Manufacturing method for a facing having a two-layered structure

Abstract

A manufacturing process for a two-layered facing 1 includes: a front material preparation step 11 ; a backing material preparation step 21 ; and a molding step 31 . The backing material preparation step 21 includes the following steps: a papermaking step 22 in which short fibers and pulp material are blended and made into a paper, the paper is then coated with a binding agent and dried to obtain a paper sheet 4 ; and a winding step 23 in which the paper sheet 4 is cut into a tape-like form and rolled into a ring shape to obtain a backing molding material 5 . In the molding step 31 , the two-layered facing 1 is manufactured by laminating together a front material 2 manufactured in front material preparation step 11 and the backing molding material 5 manufactured in backing material preparation step 21 and thermally molding the two materials together while applying pressure.

What is claimed is:  
     
         1 . A manufacturing method for a backing molding material that is molded integrally with a front material having a friction surface in a two-layered facing, comprising: 
 a papermaking step being configured to obtain a paper sheet by blending short fibers and pulp material and making said short fibers and pulp material into paper, coating said paper with a binding agent, and drying said paper; and    a winding step being configured to obtain a backing molding material by cutting said paper sheet into a tape-like form and winding it into a ring shape.    
     
     
         2 . The manufacturing method for a backing molding material for a two-layered facing as recited in  claim 1 , wherein 
 said papermaking step manufactures said paper sheet such that the basis weight thereof is greater than or equal to 0.025 kg/m 2  and less than or equal to 0.110 kg/m 2 .    
     
     
         3 . A manufacturing method for a two-layered facing, comprising: 
 a front material preparation step being configured to prepare a front material;    a manufacturing step being configured to manufacture a backing molding material, said manufacturing step comprising,    a papermaking step being configured to obtain a paper sheet by blending short fibers and pulp material and making said short fibers and pulp material into paper, coating said paper with a binding agent, and drying said paper, and    a winding step being configured to obtain a backing molding material by cutting said paper sheet into a tape-like form and winding it into a ring shape; and    a molding step being configured to laminate said backing molding material and said front material together and to mold to obtain a facing having a two-layered structure.    
     
     
         4 . The manufacturing method as recited in  claim 3 , wherein 
 said papermaking step manufactures said paper sheet such that the basis weight thereof is greater than or equal to 0.025 kg/m 2  and less than or equal to 0.110 kg/m 2 .    
     
     
         5 . The manufacturing method as recited in  claim 4 , wherein 
 said front material is made of a rubber substrate impregnated with a friction adjusting agent and a first thermosetting resin.    
     
     
         6 . The manufacturing method as recited in  claim 5 , wherein 
 said binding agent is made of a second thermosetting resin.    
     
     
         7 . The manufacturing method as recited in  claim 6 , wherein 
 a rubber of said rubber substrate is selected from the group consisting of NBR and SBR.    
     
     
         8 . The manufacturing method as recited in  claim 7 , wherein 
 said friction adjusting agent is selected from the group consisting of calcium carbonate, magnesium carbonate, barium sulfate, silica, cashew dust, and rubber dust.    
     
     
         9 . The manufacturing method as recited in  claim 8 , wherein 
 said thermosetting resin is phenol based.    
     
     
         10 . The manufacturing method as recited in  claim 9 , wherein 
 said first and second thermosetting resins are selected from the group consisting of resol, novolak, and denatured phenol resin.    
     
     
         11 . The manufacturing method as recited in  claim 4 , wherein 
 said short fibers are glass or aramid fibers.    
     
     
         12 . The manufacturing method as recited in  claim 11 , wherein 
 said short fibers have a fiber diameter greater than or equal to 6 μm and less than or equal to 13 μm.    
     
     
         13 . The manufacturing method as recited in  claim 12 , wherein 
 said short fibers have a fiber length greater than or equal to 3 mm and less than or equal to 24 mm.    
     
     
         14 . The manufacturing method as recited in  claim 13 , wherein 
 said pulp comprises natural and/or synthetic fibers.    
     
     
         15 . The manufacturing method as recited in  claim 14 , wherein 
 said natural fibers are selected from the group consisting of wood fibers and leaf fibers, and    said synthetic fibers are selected from the group consisting of aramid and polyester.    
     
     
         16 . The manufacturing method as recited in  claim 4 , wherein 
 said papermaking step comprises,    a raw material step in which said short fibers and pulp material are dispersed in liquid and blended to make a slurry,    a wet papermaking step in which said slurry is directed to a papermaking machine that produces a sheet of fiber substrate on a screen said sheet of fiber substrate is dewatered, removed from said screen,    a binding agent deposition step in which said binding agent is sprayed onto said sheet of fiber substrate, said binding agent comprising powdered thermosetting resin,    a drying step in which said sheet of fiber substrate is dried, and    an inspection step in which said sheet of fiber substrate is inspected prior to said winding step.    
     
     
         17 . The manufacturing method as recited in  claim 16 , wherein 
 said molding step further comprises compressing a width of said backing molding material to adhere to a predetermined thickness.    
     
     
         18 . The manufacturing method as recited in  claim 3 , wherein 
 said short fibers are glass or aramid fibers.    
     
     
         19 . The manufacturing method as recited in  claim 18 , wherein 
 said short fibers have a fiber diameter greater than or equal to 6 μm and less than or equal to 13 μm, and said short fibers have a fiber length greater than or equal to 3 mm and less than or equal to 24 mm.    
     
     
         20 . The manufacturing method as recited in  claim 19 , wherein 
 said pulp comprises natural and/or synthetic fibers, said natural fibers are selected from the group consisting of wood fibers and leaf fibers, and    said synthetic fibers are selected from the group consisting of aramid and polyester.