FRICTION MATERIAL WITH SILICON
One embodiment includes a product including a friction material including a mat including a plurality of fibers including carbon fibers, and a silicon component including at least one of silicon carbide, silica, silicon or other silicon-based compounds.
1 . A product comprising:
a friction material comprising a mat comprising a plurality of fibers, the fibers comprising a core and a layer thereon consisting essentially of carbon, and a friction modifying component on the layer or infiltrated into the fiber, the friction modifying component comprising at least one of a silicon component, a metal, a metal oxide or a ceramic material.
2 . A product as set forth in claim 1 wherein the silicon component comprising at least one of silicon carbide, silica, silicon or other silicon-based compounds.
3 . A product as set forth in claim 1 wherein the core comprises carbon.
4 . A product as set forth in claim 1 wherein the silicon component comprises particles.
5 . A product as set forth in claim 1 wherein the silicon component comprises a coating on the fibers.
6 . A product as set forth in claim 1 wherein the silicon component is silicon carbide.
7 . A product as set forth in claim 1 wherein the silicon component comprises silicon carbide particles.
8 . A product as set forth in claim 1 wherein the silicon component comprises silica.
9 . A product as set forth in claim 1 wherein the silicon component is infiltrated into the fibers.
10 . A product as set forth in claim 1 wherein the layer thereon consisting essentially of carbon is pyrolytic carbon.
11 . A product as set forth in claim 1 wherein the layer thereon consisting essentially of carbon is carbon deposited by chemical vapor deposition.
12 . A product as set forth in claim 1 wherein the friction modifying component is present in an amount of 20 percent or less of the total weight of the fibers with a core and a layer thereon.
13 . A product as set forth in claim 1 wherein the friction modifying component is present in an amount of 5 percent or less of the total weight of the fibers with a core and a layer thereon.
14 . A product as set forth in claim 1 wherein the friction modifying component is present in an amount of about 0.05 to 5 percent of the total weight of the fibers with a core and a layer thereon.
15 . A product as set forth in claim 1 wherein the friction material is substantial free of resin on the fibers.
16 . A product as set forth in claim 1 wherein the friction material has a porosity greater than 40 percent.
17 . A product as set forth in claim 1 wherein the friction material has a porosity ranging from 60 percent to 90 percent.
18 . A product as set forth in claim 1 wherein the fibers comprise at least one of continuous fibers or spun yarn.
19 . A product as set forth in claim 1 wherein the friction modifying component is on the layer as a continuous coating.
20 . A product as set forth in claim 1 wherein the friction modifying component is on the layer as a coating partially coating portion of the fiber and leaving other portion not coated by the friction modifying component.
21 . A product as set forth in claim 1 wherein the silicon component comprises SiC or a derivative thereof.
22 . A product as set forth in claim 1 wherein the friction modifying component is distributed throughout the thickness of the mat.
23 . A product as set forth in claim 1 wherein the majority of the friction modifying component is not at an upper surface of the mat.
24 . A product as set forth in claim 1 wherein the core comprises a mineral based material.
25 . A product as set forth in claim 1 wherein the core comprises a polymeric material.
26 . A process comprising providing a plurality of fibers, the fibers comprising a core, depositing a resin and a friction modifying component on the core and carbonizing the resin to provide a mat comprising modified fibers comprising the core and a layer thereon consisting essentially of carbon, and a friction modifying component on the layer or infiltrated into the fiber, the friction modifying component comprising at least one of a silicon component, a metal, a metal oxide or a ceramic material.
27 . A process as set forth in claim 26 wherein the core comprises carbon.
28 . A process as set forth in claim 26 wherein the depositing the friction modifying material is preformed separately form the depositing a resin.
29 . A process as set forth in claim 26 wherein the resin and friction modifying component are deposited as a mixture.
30 . A process as set forth in claim 26 wherein the carbonizing comprises heating the resin in a furnace or a reactor.
31 . A process comprising as set forth in claim 26 wherein the mat is essentially free of resin.
32 . A process as set forth in claim 26 wherein the mat comprises SiC or a derivative thereof on the layer of infiltrated into the modified fibers.
33 . A process as set forth in claim 26 wherein the silicon component comprising at least one of silicon carbide, silica, silicon or other silicon-based compounds.
34 . A process as set forth in claim 26 wherein the friction modifying component is distributed throughout the thickness of the fibers.
35 . A process as set forth in claim 26 wherein the majority of the friction modifying component is not at an upper surface of the mat.
36 . A process as set forth in claim 26 wherein the core comprises a mineral based material.
37 . A process as set forth in claim 26 wherein the core comprises a polymeric material.
38 . A process as set forth in claim 26 wherein the friction modifying component is present in an amount of 10 percent or less of the total weight of the fibers with a core and a layer thereon.
39 . A process as set forth in claim 26 wherein the friction modifying component is present in an amount of 5 percent or less of the total weight of the fibers with a core and a layer thereon.
40 . A process as set forth in claim 26 wherein the friction modifying component is present in an amount of about 0.05 to 2 percent of the total weight of the fibers with a core and a layer thereon.
41 . A process as set forth in claim 26 wherein the friction material has a porosity greater than 40 percent.
42 . A process as set forth in claim 26 wherein the friction material has a porosity ranging from 60 percent to 90 percent.
43 . A process as set forth in claim 26 wherein the resin comprises a phenol resin.
44 . A process as set forth in claim 26 wherein the resin comprises a epoxy-phenol resin.
45 . A process as set forth in claim 26 wherein the friction modifying component is deposited on the core first and thereafter the resin is deposited thereon.
46 . A process comprising providing a mat comprising a plurality of fibers, the fibers comprising a core and a layer thereon consisting essentially of carbon, and depositing a friction modifying component on the layer or infiltrating a friction modifying component into the fiber, the friction modifying component comprising at least one of a silicon component, a metal, a metal oxide or a ceramic material. and depositing a silicon component on the fibers.