Darrell A Johnson

US Patent:

20050271876, Dec 8, 2005

Filed:

Jun 4, 2004

Appl. No.:

10/861991

Inventors:

Terrence Walker - South Bend IN, US
Darrell Johnson - South Bend IN, US

International Classification:

C01B031/02
B32B009/00

US Classification:

428408000, 264029100, 264029500

Abstract:

Method of manufacturing a brake pad that has improved initial friction coefficient or “bite”. The method involves molding a carbon-carbon preform into the desired shape; carbonizing the preform by gradually heating it to 650-900 C. and holding it at that temperature for approximately one hour, heating the carbonized preform at 1950-2050 C. for approximately 4 hours, infiltrating the preform with colloidal silica to fill pores in the preform matrix with silicon carbide, heating the silica-containing preform at about 1800 C. for approximately 4 hours to convert the silica to silicon carbide, subjecting the preform to Carbon Vapor Deposition (CVD) for from 500-1000 hours, and heating the preform at 1600-2800 C. for approximately 4 hours to produce the brake pad material.

US Patent:

20060194059, Aug 31, 2006

Filed:

Feb 15, 2006

Appl. No.:

11/354083

Inventors:

Alan Arico - South Bend IN, US
David Parker - Granger IN, US
Darrell Johnson - South Bend IN, US
Akshay Waghray - Granger IN, US

International Classification:

G01B 11/00
C04B 35/64
B32B 9/00
C04B 33/32

US Classification:

428408000, 264608000, 264408000, 264409000, 428409000

Abstract:

A furnace spacer () for spacing a first annular preform () from a second annular preform () in a furnace (), each of the first and second annular preforms () having an outer periphery and a width and an inner opening having a periphery and a width, the spacer () having an annular body () having an inner diameter and an outer diameter. Also a method of alternately stacking spacers and preforms in a furnace.

US Patent:

20070193836, Aug 23, 2007

Filed:

Feb 23, 2006

Appl. No.:

11/361938

Inventors:

Terence Walker - South Bend IN, US
Darrell Johnson - South Bend IN, US
Laurie Booker - South Bend IN, US

International Classification:

F16D 55/36

US Classification:

1882180XL, 188071500

Abstract:

A method and a brake disc with a composite insert member is disclosed. The method discloses the coupling of a carbon-carbon composite insert member with the brake disc to provide an interface for the brake disc.

US Patent:

20100000070, Jan 7, 2010

Filed:

Jan 4, 2005

Appl. No.:

11/028719

Inventors:

Mark L. La Forest - Granger IN, US
Slawomir T. Fryska - Granger IN, US
Christopher S. Wahlers - South Bend IN, US
Darrell L. Johnson - South Bend IN, US
Allen H. Simpson - Buchanan MI, US

International Classification:

B21J 15/00
B32B 37/02

US Classification:

2952506, 156 60, 264259, 42725528

Abstract:

Method of manufacturing carbon-carbon composite brake disc comprising a dense reusable core. Preferably, the reusable core has a density of 1.8-2.05 g/cc. The method includes: forming a dense carbon-carbon composite core; positioning the dense core in a location within a carbon-carbon composite brake disc; and fixing the dense carbon-carbon composite core in place in its location within the carbon-carbon composite brake disc. It is economically advantageous to recover the dense core from a worn brake disc prior to positioning it in the brake disc. Also, an annular carbon-carbon composite brake disc made up of a friction surface containing 15-75 weight-% carbon-containing fibers and 25-85 weight-% resin binder and a dense carbon-carbon composite core comprising 40-75 weight-% carbon-containing fibers and 25-60 weight-% resin binder.