Efficacy of high-performance epoxy resin as a binder to replace eco-unfriendly phenolic resins in Cu-free brake pads

This research explored high-performance epoxy resin (EPR) for the first time as a binder in the formulation of brake pads to overcome the limitations of phenolic resins (short shelf life, harmful emissions, etc.) and compared them to phenolic pads to determine their potential. EPRs offered higher heat resistance, lower density, post-curing free, and longer shelf life. Brake pads (15%, 20%, and 25% epoxy, and 20 vol% phenolic) were assessed for physical, mechanical, thermal, tribological, and noise - vibration (NV) properties. The findings revealed promising tribological and NV performance for epoxy pads, suggesting EPR has the potential to replace phenolic resins in the friction industry.