A friction material comprising: (a) at least one lubricant, wherein the at least one lubricant includes an amount of graphite, and wherein at least about 30 percent by weight of the graphite has a particle size of greater than about 500 microns using a sieve analysis; (b) at least one metal containing constituent for imparting reinforcement, thermal conductivity, and/or friction when the friction material is brought into contact with a movable member, wherein the at least one metal containing constituent includes iron and an iron containing compound; (c) a micro-particulated material; (d) one or more filler materials; (e) optionally at least one processing aid; (f) a balance being an organic binder, wherein the organic binder has less than 1 percent by weight of free phenol; wherein the friction material is free of asbestos and substantially devoid of copper.

The present invention is concerned with a frictional material composition not containing copper as an element or having the content of copper of 0.5 mass % or less, the composition containing a cashew dust; (A) potassium titanate; (B) one or more selected from the group consisting of lithium potassium titanate and magnesium potassium titanate; and (C) one or more selected from the group consisting of zirconium silicate, zirconium oxide, and magnesium oxide, wherein the content of the cashew dust is 1 to 10 mass %, and the content of the component (C) is 11 to 30 mass %.

An arrangement and method for mounting a brake disc to on axle hub of a vehicle is provided. The arrangement includes wedge-shaped holes at an radially inner region of the brake disc, corresponding wedge-shaped key inserts, a retaining device such as a retaining ring, and mounting devices such as bolts or studs and nuts that pass through the retaining ring and keys to bias the keys against the axle hub. The circumferential sides of the wedge shapes are aligned with radial lines extending from the rotation axis of the axle hub. This arrangement and method provides a simple, robust and easily installed brake disc mounting that minimizes heat transfer between the brake disc and the axle hub and accommodates thermal expansion of the brake disc and the axle hull to minimize thermal ex pans ion-induced stresses to the brake disc.

A method for manufacturing a braking band may include providing a braking band with a base band having an upper face and a lower face, where the base band being is made of titanium or titanium alloy. The method may also include directly depositing a material in particulate form consisting of ceramic and metal and/or intermetallic particles above at least the upper face and/or the lower face so to create an upper coating layer and/or lower coating layer. A braking band for a brake disc may have a base band entirely made of titanium alloy and having an upper face and a lower face, an upper coating layer, and a lower coating layer joined to the base band along the lower face. The upper coating layer and the lower coating layer consist of a mixture of ceramic and metal and/or intermetallic particles.

A friction material containing a fiber base material, a binder, an organic filler, and an inorganic filler, wherein the copper content in the friction material in terms of elemental copper is 0.5% by weight or less relative to the whole friction material, and a particulate or fibrous aluminum alloy and zinc oxide are contained as the inorganic filler.

It has been found that metal parts having rough surfaces can be manufactured by (1) compacting a metal powder under high pressure in a mold to make a green part, wherein at least one face of the mold is roughened by electrical discharge machining to have an R.sub.a of 10 to 200 micro-inches, as measured with a profilometer having a stylus tip, (2) heating the green metal part to a temperature of at least 1500 F. to sinter the green metal part to produce the metal part having at least one rough surface, wherein the rough surface has an R.sub.a which is within the range of 10 to 200 micro-inches, as measured with a profilometer having a chisel tip, and (3) optionally, buffing, classifying, deburring and/or washing the metal part. This method can be beneficially used in manufacturing clutch plates, pressure plates, and cam shaft sprockets.

A shaft coupling includes a drive hub that is coupled to a drive shaft to rotate integrally with the drive shaft, a driven hub that is coupled to a driven shaft to rotate integrally with the driven shaft, and a rotation transmission portion that transmits rotation between the drive hub and the driven hub. A dynamic vibration absorber is integrally coupled to a section of at least one of the drive hub and the driven hub. The section is an uninvolved section that is not involved in a torsional stiffness of the whole shaft coupling.

It has been found that metal parts having rough surfaces can be manufactured by (1) compacting a metal powder under high pressure in a mold to make a green part, wherein at least one face of the mold is roughened by electrical discharge machining to have an R.sub.a of 10 to 200 micro-inches, as measured with a profilometer having a stylus tip, (2) heating the green metal part to a temperature of at least 1500 F. to sinter the green metal part to produce the metal part having at least one rough surface, wherein the rough surface has an R.sub.a which is within the range of 10 to 200 micro-inches, as measured with a profilometer having a chisel tip, and (3) optionally, buffing, classifying, deburring and/or washing the metal part. This method can be beneficially used in manufacturing clutch plates, pressure plates, and cam shaft sprockets.

A power tool is provided having a motor and a motor shaft, wherein a fan wheel in the power tool is designed to generate an air flow for cooling the motor. The power tool provides a coupling formed magnetically between the fan wheel and the motor shaft such that the motor shaft drives the fan wheel in a rotary movement with a speed that is less than a speed of the motor shaft. As a result of the magnetic coupling of the fan wheel and motor shaft, the movements of the two components can be decoupled from one another such that an increase in the rotational speed of the motor shaft does not also result in an increased speed at the fan wheel. As a result, fan losses can be considerably reduced and the efficiency of the motor of the power tool can be significantly improved. A method is also provided for cooling a motor of a power tool, wherein there is a magnetic coupling between a fan wheel and a motor shaft of the power tool.

A hybrid torque tube for a brake assembly may comprise a tube portion having a centerline axis, and a conical back-leg portion extending from the tube portion. A stator spline may be formed on a radially outward surface of the tube portion. A foot may be formed on a radially inward surface of the tube portion. The tube portion is formed using a first manufacturing process and at least one of the conical back-leg, stator spline, or foot is formed using additive manufacturing.