Electrically-calcined Anthracite (also known as ECA or CA) is a carbon-based material made of coal. It is produced through heating anthracite in the absence of oxygen to high temperatures, thus removing sulfur and volatile matter. The resultant material is extremely pure and contains little ash. It's widely used in steel smelting, casting, and friction material manufacture. It is also used as an ingredient in the manufacture of carbon electrodes, brake linings and other refractory products.
Brake lining manufacturers often combine a variety of materials and thicknesses to create their final friction materials. Materials such as aramids fibers carbon composites cellulose fibers and glass chopped may be used. In addition, they can incorporate metals and nonmetallic materials like ceramics. Additives such as aluminum dioxide and silica, which are abrasive but not abrasive, can also be added. The resulting friction materials have their compositions molded and then tested to determine the wear, strength, or moldability properties.
This ratio is a close approximation to the ideal proportion of vermiculite and resin found in a commercial asbestos-free asbestos substitute brake lining formulation comprising 53 wt % anthracite coal, 15 wt % phenolic resin, 10 wt % cashew particles 6 lt % rubber particles 4 lt % zinc chips and 1 lt c aluminate. This ratio is very close to that of a commercially available asbestos-free asbestos alternative brake lining formulation, which contains 53 wt% anthracite, 15 wt% phenolic, 10 wt% cashew, 6 wt% rubber, 4 wt% zinc chips, and 1 wt% calcium aluminate. The resulting composition has been found to provide acceptable braking and the moldability and friction characteristics of the brake lining have been comparable with those of a conventional asbestos-type brake lining having a similar composition.
Asbestos-free brake lining systems are increasingly being used in the production of motor vehicles. The reason for this is that it was found in recent years that the inhalation of small asbestos fibers can cause lung diseases. These diseases include mesothelioma and lung cancer. In order to avoid asbestos-based brake linings, it is essential that substitutes are found. Until recently, the most popular brake lining material was asbestos. The asbestos used in brake linings poses a risk to the health of workers. This has led to a number of government and private investigations concerning asbestos related problems. The results of the investigations showed that asbestos brake linings can pose a health hazard to brake lining technicians. The need for new asbestos-free systems to meet the same performance and safety standards as the older asbestos systems has been created. The present invention offers a more cost-effective and noncarcinogenic alternative to older asbestos-based brake lining systems. Moreover, this invention achieves all of these properties without compromising on the safety and effectiveness of the brake linings. This brake lining also has a much lower surface cracking rate when it is used on a vehicle. The invention uses vermiculite which has the asbestos reinforcing quality.
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