Pultrusion method of making composite friction units

Abstract

A composite friction unit includes a three dimensional composite body formed of a substantially uniform array of predominately glass strands of primary reinforcing fibers in matrix of phenolic resin material, the reinforcing fibers distributed throughout the body in a predetermined uniform distribution and orientation, and a substantially uniform array and distribution of secondary fibers extending transverse to the primary fibers thereby forming a friction unit having a predetermined size and configuration and uniform distribution and alignment of fibers throughout.

I claim: 
     
       1. A continuous manufacturing process for making composite friction units comprising the steps of: selecting a substantially uniform array of predominately glass strands of primary reinforcing fibers;   wetting said plurality of strands of primary reinforcing fibers with a phenolic resin material;   pulling said wetted strands of reinforcing fibers in a predetermined uniform distribution and orientation through a composite forming die for forming a body having a peripheral configuration of said friction units;   introducing a continuous array of predominately transverse secondary fibers between selected pairs of said plurality of primary fibers prior to entry into said forming die;   solidfying said body by curing said resin; and   selectively cutting said body at least along one path transverse to said strands into .[.it.]. .Iadd.a .Iaddend.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.   
     
     
       2. A process according to claim 1 wherein the step of selecting said primary reinforcing fibers selecting said fibers to make up about 50 to about 70% by weight of said body, and said step of introducing said secondary fibers includes introducing sufficient secondary fibers to make up from 5% to 20% by weight of said body. 
     
     
       3. A process according to claim 2 wherein said resin is selected to contain one to ten percent by weight of powder taken from the group consisting of rubber, copper, barite, talc, ceramic, and nut shell flower. 
     
     
       4. A process according to claim 1 wherein said resin is selected to contain about 2 to 5% by weight of talc powder, about 5 to 10% by weight of copper powder and 3 to 5% by weight of one of nut shell flower. 
     
     
       5. A process according to claim 1 wherein said step of cutting said body is at an angle other than ninety degrees and forms a friction surface at said angle to the fibers. 
     
     
       6. A process according to claim 1 wherein said step of heating said resin is carried out by RF prior to entry of the fibers into the die. .Iadd. 
     
     
       7.  A process according to claim 1, wherein in the step of selectively cutting said body at least along one path transverse to said strands into a plurality of said friction units, the selective cutting is performed so that the primary fibers are substantially parallel to a friction surface on said friction units. .Iaddend..Iadd.8. A process according to claim 1, wherein in the step of selectively cutting said body at least along one path transverse to said strands into a plurality of said friction units, the selective cutting is performed so that the secondary fibers are substantially parallel to a friction surface on said friction units. .Iaddend..Iadd.9. A process according to claim 1, wherein in the step of selecting the substantially uniform array of primary reinforcing fibers, the fibers are selected from the group consisting of individual strands, woven fabrics, matting, stitched fabrics and combinations thereof. .Iaddend..Iadd.10. A process according to claim 1, wherein in the step of selecting the substantially uniform array of primary reinforcing fibers, the selected fibers are woven fabric. .Iaddend..Iadd.11. A process according to claim 2, wherein in the step of selectively cutting said body at least along one path transverse to said strands into a plurality of said friction units, the selective cutting is performed so that the primary fibers are substantially parallel to a friction surface on said friction units. .Iaddend..Iadd.12. A process according to claim 2, wherein in the step of selectively cutting said body at least along one path transverse to said strands into a plurality of said friction units, the selective cutting is performed so that the secondary fibers are substantially parallel to a friction surface on said friction units. .Iaddend..Iadd.13. A process according to claim 4, wherein in the step of selectively cutting said body at least along one path transverse to said strands into a plurality of said friction units, the selective cutting is performed so that the primary fibers are substantially parallel to a friction surface on said friction units. .Iaddend..Iadd.14. A process according to claim 4, wherein in the step of selectively cutting said body at least along one path transverse to said strands into a plurality of said friction units, the selective cutting is performed so that the secondary fibers are substantially parallel to a friction surface on said 
     
     
        friction units. .Iaddend..Iadd.15.  A process for making composite friction units having at least one friction surface, the process comprising the steps of: selecting a substantially uniform array of reinforcing fibers, the fibers impregnated with a resin;   pulling said reinforcing fibers in a predetermined uniform distribution and orientation through a forming die;   introducing a plurality of secondary fibers to the primary fibers prior to entry into said forming die, the secondary fibers transverse to the primary fibers, the primary and secondary fibers forming a body;   solidifying said body by curing the resin; and   selectively cutting said body into a plurality of said composite friction units, so that the primary fibers are substantially parallel to the friction surface. .Iaddend..Iadd.16. A process according to claim 15, wherein in the step of selectively cutting said body into a plurality of said composite friction units, the selective cutting is performed so that the secondary fibers are substantially parallel to the friction surface. .Iaddend..Iadd.17. A process according to claim 15, wherein in the step of selecting the substantially uniform array of reinforcing fibers, the   
     
     
        fibers are impregnated before they are selected. .Iaddend..Iadd.18.  A process according to claim 15, wherein in the step of selecting the uniform array of fibers, the fibers are selected from the group consisting of individual strands, woven fabrics, matting, stitched fabrics and combinations thereof. .Iaddend..Iadd.19. A process according to claim 15, wherein in the step of selecting the uniform array of fibers, the selected 
     
     
        fibers are woven fabric. .Iaddend..Iadd.20.  A process according to claim 15, wherein in the step of selecting the uniform array of fibers, the fibers are selected from the group consisting of glass, rock, ceramic, carbon, graphite, aramid, wool, cotton, organic fibers, and inorganic fibers. .Iaddend.