Friction materials and methods of producing same

1. A friction material composition, comprising an abrasive, a filler, a binder, and a friction modifier, said friction modifier comprising a spherical molybdenum disulfide powder, said spherical molybdenum disulfide powder comprising generally flake-shaped molybdenum disulfide sub-particles that are agglomerated together to form individual, substantially spherically-shaped particles, said spherical molybdenum disulfide powder comprising at least about 90% by weight molybdenum disulfide.

2. The friction material composition of claim 1 , wherein said spherical molybdenum disulfide powder is present in an amount ranging from about 0.1% by weight to about 10% by weight of said friction material composition.

3. The friction material composition of claim 1 , wherein said spherical molybdenum disulfide powder is present in an amount ranging from about 0.5% by weight to about 8% by weight of said friction material composition.

4. The friction material composition of claim 1 , wherein said spherical molybdenum disulfide powder is present in an amount ranging from about 1% by weight to about 5% by weight of said friction material composition.

5. The friction material composition of claim 1 , wherein the individual, substantially spherically shaped agglomerated particles have sizes in a range of from about 1 μm to about 500 μm.

6. The friction material composition of claim 1 , wherein the individual, substantially spherically shaped agglomerated particles have sizes in a range of from about 20 μm to about 200 μm.

7. The friction material composition of claim 1 , wherein the individual, substantially spherically shaped agglomerated particles have sizes in a range of from about 50 μm to about 100 μm.

8. The friction material composition of claim 1 , wherein said abrasive is present in an amount ranging from about 1% by weight to about 15% by weight of said friction material composition.

9. The friction material composition of claim 8 , wherein said abrasive comprises one or more selected from the group consisting of aluminum oxides, iron oxides, quartz, silica, and zirconium silicate.

10. The friction material composition of claim 1 , wherein said filler is present in an amount ranging from about 10% by weight to about 50% by weight of said friction material composition.

11. The friction material composition of claim 10 , wherein said filler comprises one or more selected from the group consisting of organic fibers, inorganic fibers, metal fibers, lime, potassium titanate, rubber, and zinc oxide.

12. The friction material composition of claim 1 , wherein said binder is present in an amount ranging from about 5% by weight to about 25% by weight of said friction material composition.

13. The friction material composition of claim 12 , wherein said binder comprises one or more selected from the group consisting of phenolic resins, modified resins, cresol, epoxy, cashew dust, polyvinyl butyral, rubber, linseed oil, and boron.

14. A friction material composition, comprising an abrasive, a filler, a binder, and a spherical molybdenum disulfide powder comprising substantially spherically-shaped particles of molybdenum disulfide that are agglomerations of generally flake-shaped sub-particles of molybdenum disulfide, said spherical molybdenum disulfide powder comprising at least about 90% by weight molybdenum disulfide.

15. In a friction material composition of the type including an abrasive material, a filler material, and a binder material, the improvement comprising the addition of a spherical molybdenum disulfide powder to the friction material composition during manufacture so that said spherical molybdenum disulfide powder is substantially evenly dispersed throughout the friction material composition, said spherical molybdenum disulfide powder comprising agglomerations of generally flake-shaped sub-particles of molybdenum disulfide and at least about 90% by weight molybdenum disulfide.

16. A method of making a friction material composition comprising:

providing respective supplies of an abrasive material, a filler material, and a binder material;

providing a supply of a spherical molybdenum disulfide powder, said spherical molybdenum disulfide powder comprising agglomerations of generally flake-shaped sub-particles of molybdenum disulfide and at least about 90% by weight molybdenum disulfide;

mixing together said abrasive material, said filler material, said binder material, and said spherical molybdenum disulfide powder to form a substantially homogeneous mixture;

compacting the substantially homogeneous mixture to form a pre-formed article; and

hot-pressing the pre-formed article to form the friction material composition.