Abstract: A method for forming a friction material. The method includes mixing a fibrous base material and filler particles to form a substrate. The method further includes saturating the substrate with a silane solution including a silane to form a uniformly impregnated silane matrix. The method also includes curing the uniformly impregnated silane matrix to form a cured uniformly impregnated silane matrix. The method also includes saturating the cured uniformly impregnated silane matrix with a phenolic resin solution to form a uniformly impregnated silane, phenolic resin matrix. The method also includes curing the uniformly impregnated silane, phenolic resin matrix to form the friction material.

Abstract: A clutch assembly for a motor vehicle drivetrain includes a rigid support and a wet friction material fixed to a surface of the rigid support. The wet friction material includes a base material including a matrix of fibers and filler particles embedded in the matrix of fibers; a binder embedded in the base material; and a colloidal silica coating applied onto an outer surface of the base material.

Abstract: A clutch assembly for a motor vehicle drivetrain includes a rigid support and a wet friction material fixed to a surface of the rigid support. The wet friction material includes a base material including a matrix of fibers and filler particles embedded in the matrix of fibers; and a binder embedded in the base material. The base material includes, by weight percent, 30-55% cellulose fibers and 10-50% calcined kaolin clay. The base material also includes at least one of 1-20% graphite having a mean particle size of 35 to 85 microns, 20-40% diatomaceous earth in combination with the binder being tung modified phenolic resin, 5-20% chopped aramid fibers, or 5-20% of novoloid fibers.

Abstract: A wet friction material includes a base including a matrix of fibers and filler particles embedded in the matrix of fibers; a binder embedded in an interior of the base; and a quaternary ammonium salt containing coating on an outer surface of the base. The quaternary ammonium salt containing coating can include a quaternary ammonium salt and a solution binder.

Abstract: A clutch assembly for a motor vehicle drivetrain includes a rigid support and a wet friction material fixed to a surface of the rigid support. The wet friction material includes a base material including a matrix of fibers and filler particles embedded in the matrix of fibers. The filler particles include calcined kaolin clay, and the base material includes, by percent weight, 5 to 60% of calcined kaolin clay. The wet friction material also includes a binder embedded in the base material. The binder is tung modified phenolic resin.

Abstract: A wet friction material includes a base including a matrix of fibers and filler particles embedded in the matrix of fibers; a binder embedded in an interior of the base; and a quaternary ammonium salt containing coating on an outer surface of the base.

Abstract: A method of making a wet friction material includes joining filler particles and fibers together and forming a base; coating an outer surface of the base with a quaternary ammonium salt containing solution; and drying the quaternary ammonium salt containing solution to form a quaternary ammonium salt containing coating on the outer surface of the base.

Abstract: A method of making a wet friction material includes coating a first outer surface of a cellulose layer with a friction coating; placing a matrix of fibers and filler particles on a second outer surface of the cellulose layer; and saturating the matrix of fibers and filler particles with a binder and curing the binder to join the matrix of fibers and filler particles together to form a wet friction material base layer and to join wet friction material base layer to the second outer surface of the cellulose layer.

Abstract: A method of making a wet friction material includes joining filler particles and fibers together and forming a base; coating an outer surface of the base with a quaternary ammonium salt containing solution; and drying the quaternary ammonium salt containing solution to form a quaternary ammonium salt containing coating on the outer surface of the base.

Abstract: A friction plate for a clutch includes a face and a first friction material disposed on the face. The first friction material has a first composition including a first filler material at a first weight concentration of a total weight of the first friction material. A second friction material is disposed on the face and has a second composition that is different than the first composition and including a second filler material at a second weight concentration of a total weight of the second friction material. The second weight concentration is higher than the first weight concentration.

Abstract: A method of producing a friction material. The method includes mixing silica containing filler particles and a liquid binder to form a binder-filler liquid mixture. The method also includes saturating a fibrous base material with the binder-filler liquid mixture to form a saturated fibrous base material. The method further includes curing the saturated fibrous base material at a predetermined temperature for a predetermined time to cure the saturated fibrous base material to form the friction material.

Abstract: A method of making a wet friction material includes providing an outer layer on a base layer to form the wet friction material. The base layer includes a first proportion of fiber material and a first proportion of filler material. The outer layer includes a second proportion of fiber material and a second proportion of filler material. The second fiber proportion is less than the first fiber proportion and the second filler proportion is greater than the first filler proportion. The method further includes forming a modified outer layer by burning off the fiber material of the outer layer.

Abstract: A method for forming a friction material. The method includes mixing a fibrous base material and filler particles to form a substrate. The method further includes saturating the substrate with a silane solution including a silane to form a uniformly impregnated silane matrix. The method also includes curing the uniformly impregnated silane matrix to form a cured uniformly impregnated silane matrix. The method also includes saturating the cured uniformly impregnated silane matrix with a phenolic resin solution to form a uniformly impregnated silane, phenolic resin matrix. The method also includes curing the uniformly impregnated silane, phenolic resin matrix to form the friction material.

Abstract: A method of producing a friction material. The method includes mixing silica containing filler particles and a liquid binder to form a binder-filler liquid mixture. The method also includes saturating a fibrous base material with the binder-filler liquid mixture to form a saturated fibrous base material. The method further includes curing the saturated fibrous base material at a predetermined temperature for a predetermined time to cure the saturated fibrous base material to form the friction material.

Abstract: A friction plate for a clutch includes a face and a first friction material disposed on the face. The first friction material has a first composition including a first filler material at a first weight concentration of a total weight of the first friction material. A second friction material is disposed on the face and has a second composition that is different than the first composition and including a second filler material at a second weight concentration of a total weight of the second friction material. The second weight concentration is higher than the first weight concentration.

Abstract: Wet friction materials are disclosed. One wet friction material may include a plurality of fibers and a filler material including mica silicate. The mica silicate may comprise from 5 to 20 percent by weight of a total composition of the fibers and the filler material. In another example, the mica silicate may comprise from 7.5 to 17.5 percent by weight of a total composition of the fibers and the filler material. The filler material may include an additional silica-containing material.

Abstract: A method of making a wet friction material layer includes joining filler particles and fibers together to form a material base; adding water based phenolic resin to the material base; and curing the water based phenolic resin.

Abstract: A method of making a wet friction material layer includes adding a media in liquid form to a material base including filler particles embedded in a matrix of fibers; drying the media to solidify the media on the filler particles such that the media plugs holes in the filler particles; adding a binder to the material base; and unplugging at least some of the holes in the filler particles by removing at least some of the media from the material base.

Abstract: A method of making a wet friction material is provided. The method includes obtaining a base layer sheet; obtaining an outer layer sheet; and laminating the outer layer sheet and the base layer sheet together to form the wet friction material. The base layer sheet includes a proportion of first fiber material and a proportion of first filler material and the outer layer sheet includes a proportion of second fiber material and a proportion of second filler material. The proportion of second fiber material is less than the proportion of first fiber material and the proportion of second filler material is greater than the proportion of first filler material.

Abstract: A method of making a wet friction material includes providing an outer layer on a base layer to form the wet friction material. The base layer includes a first proportion of fiber material and a first proportion of filler material. The outer layer includes a second proportion of fiber material and a second proportion of filler material. The second fiber proportion is less than the first fiber proportion and the second filler proportion is greater than the first filler proportion. The method further includes forming a modified outer layer by burning off the fiber material of the outer layer.