Application Bulletin

Bakelite® phenolic resin systems

from Hexion Inc. (Hexion) have

been meeting the varied process

and performance criteria of friction

material applications for decades.

We have deep expertise in phenolic

resin systems for disc brake pads,

brake shoes, drum brake lining,

clutch facings and industrial

friction products which allows us

to help customers reduce cycle

times and increase productivity,

while increasing material

performance.

Evolving Selection of Product Options

Hexion’s Bakelite® Phenolic Resins are the leading performers in the friction in-dustry. As the friction materials market evolves, so do our product offerings. We supply a wide range of unmodified and modified resins, in both liquid and powder forms. These resin systems are compatible with numerous formula-tions that perform efficiently in a variety of manufacturing processes. Hexion maintains a comprehensive portfolio of resins specifically developed to meet performance requirements for trans-portation and industrial friction materi-als.

Chemical Modifications Enhance Friction Performance

To meet our customers’ needs, Hexion offers both unmodified and modified phenolic resin systems in solid (powder) and liquid forms. Our resins can satisfy a wide variety of process and perfor-mance criteria, including compatibility with a range of different materials. Providing:

■ Strength and wear resistance ■ Flexibility ■ High temperature performance ■ Noise, vibration and harshness(NVH) reduction

■ Moisture resistance ■ Adhesion and compatibility

To learn more about modifications for better friction performance, see the chart on the next page.

Bakelite® Resins for Friction Applications

Transportation / Industrial

Specialized Binders for Exceptional Performance

2

Modification of Phenolic Polymers: Effects on Friction Performance

Product Description Fiber Type Performance Modification Effect on Friction Performance

Generic Modification

Modification

Solid

Liqu

id

Glas

s

Min

eral

Othe

r

Stee

l

Stre

ngth

Cold

Wea

r

Hot W

ear

Com

fort

Unmodified Unmodified Novolac • • • • • • • • Strength and wear resistance

Unmodified Resole • • • • • • • •

Elastomer Acrylonitrile-Butadiene Rubber (NBR) Elastomer Modified Novolac

• • • • • • Flexibility and conformability

Chloroprene Rubber (CR) Modified Novolac • • • • • • • Flexibility and conformability combined with high temperature performance

High (NBR) Elastomer Modified Novolac • • • • • • • • Energy damping for improved comfort and reduced noise; enhanced flexibility and conformability/compressibility

CNSL Condensation of cashew nut shell liquid with formaldehyde (CNSL) Modified Novolac

• • • • • • Flexibility and increased strength through rubber reinforcement; improved wetting properties on certain reinforcing fibers; improved processing of rubber binders

Organic Epoxy Modified Novolac • • • • • • • • Compatibility with steel fiber

Alkyl Phenol Modified Novolac • • • • Improved flexibility and increased adhesion to fillers and fibers

Inorganic Boron Phosphorous Nitrogen (BPN) Modified Novolac

• • • • • • • Improved high temperature performance through increased temperature stability

• Suitable, •• Especially recommended for compatibility with this fiber

3

Bakelite® Product Offerings

Bakelite® Unmodified Phenolic Resins

Developed specifically to meet the per-formance requirements of customers in the friction industry, Hexion’s unmodi-fied phenolic resins consist of novolacs which vary in molecular weight (glass plate flow), cure speed, hexamethylene tetramine (Hexa) content and free phe-nol content. These variations determine the resin’s crosslink density in the final friction material, and also affect the rheology of the resin system during processing. Our unmodi-fied resin systems impart enhanced friction properties such as improved strength, thermal performance and wear resistance.

Bakelite® Liquid Phenolic Resins

Hexion’s product portfolio for friction applications includes liquid resins that ensure excellent fiber wetting paper saturation, and good metal adhesion. Specific grades have been developed specifically for backing plate adhesives.

Bakelite® Modified Phenolic Resins

Hexion scientists modify phenolic resins to adjust key properties that will influence a friction material’s behavior. Some of the most useful modifications enhance high temperature perfor-mance, flexibility and compatibility with fillers and fibers. Improvements in these areas can contribute to better friction level stability, resistance to fade and wear, and enhanced compressability improved NVH performance.

