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Phenolic resins have been widely used as a binder for friction materials such as disk pads and brake linings. Requirements for disk pads are flexibility, heat resistance, low wear and so on. To solve the above requirements, we have developed various modified resins. At the same time, reduction of manufacturing cost is also required to maintain price competitiveness. The way to reduce manufacturing costs is to cut down the molding cycles and post-baking time, as well as use raw materials with a low price. To increase the molding temperature is one of the effective methods for reducing molding cycle, because the reactivity of phenolic resin increases. However, it is much more difficult to determine the gas release time because large amounts of gas evolve in a very short period of time. The phenol-hexamine curing system is limited in its ability to reduce the molding cycle. In this study we developed a gas-free resin system.

Phenolic resins have been widely used as a binder for friction materials. Increased performance requirements have exceeded the capabilities of standard phenolic resins. Various modified phenolic resins have been developed with proven capabilities and performance levels. The impact on the environment and work place must also be considered when developing new products. In addition to improved performance, new phenolic resins for friction applications should also be improved to address environmental and work place issues. In order to achieve further improvement, fundamental studies, such as morphology, are needed. An EPMA (Electron Probe Micro Analyzer) is useful to identify elements, while former investigations have developed the technology to identify some ingredients in friction materials. However, it has been impossible to show phenolic resin in friction materials since they contain many other ingredients also made from carbon.

Phenolic resins have been widely used as a binder for friction materials, but due to the demand for increased performance requirements, it has made the friction suppliers look at modifications to standard phenolic resins. Various modified phenolic resins have been developed and their performance levels and capabilities have been improved. Concern for both the environment and the work place must be considered during the development of any new product. New phenolic resins for friction should therefore be improved to address environmental issues as well as performance issues. New processes have been developed to reduce free phenol and increase yield, at the same time reducing the waste phenol by-product.. Technology for “dust free” resins provides a cleaner working environment at reduced production costs. Furthermore, a combination of these environmental technologies and modifications solves both performance requirements and environmental concerns in the friction industry.

Phenolic resins have been widely used as binders for Friction Materials. Increased performance requirements have driven the improvement of phenolic resins. Phenolic resins modified with silicone gel, NBR, and aromatic compounds were presented at the 18th ANNUAL BRAKE COLLOQUIUM & EXHIBITION in 2000, their performance levels and capabilities were described. As market demands increase, enhanced phenolic resins as binders are needed to provide high performance friction products with superior heat resistance and noise properties. This presentation will review the following resins: PR-ANP-50LB (a high resistant resin) its heat resistance has been greatly improved compared with the resin presented last year. PR-54365 (acrylic rubber modified resin) providing excellent flexibility and vibration absorption. PR-EPN (gas free resin) is able to reduce frequency of gas venting during molding frictions, thus shortening the molding time.