A method of making a wet friction material includes joining filler particles and fibers together and forming a base; coating an outer surface of the base with a quaternary ammonium salt containing solution; and drying the quaternary ammonium salt containing solution to form a quaternary ammonium salt containing coating on the outer surface of the base.

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 provides a friction material and a brake pad having excellent wear resistance while exhibiting a high friction coefficient under high-temperature and high-speed conditions. A friction material containing: 40 mass % or more and 80 mass % or less of a matrix containing at least one kind selected from the group consisting of Ni and Fe; 10 mass % or more and 30 mass % or less of inorganic particles containing zircon particles, titania particles, and mullite particles; and 10 mass % or more and 30 mass % or less of a lubricant containing at least one kind selected from the group consisting of graphite, molybdenum disulfide, boron nitride and calcium fluoride, wherein a content of the zircon particles is 30 vol % or more and 36 vol % or less, a content of the titania particles is 30 vol % or more and 36 vol % or less, and a content of the mullite particles is 30 vol % or more and 36 vol % or less with respect to a total content of 100 vol % of the zircon particles, the titania particles, and the mullite particles.

A continuous fiber brake rotor preform and apparatuses and methods for manufacturing the preform are disclosed herein. The preform comprises a plurality of continuous fiber streams or filaments forming a substantially helical structure having layers or flights compressed together in the preform's longitudinal direction. Each continuous fiber stream or filament may comprise the same or different types of fiber, extends substantially between longitudinally disposed preform ends, and resides laterally adjacent to another continuous fiber stream or filament within each layer or flight of the helical structure. The radial distance between each continuous fiber stream or filament and the preform's longitudinal axis varies with angular location about the longitudinal axis. The preform further comprises web or z-direction fiber interspersed within the helical structure with certain of the web or z-direction fibers and continuous fiber streams or filaments extending at least partially in the longitudinal direction between the preform's layers or flights.

A friction material includes a friction-generating layer and a base layer. The base layer includes base fibers and presents a bonding surface. The friction-generating layer includes friction-adjusting particles deposited on the base layer and presents a friction-generating surface facing opposite the bonding surface of the base layer. A curable resin is present in the friction-generating layer and the base layer. The friction material also includes a composition including a plurality of triglycerides. The composition is present in at least one of the friction-generating layer and the base layer. The plurality of triglycerides comprises polyunsaturated fatty acid in a content of from 60 to 90% by weight based on a total weight of the plurality of triglycerides included in the composition.

A thermosetting resin composition for a friction material includes a thermosetting resin and a lignocellulose nanofiber dispersed in the thermosetting resin. A method for producing a thermosetting resin composition for a friction material includes a first step and a second step. In the first step, a plant-based biomass containing a lignocellulose is mixed with a dispersion medium to obtain a mixture thereof, and the mixture is subjected to a defibration treatment to obtain a slurry of a lignocellulose nanofiber. In the second step, phenol is reacted with an aldehyde in the presence of an acid catalyst to obtain a thermosetting resin, and the slurry is added to the thermosetting resin. The lignocellulose nanofiber is dispersed in the thermosetting resin while removing the dispersion medium and unreacted phenol.

A friction material which comprises a fibrous base, a binder, a lubricating material, an organic filler, and an inorganic filler, the friction material having a copper element content of 0.5 wt % or less with respect to the whole friction material, wherein the lubricating material comprises graphite having an average particle diameter of 10.0 μm or smaller and the inorganic filler includes barium sulfate, which comprises small-diameter barium sulfate having an average particle diameter of 1.5 μm or smaller and a purity of 95.0% or higher.

A friction material has a first outermost surface and a second outermost surface spaced apart from the first outermost surface. The friction material includes a base which forms at least a portion of the first outermost surface. The base includes fibers present in an amount of from 20 to 80 weight percent, a filler present in an amount of from 20 to 80 weight percent, and a deposit which forms at least a portion of the second outermost surface and includes a friction adjusting agent. The friction material further includes a resin disposed throughout the friction material. The deposit is disposed in the friction material in a gradated pattern. At least a portion of the deposit is exposed to the environment and the second outermost surface has a surface roughness of from 2 to 11 micrometers as determined by non-contact laser measurement according to ISO 25178.

A method of manufacturing a carbon structure can comprise: infiltrating the carbon structure with a silicon oxycarbide (SiOC) precursor sol; and densifying the carbon structure by chemical vapor infiltration (CVI) to form a carbon and ceramic matrix composite material, the carbon and ceramic matrix composite material comprising between 0% and 15% by weight of a plurality of ceramic particles from the ceramic compound, densifying the carbon structure including adjusting a temperature gradient across the carbon structure.

The invention provides a friction material and a method of making the friction material. The friction material comprises man-made vitreous fibres whose chemical composition comprises: less than 2 wt % Fe.sub.2O.sub.3; 30-40 wt % MgO+CaO; 35-45 wt % SiO.sub.2; 17-24 wt % Al.sub.2O.sub.3; and 1-5 wt % K.sub.2O+Na.sub.2O.