The present invention relates to a lightweight composite material having a binder and at least one first and at least one second filler, the first filler having a density of >2 kg/l and a Mohs hardness of >4 and the second filler having a bulk density of <2.5 kg/l. The concentration of the first filler in the composite material decreases starting from a first surface of the composite material in the direction of an opposite second surface of the composite material. In addition, the invention relates to a method for producing a composite material. This method includes the steps of providing a first filler which has a density of >2 kg/l and a Mohs hardness of >4, and providing a second filler which differs from the first filler and has a bulk density of <2.5 kg/l, and setting a concentration of the first filler in the resin that decreases in the vertical direction from a base surface of the casting mould by utilising the different mobilities of the filler particles in the resin.

Method for creating a brake pad with a block of friction material, in which sodium hydroxide and sodium silicate are dissolved in water, the aqueous solution of sodium hydroxide and sodium silicate is mixed with commercial metakaolin until a wet paste is obtained, the wet paste is formed and dried until a dried geopolymeric aggregate is obtained, the aggregate is ground to a powder, the dried ground aggregate is used as an exclusive or almost-exclusive inorganic geopolymeric binder in a friction material compound and the raw compound is hot-molded under a pressure greater than a water saturation pressure at the molding temperature.

Method for creating a brake pad with a block of friction material, in which sodium hydroxide and sodium silicate are dissolved in water, the aqueous solution of sodium hydroxide and sodium silicate is mixed with commercial metakaolin until a wet paste is obtained, the wet paste is formed and dried until a dried geopolymeric aggregate is obtained, the aggregate is ground to a powder, the dried ground aggregate is used as an exclusive or almost-exclusive inorganic geopolymeric binder in a friction material compound and the raw compound is hot-molded under a pressure greater than a water saturation pressure at the molding temperature.

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 by a hydrated geopolymer or a blend of hydrated geopolymers.

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 by a hydrated geopolymer or a blend of hydrated geopolymers.

In a method for manufacturing articles in the form of a slab or block, obtained by means of a procedure during which an initial mix comprising aggregates and a binder undergo vacuum vibro-compression followed by a step involving hardening of the binder, the aggregates comprise synthetic aggregates and fillers with a hardness greater than or equal to 5 Mohs, which contain silicon dioxide substantially only in amorphous form.

Portland cement has high embodied energy and embodied carbon associated with its manufacture. In many construction applications, the need for concrete and mortar abrasion resistance requires the consumption of significantly higher amounts of Portland cement for higher concrete and mortar compressive strength. The invention comprises a new method for producing a chemically inert, low embodied energy and carbon mineral additive, with specific hardness and particle size, during Portland cement manufacturing that replaces a significant portion of the Portland cement by mass in the final composition. Alternatively, the mineral additive is produced separately and combined with Portland cement. The resulting mineral additive Portland cement composition has significantly lower embodied energy and carbon and imparts significantly higher abrasion resistance to concrete and mortar.

Portland cement has high embodied energy and embodied carbon associated with its manufacture. In many construction applications, the need for concrete and mortar abrasion resistance requires the consumption of significantly higher amounts of Portland cement for higher concrete and mortar compressive strength. The invention comprises a new method for producing a chemically inert, low embodied energy and carbon mineral additive, with specific hardness and particle size, during Portland cement manufacturing that replaces a significant portion of the Portland cement by mass in the final composition. Alternatively, the mineral additive is produced separately and combined with Portland cement. The resulting mineral additive Portland cement composition has significantly lower embodied energy and carbon and imparts significantly higher abrasion resistance to concrete and mortar.

In a method for manufacturing articles in the form of a slab or block, the articles are obtained from an initial mix comprising aggregates and a binder. Synthetic aggregates and fillers have a hardness greater than or equal to 5 Mohs, and contain silicon dioxide substantially only in amorphous form, the silicon dioxide in crystalline form being present in quantities of less than 1% by weight.

Method for creating a brake pad with a block of friction material, in which sodium hydroxide and sodium silicate are dissolved in water, the aqueous solution of sodium hydroxide and sodium silicate is mixed with commercial metakaolin until a wet paste is obtained, the wet paste is formed and dried until a dried geopolymeric aggregate is obtained, the aggregate is ground to a powder, the dried ground aggregate is used as an exclusive or almost-exclusive inorganic geopolymeric binder in a friction material compound and the raw compound is hot-molded under a pressure greater than a water saturation pressure at the molding temperature.