A friction material, such as those belonging to the NAO or LS classes. The friction material is substantially free from copper and includes non-spherical particles in the form of powders and/or fibres each constituted by a preferably ferrous metallic core and by an at least partial coating of core formed at least partially or totally by tin and/or tin compounds, such as intermetallic Fe—Sn compounds.

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.

To provide a friction pair having an excellent stability of a braking effect and wear resistance of a friction material, where the friction pair is consisting of a disc brake pad having a friction material manufactured from a friction material composition containing a binder, a fiber base material, and a friction modifier, but not containing a copper component and a ferrous-base metallic fiber, and a stainless steel disc rotor. The present invention uses a friction material composition that does not contain a metallic fiber other than a ferrous-base metallic fiber but contains 10-15 weight % of a carbonaceous lubricant as a friction modifier relative to an entire friction material composition, and 15-30 weight % of an inorganic friction modifier with Mohs hardness of 6 or more relative to the entire friction material composition, where a thermal conductivity of the friction material is 1.2-3.0 W/m.Math.K.

An asbestos-free friction material includes inorganic and/or organic and/or metallic fibers, at least one binder, at least one friction modifier or lubricant, at least one filler or abrasive and a carbonaceous material constituted by a microstructure. The microstructure is in the form of flakes or scales of micrometric planar dimensions and of nanometric thickness consisting of a substantially pure graphene mono- or multilayers, preferably pre-blended with at least part of the organic binder.

A friction assembly includes a dry-running disc pack with at least one lining disc and at least one counter disc, which are arranged one behind the other in an alternating manner in an axial direction of the disc pack, and which can be brought into frictional contact with one another, wherein the lining disc has at least one mass-pressed dry-running friction lining.

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.

[Object]

To provide the method of manufacturing the friction material that is capable of uniformly scorching into the deep part of the surface layer of the friction material in a short period of time.

[Means to Resolve]

In the method of manufacturing the friction material including the scorching step of scorching the surface of the friction material with the laser, the friction material contains 5 to 25% by weight of one or more types of black materials relative to the total amount of the friction material composition, and the L* of the CIE Lab of the surface of the friction material before scorching is 20 to 60.

[Object] This invention relates to a friction material used for a disc brake pad, which is manufactured by forming a non-asbestos-organic (NAO) friction material composition that contains a binder, a fiber base material, a friction modifier, a lubricant, a pH adjuster, and a filler, which satisfies requirements for the required braking effectiveness, crack resistance, and fade resistance.

[Means to Resolve] The friction material, which is made from the NAO friction material composition, which includes the binder, the fiber base material, the friction modifier, the lubricant, the pH adjuster, and the filler, where the friction modifier contains 5-30 mass % of a magnesium potassium titanate, which has the alkali elution rate of 0.1-2.5 mass %, relative to the total amount of the friction material composition. Preferably, in the friction material, the titanate is a magnesium potassium titanate, and as the friction modifier, 5-25 mass % of a zirconium oxide relative to the total amount of the friction material composition and 1-5 mass % of a fibrillated organic fiber as the fiber base material relative to the total amount of the friction material composition are contained.

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.

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.