4

Liquid Resins

Product Portfolio Key Parameters Liquid Dry Friction Application Comments

Product Solvent Viscosity (mPa*s) Solid content ( % )

Free Phenol (%)

Heav

y-du

ty

Vehi

cles

Med

ium

-siz

e Ve

hicl

es

Ligh

t Veh

icle

s

Mas

s Tr

ansi

t (R

ail)

Indu

stria

l

Airc

raft

/Ae

rosp

ace

Mis

cella

neou

s

Disk

Bra

ke

Pads

Drum

Bra

ke

Lini

ngs

Brak

e Sh

oes

(Blo

ck)

Auto

mat

ic (W

et)

Clut

ch F

acin

gs

Man

ual (

Dry)

Cl

utch

Fac

ings

Back

ing

Plat

e Ad

hesi

ves

Bakelite® PF 8406RW Water 300 400** 73.5 77.5 max. 9.9 Water based system

Bakelite® PF 9342RL Ethanol 200 300 65 70 max. 11.5 Paper saturation

Bakelite® FL-1251E Ethanol 45 60*** 38 42 Improved metal adhesions / high shear strength

Bakelite® FL-756A MEK 110 210*** 57 63 max. 5.5 Good wetability of Carbon Fiber (Carbon-Carbon application)

Solid Resins

Product Portfolio Key Parameters Solid Dry Friction Application Comments

Product Modification Glass Plate Flow at 125 °C (mm)

Hexa Content (%) Cure Speed Free Phenol* (%)

Heav

y-du

ty

Vehi

cles

Med

ium

-siz

e Ve

hicl

es

Ligh

t Veh

icle

s

Mas

s Tr

ansi

t (R

ail)

Indu

stria

l

Airc

raft

/Ae

rosp

ace

Mis

cella

neou

s

Disk

Bra

ke

Pads

Drum

Bra

ke

Lini

ngs

Brak

e Sh

oes

(Blo

ck)

Auto

mat

ic (W

et)

Clut

ch F

acin

gs

Man

ual (

Dry)

Cl

utch

Fac

ings

Back

ing

Plat

e Ad

hesi

ves

Bakelite® PF 0223SP Unmodified 15 20  13.5 Standard  max. 0.2 Temperature stability and increase porosity (Noise reduction)

Bakelite® PF 0222SP04 Unmodified 15 20 9 Standard max. 0.2 Increase porosity (Noise reduction)

Bakelite® PF 6013RP Unmodified 15 23 6.5 Standard max. 0.2 Dust reduced, improve workplace environment and improve flexibility

Bakelite® PF 9760RP Unmodified 20 30 7.5 Fast  max. 0.2 Improve (reduce) process cycle time

Bakelite® FD-G128 Unmodified 30 42 8 Standard max. 3.0 Good processing latitude

Bakelite® D_FD-1013E Unmodified 30 40 8 Standard max. 5 Good processing latitude, improve wettability

Bakelite® PF 7026DP Unmodified 30 46  9  Standard max. 0.2 Good flowability

Bakelite® AD-5195 Unmodified 31 44 9 Fast  max. 0.9 Improve (reduce) process cycle time, good flowability

Bakelite® FD-718C Unmodified 33 45 8.5 Standard max. 4.9 Good processing latitude, improve wettability

Bakelite® PF 0222SP06 Unmodified 35 40 9 Standard max. 0.2 Good flowability

Bakelite® PF GAT 8/R Unmodified 35 40 9 Fast  max. 0.9 Improve (reduce) process cycle time

Bakelite® PF 7300 DP Unmodified 40 60  9 Fast  max. 0.2 Improve (reduce) process cycle time, good flowability

Bakelite® PF GAT10/R Unmodified 45 55 9 Fast  max. 0.9 Improve (reduce) process cycle time, good flowability

Bakelite® PF 7307RP Unmodified 52 68  6.5 Standard max. 3.9 Improve flexibility and wetability

Bakelite® PF 6109FP Unmodified 90 120 9.1 Standard max. 0.2 Improve wettability of fibers and filler

Bakelite® J1016H Proprietary 18 35 7.3 Fast max. 0.9 High reactivity, improve (reduce) process cycle time

Bakelite® J1077H Proprietary 16 34 9.5 Very Fast max. 0.9 High reactivity, excellent productivity, high thermal stability prefered for hot press process

Bakelite® J1098H Proprietary 30 50 9.1 Very Fast max. 0.9 High reactivity, excellent productivity, preferred for hot press process

Bakelite® FD-1188E Proprietary 25 40 9 Standard max. 2.8 • • • • • • • • • Good processing latitude, increase cross link density

Bakelite® FD-2170 Proprietary 29 43 8 Standard max. 2.8 • • • • • • • • • Good processing latitude

Bakelite® J1506H Epoxy 35 50 10 Standard max. 8 Improve wettability of fibers and fillers (good metal adhesion)

Bakelite® PF 9587RP BPN 20 30 7 Standard max. 0.9 Increase thermal stability

Bakelite® PF 9753RP Medium NBR 12 20 8.5 Standard max. 0.9 Enhanced flexibility, good compatibility with rubber components, noise reduction, good confort behavior

Bakelite® J1311H Low NBR 16 22 9.1 Standard max. 3.0 Enhanced flexibility, good compatibility with rubber components, improve wettability, good confort behavior

