[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.

A friction material presents a friction-generating surface and a bonding surface opposite the friction-generating surface. The friction material includes unbranched fiber having a diameter of from 0.5 to 50 μm and a length of from 0.2 to 15 mm, branched fiber having a diameter of from 1 to 50 μm, and a resin disposed throughout the friction material. The friction material is substantially free of particles and defines a plurality of pores having a pore size distribution with a D10 value of from 5 to 15 μm, a D50 value of from 15 to 30 μm, and a D90 value of from 30 to 60 μm.

A friction member according to an embodiment is a friction material having a copper content of less than 5 wt %, the friction material including a titanic acid salt having a content of 1 wt % or more and 8 wt % or less, a cryolite powder having a content of 0.5 wt % or more and 5 wt % or less, and an iron oxide powder having a median diameter of 15 to 30 μm (D50) and a content of 1 wt % or more and 10 wt % or less.

Provided is a friction material that includes a boron-containing solid lubricant. The friction material may be used to form a brake pad for automotive vehicles. The friction material may include, by weight, about 1.0% to about 6.0% of the boron-containing solid lubricant, about 5.0% to about 15.0% of a fibrous or powdered metal material, an abrasive, an organic filler, an inorganic filler, and a binder. Advantageously, an antimony free and copper free friction material of the present disclosure may still achieve high fiction performance and long pad life, providing a more environment friendly solution to brake systems.

There are provided a friction material composition containing no copper or having a reduced content of copper that can provide a friction material in which the stability of the friction coefficient after standing in a cold environment, the abrasion resistance, and the low rust fixation properties are excellent, and squeal (particularly low temperature squeal) is suppressed, and a friction material obtained by molding the friction material composition, and a friction member using the friction material. The friction material composition is specifically a friction material composition comprising a bonding material, an organic filler, an inorganic filler, and a fiber substrate, in which the friction material composition comprises no copper, or has a content of copper of less than 0.5% by mass in terms of a copper element even if comprising the copper, and comprises, as the organic filler, cashew particles to which a silicone resin adheres.

A method for manufacturing a friction material containing a friction modifier, a fibrous material and a binder as raw materials is provided. The method includes a step of mixing and agitating the raw materials by low frequency acoustic agitation. A content of the fibrous material in the friction material may be 1 mass % or more and 50 mass % or less. The content of the fibrous material in the friction material may be 3 mass % or more and 40 mass % or less.

Provided is a friction modifier giving excellent formability in producing a friction material and capable of reducing rust formation on a rotor even when the moisture-absorbed friction material is left pressed against the rotor for a long. The friction modifier is made of a titanate compound having a tunnel crystal structure, wherein the titanate compound has a rate of chlorine ion dissolution of 0.5 ppm to 400 ppm.

There is provided a method for producing a wet friction plate that can improve the retention property of lubricating oils in a fine groove formed by laser light. In a method for producing a wet friction plate (200), a friction material (210) is produced by sheet making processing in a first step. Thereafter, in a second step, a fine groove (211) is formed on the friction material (210). The friction material (210) is produced such that thermosetting resin therein is in a semi-cured state. The cross-sectional shape of the fine groove (211) is formed into a V shape by laser light. Subsequently, in a third step, the friction material (210) is disposed on a core metal (201) via an adhesive agent including thermosetting resin. Subsequently, in a fourth step, the friction material (210) is pressed while heated to crush the fine groove (211). In this manner, unevenness is formed on an intra-groove surface (212), and the thermosetting resin is completely cured.

The friction material composition has superior conductivity of a friction material, superior adherence of a coating during powder coating, superior film formation of coating and superior abrasion resistance without containing copper having serious environmental effects, the friction material composition includes a binder, an organic filler material, an inorganic filler material, and a fibrous substrate material, wherein the friction material composition contains 8 to 35 mass % of ferrosoferric oxide (Fe.sub.3O.sub.4).

Technologies are generally described for a composition for an under-layer of a brake pad of a brake disc rotor. The composition may include a fiber pack, a powdered rubber, at least one binder, and at least one filler, wherein the fiber pack includes aramid fibers up to about 3 wt %.