 20, wherein the flame retardant comprises a phosphonate type material.

22. The friction material of claim 21, wherein the flame retardant material comprises N-methylol phosphonate.

23. The friction material of claim 20 wherein the flame retardant is present at about 35 to about 40% on a per solids basis (about one phosphonate per phenolic unit).

24. The friction material of claim 5, wherein the base material is a woven fibrous material.

25. The friction material of claim 5, wherein the base material comprises from about 5 to about 75% cotton fibers, about 5 to about 75% aramid fibers, and 5 to about 75% carbon fibers.

26. The friction material of claim 5, wherein the base material has an average pore diameter of about 0.5 to about 200 μm.

27. The friction material of claim 5, wherein the base material comprises about 5 to about 75%, by weight, of a less fibrillated aramid fiber; about 5 to about 75%, by weight, cotton fibers, about 5 to about 75%, by weight, carbon fibers; and, about 5 to about 75%, by weight of a filler material.

28. A friction element according to claim 5 in the form of a clutch facing.

29. A friction element according to claim 5 in the form of a brake shoe lining.

30. A friction element according to claim 5 in the form of a synchronizer.

31. The friction material of claim 5, wherein the length of the chain and density of the groups is altered so that the phenolic resin has proper interactions with polar molecules.

32. The friction material of claim 5, wherein the length of the chain is between 3 and 90 carbons and density of the groups is greater than 30% based on the number of units in the polymer chain.