Bakelite® PF 8686SP High NBR 25 35  6.5 Standard max. 0.9 Enhanced flexibility and comfort behavior, suitable for underlayer application

Bakelite® J1309H CR 20 30 9.1 Standard max. 4.5 Good temperature resistance, low fading, good confort proprierties

Bakelite® J1134H CNSL 20 50 7 Standard max. 0.9 Improved processing of rubber binder

Powder Safety Information: Hexion's solid products, including but not limited to powders and flake resin products, can be combustible and present a fire or explosion hazard under certain conditions (including, but not limited to when dusts are finely divided and suspended in air and/or allowed to accumulate on surfaces). Fine dust clouds may form explosive mixtures. The buyer must comply with all laws, regulations and standards applicable to the possession, handling and use of solid products by the buyer. Please consult US NFPA Standard 654, UK HSE Guidance HSG 103, or other national guidance on safe handling of combustible dusts.

5

Liquid Resins

Product Portfolio Key Parameters Liquid Dry Friction Application Comments

Product Solvent Viscosity (mPa*s) Solid content ( % )

Free Phenol (%)

Heav

y-du

ty

Vehi

cles

Med

ium

-siz

e Ve

hicl

es

Ligh

t Veh

icle

s

Mas

s Tr

ansi

t (R

ail)

Indu

stria

l

Airc

raft

/Ae

rosp

ace

Mis

cella

neou

s

Disk

Bra

ke

Pads

Drum

Bra

ke

Lini

ngs

Brak

e Sh

oes

(Blo

ck)

Auto

mat

ic (W

et)

Clut

ch F

acin

gs

Man

ual (

Dry)

Cl

utch

Fac

ings

Back

ing

Plat

e Ad

hesi

ves

Bakelite® PF 8406RW Water 300 400** 73.5 77.5 max. 9.9 Water based system

Bakelite® PF 9342RL Ethanol 200 300 65 70 max. 11.5 Paper saturation

Bakelite® FL-1251E Ethanol 45 60*** 38 42 Improved metal adhesions / high shear strength

Bakelite® FL-756A MEK 110 210*** 57 63 max. 5.5 Good wetability of Carbon Fiber (Carbon-Carbon application)

** at 20 °C, *** at 25 °C

Solid Resins

Product Portfolio Key Parameters Solid Dry Friction Application Comments

Product Modification Glass Plate Flow at 125 °C (mm)

Hexa Content (%) Cure Speed Free Phenol* (%)

Heav

y-du

ty

Vehi

cles

Med

ium

-siz

e Ve

hicl

es

Ligh

t Veh

icle

s

Mas

s Tr

ansi

t (R

ail)

Indu

stria

l

Airc

raft

/Ae

rosp

ace

Mis

cella

neou

s

Disk

Bra

ke

Pads

Drum

Bra

ke

Lini

ngs

Brak

e Sh

oes

(Blo

ck)

Auto

mat

ic (W

et)

Clut

ch F

acin

gs

Man

ual (

Dry)

Cl

utch

Fac

ings

Back

ing

Plat

e Ad

hesi

ves

Bakelite® PF 0223SP Unmodified 15 20  13.5 Standard  max. 0.2 Temperature stability and increase porosity (Noise reduction)

Bakelite® PF 0222SP04 Unmodified 15 20 9 Standard max. 0.2 Increase porosity (Noise reduction)

Bakelite® PF 6013RP Unmodified 15 23 6.5 Standard max. 0.2 Dust reduced, improve workplace environment and improve flexibility

Bakelite® PF 9760RP Unmodified 20 30 7.5 Fast  max. 0.2 Improve (reduce) process cycle time

Bakelite® FD-G128 Unmodified 30 42 8 Standard max. 3.0 Good processing latitude

Bakelite® D_FD-1013E Unmodified 30 40 8 Standard max. 5 Good processing latitude, improve wettability

Bakelite® PF 7026DP Unmodified 30 46  9  Standard max. 0.2 Good flowability

Bakelite® AD-5195 Unmodified 31 44 9 Fast  max. 0.9 Improve (reduce) process cycle time, good flowability

Bakelite® FD-718C Unmodified 33 45 8.5 Standard max. 4.9 Good processing latitude, improve wettability

Bakelite® PF 0222SP06 Unmodified 35 40 9 Standard max. 0.2 Good flowability

Bakelite® PF GAT 8/R Unmodified 35 40 9 Fast  max. 0.9 Improve (reduce) process cycle time

Bakelite® PF 7300 DP Unmodified 40 60  9 Fast  max. 0.2 Improve (reduce) process cycle time, good flowability

Bakelite® PF GAT10/R Unmodified 45 55 9 Fast  max. 0.9 Improve (reduce) process cycle time, good flowability

Bakelite® PF 7307RP Unmodified 52 68  6.5 Standard max. 3.9 Improve flexibility and wetability

