This invention relates to a paper friction material and a method of manufacturing the same, wherein the paper friction material is configured such that dispersibility and bondability are increased between a filler and a matrix. The paper friction material which is suitable for use in a vehicle, includes a friction base including pulp and a coating layer formed on the friction base using a mixture of latex and a functional material. The OH reactive group of the pulp and the aromatic ring of the latex are hydrogen-bonded so that the friction base and the coating layer are coupled with each other.

An asbestos free friction material having at least one of the group consisting of inorganic, organic and metallic fibers, at least one binder, at least one friction modifier or lubricant and at least a filler or abrasive, wherein the binder is almost completely and exclusively inorganic and is constituted almost exclusively or exclusively by a hydrated geopolymer or a blend of hydrated geopolymers.

A method of making a ceramic matrix composite (CMC) brake component may include the steps of applying a pressure to a mixture comprising ceramic powder and chopped fibers, pulsing an electrical discharge across the mixture to generate a pulsed plasma between particles of the ceramic powder, increasing a temperature applied to the mixture using direct heating to generate the CMC brake component, and reducing the temperature and the pressure applied to the CMC brake component. The ceramic powder may have a micrometer powder size or a nanometer powder size, and the chopped fibers may have an interphase coating.

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) potassium titanate; and

(B) one or more selected from the group consisting of lithium potassium titanate and magnesium potassium titanate,

in a total content of the component (A) and the component (B) of 10 to 35 mass %, wherein

on heating a molded product of the frictional material composition to 500 C. at a temperature rise rate of 10 C./min under an air atmosphere, the mass reduction rate is 5 to 20%.

A method for forming a vehicular brake rotor involving loading a shaped metal substrate with a mixture of metal alloying components and ceramic particles in a dieheating the contents of the die while applying pressure to melt at least one of the metal components of the alloying mixture whereby to densify the contents of the die and form a ceramic particle-containing metal matrix composite coating on the metallic substrate; and cooling the resulting coated product.

A method for forming a vehicular brake rotor involving loading a shaped metal substrate with a mixture of metal alloying components and ceramic particles in a dieheating the contents of the die while applying pressure to melt at least one of the metal components of the alloying mixture whereby to densify the contents of the die and form a ceramic particle-containing metal matrix composite coating on the metallic substrate; and cooling the resulting coated product.

This invention relates to a paper friction material and a method of manufacturing the same, wherein the paper friction material is configured such that dispersibility and bondability are increased between a filler and a matrix. The paper friction material which is suitable for use in a vehicle, includes a friction base including pulp and a coating layer formed on the friction base using a mixture of latex and a functional material. The OH reactive group of the pulp and the aromatic ring of the latex are hydrogen-bonded so that the friction base and the coating layer are coupled with each other.

A brake pad unit for a disc brake assembly. The brake pad unit comprises a backing plate and a friction pad. The backing plate comprises a first side and a second side having a length L, a width W, and an edge wall which defines a thickness T of the backing plate. The first side defines an engagement surface for engaging with the disc brake assembly. The second side defines a friction material mounting surface. The backing plate is formed from a composite material comprising reinforcement fibres, wherein the composite material extends throughout of the backing plate. The backing plate comprises a layer of reinforcement fibres which are provided as continuous fibres which extend from a first point on the edge wall to a second point on the edge wall. The friction pad comprises a friction material provided on the friction material mounting surface of the backing plate.

A friction pad body having a backing part and a friction part, which integrally consist of the same ceramic material, without a seam and joint. The ceramic material has a purity of at least 80% in relation to the total weight of the friction pad body. The friction pad body is preferably produced in the form of a sintered body by isostatic pressing so that a single-stage production process can be achieved.

An asbestos free friction material having at least one of the group consisting of inorganic, organic and metallic fibers, at least one binder, at least one friction modifier or lubricant and at least a filler or abrasive, wherein the binder is almost completely and exclusively inorganic and is constituted almost exclusively or exclusively by a hydrated geopolymer or a blend of hydrated geopolymers.