Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: A friction material comprising: (a) at least one metal containing constituent, wherein the at least one metal containing constituent includes a ferrous metal; (b) one or more lubricating components including: one or more lubricants that are a non-carbonaceous lubricant and (i) a molybdenum containing compound; (ii) a tungsten containing compound; (iii) a zinc sulfide; (iv) a fluoride and metal containing compound; (v) an alkali earth metal phosphate, sulfate, or both; (vi) or a combination of (i) through (v); (c) one or more filler materials; (d) optionally at least one processing aid; (e) an organic binder; and wherein the friction material is free of asbestos and substantially devoid of copper.

Abstract: 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.

Abstract: The present invention is predicated upon friction material and more particularly to chopped basalt reinforcement fibers within a friction material.

Abstract: The present invention is predicated upon friction material and more particularly to chopped basalt reinforcement fibers within a friction material.

Abstract: An improved method of producing a friction material for use in the production of brake pads. A first mixing step blends binder, fiber, and filler materials together in a mixer to create a pre-mix, with one of the materials doubling as a wetting agent promoting the homogeneity of the mixture. A second non-asbestos material is added to the pre-mix in the same mixer, and the two are mixed together to produce the final friction material.

Abstract: An improved method of producing a friction material for use in the production of brake pads. A first mixing step blends binder, fiber, and filler materials together in a mixer to create a pre-mix, with one of the materials doubling as a wetting agent promoting the homogeneity of the mixture. A second non-asbestos material is added to the pre-mix in the same mixer, and the two are mixed together to produce the final friction material.

Abstract: The present invention provides a brake pad or shoe and method to manufacture the same. The brake pad or shoe includes a first friction material such as a non-asbestos organic material and a second friction material such a semi-metallic material. The friction materials are configured as discrete buttons or other suitable shapes and connected to a structural backing of the brake pad or shoe in a spaced-apart configuration. The first friction material may be located at an outboard location of the structural backing and the second friction material may be located at an inboard location. Use of the two friction materials provides superior performance compared to use of a single friction material. Configuring the friction material as discrete buttons makes the friction material fabrication process independent of the structural backing configuration, which reduces complexity and cost.

Abstract: A braking element generally including a friction material having one of iron fibers, aluminum, zinc, tin and combinations thereof. An amount of the iron fibers in the friction material is in a range between about 1 v % to about 10 v %. An amount of one of the aluminum, the zinc, the tin and the combinations thereof is in a range between about 1 v % to about 5 v %. The friction material is free of elemental copper. As the friction material wears, elemental copper is not released into the environment.

Abstract: A method and apparatus for the production of composite molded materials in which a portion of the mold tooling is a porous, gas-permeable material that enables the venting of entrapped air, moisture, and reactant or by-product gases without the necessity for a physical disruption of the mold components to accomplish the venting. This enables a reduction in cycle time to produce the molding product which reduces manufacturing costs. Applications in which the use of such mold and molding method are advantageous include, among others, the molding of friction materials, composite parts made with various synthetic thermosetting resins, such as phenolic resins, and structural components which may contain reinforcements, such as solid moldings, pre-fabricated composite structures, and shaped articles such as refractory bricks.

Abstract: The present invention provides a brake pad or shoe and method to manufacture the same. The brake pad or shoe includes a first friction material such as a non-asbestos organic material and a second friction material such a semi-metallic material. The friction materials are configured as discrete buttons or other suitable shapes and connected to a structural backing of the brake pad or shoe in a spaced-apart configuration. The first friction material may be located at an outboard location of the structural backing and the second friction material may be located at an inboard location. Use of the two friction materials provides superior performance compared to use of a single friction material. Configuring the friction material as discrete buttons makes the friction material fabrication process independent of the structural backing configuration, which reduces complexity and cost.

Abstract: A friction material having a reinforcement material that includes mineral fibers, metal fibers, aramid fibers, cellulose fibers and combinations thereof but does not include carbon steel. The friction material has a relatively uniform coefficient of friction and causes relatively less wear of braking components.

Abstract: A friction material having a filler that includes titanium dioxide particles having a diameter that is less than about fifteen micrometers. The friction material has a relatively uniform coefficient of friction and causes relatively less wear of braking components.