Bakelite® PF 6109FP Unmodified 90 120 9.1 Standard max. 0.2 Improve wettability of fibers and filler

Bakelite® J1016H Proprietary 18 35 7.3 Fast max. 0.9 High reactivity, improve (reduce) process cycle time

Bakelite® J1077H Proprietary 16 34 9.5 Very Fast max. 0.9 High reactivity, excellent productivity, high thermal stability prefered for hot press process

Bakelite® J1098H Proprietary 30 50 9.1 Very Fast max. 0.9 High reactivity, excellent productivity, preferred for hot press process

Bakelite® FD-1188E Proprietary 25 40 9 Standard max. 2.8 • • • • • • • • • Good processing latitude, increase cross link density

Bakelite® FD-2170 Proprietary 29 43 8 Standard max. 2.8 • • • • • • • • • Good processing latitude

Bakelite® J1506H Epoxy 35 50 10 Standard max. 8 Improve wettability of fibers and fillers (good metal adhesion)

Bakelite® PF 9587RP BPN 20 30 7 Standard max. 0.9 Increase thermal stability

Bakelite® PF 9753RP Medium NBR 12 20 8.5 Standard max. 0.9 Enhanced flexibility, good compatibility with rubber components, noise reduction, good confort behavior

Bakelite® J1311H Low NBR 16 22 9.1 Standard max. 3.0 Enhanced flexibility, good compatibility with rubber components, improve wettability, good confort behavior

Bakelite® PF 8686SP High NBR 25 35  6.5 Standard max. 0.9 Enhanced flexibility and comfort behavior, suitable for underlayer application

Bakelite® J1309H CR 20 30 9.1 Standard max. 4.5 Good temperature resistance, low fading, good confort proprierties

Bakelite® J1134H CNSL 20 50 7 Standard max. 0.9 Improved processing of rubber binder

* Low free phenol (< 1%) for improved workplace environment

6

Unmodified novolac hexa resin / standard reactivity

The figure gives a simplified view of the relationship between melting range and flow distance. The flow distance is es-sentially affected by the melting range, melt viscosity and reactivity (B-time).

The figure shows the melt viscosities of novolacs with different flow distances as a function of temperature.

Properties of Bakelite® Novolac Resins

Flow

dis

tanc

e [ m

m ]

120

100

80

60

40

20

090 100 1108070

Melting range [ °C ]

Melting range

9% Hexa content

Vis

cosi

ty [

mP

a·s

]

100,000

50 mm

115 mm

15 mm

10,000

1,000

100

0150 175 200125

Temperature [ °C ]

Flow distance

Flow distance

(Flow distance and melting range are strongly dependent upon the reactivity of the resin used and the type and extent of modification.)

7

In-House Testing Facilities

Hexion’s customers may benefit of world class technical specialists and testing capabilities used to develop and optimize solutions to meet their spe-cific requirements. Hexion's in-house facilities for developing, preparing and testing friction resins as well as support-ing problem solving activities with our customers feature of a comprehensive range of instrumentation:

Differential Scanning Calorimetry (DSC)for the determination of polymers glass transition , Thermal Gravimeter Analysis (TGA) to investigate thermal degradation and impurity presence in polymers, Gel Permeation Chromatography (GPC), Gas Chromatography (GC)and Infrared spectroscopy (IR) for defining polymers footprint, viscometers and rheometers for the study of the flow behavior of polymers and slurries, a modern dyna-mometer inertia facility for mechanical testing, pilot plants for manufacturing new products and applications specific testing.

Our problem solving capabilities are extended, when necessary, directly to the field.

The synergy between Hexion’s exper-tise in resin technology and our testing facilities makes us an outstanding, value-oriented partner — more than just a supplier of resins.

World Headquarters180 East Broad Street Columbus, OH 43215-3799

© 2017 Hexion Inc. All rights reserved. ® and ™ denote trademarks owned or licensed by Hexion Inc. HXN-698 03/17.

The information provided herein was believed by Hexion Inc. ("Hexion") to be accurate at the time of preparation or prepared from sources believed to be reliable, but it is the responsibility of the user to investigate and understand other pertinent sources of information, to comply with all laws and procedures applicable to the safe handling and use of the product and to determine the suitability of the product for its intended use. All products supplied by Hexion are subject to Hexion's terms and conditions of sale. HEXION MAKES NO WARRANTY, EXPRESS OR IMPLIED, CONCERNING THE PRODUCT OR THE MERCHANTABILITY OR FITNESS THEREOF FOR ANY PURPOSE OR CONCERNING THE ACCURACY OF ANY INFORMATION PROVIDED BY HEXION, except that the product shall conform to Hexion's specifications. Nothing contained herein constitutes an offer for the sale of any product.

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Please refer to the literature code HXN-698 when contacting us.