Friction material

Claim 2

A FRICTION MATERIAL FOR USE AS A BRAKE LINING CONSISTING OF A METALLIC POWDER MATERIAL SELECTED FROM A GROUP CONSISTING OF COPPER ION, NICKEL, AND MIXTURES THEREOF FOR FORMING A MATRIX UPON BEING SINTERED, SAID SELECTED METALLIC MATERIAL COMPRISING FROM 25% TO 80% BY VOLUME OF THE TOTAL FRICTION MATERIAL; A CRYSTALLINE CERAMIC POWDER MATERIAL SELECTED FROM A GROUP CONSISTING OF ALUMINUM OXIDE, CRYSTALLINE SILICON OXIDE, MULLITE, KYANITE, SILLIMANITE, CORDIERITE FORSTERITE AND MIXTURES THEREOF FOR ENHANCING THE FRICTIONAL CHARACTERISTICS OF THE FRICTION MATERIAL, SAID SELECTED CERAMIC MATERIAL COMPRISING FROM 0% TO 30% BY VOLUME OF THE TOTAL FRICTION MATERIAL; GRAPHITE PARTICLES COMPRISING FROM 0% TO 32% BY VOLUME OF THE TOTAL FRICTION MATERIAL FOR CONTROLLING OXIDATION OF THE BRAKE LINING; AND SILICATE GLASS POWDER PARTICLES HAVING A VISCOSITY ABOVE 102.5 POISES AT TEMPERATURE BETWEEN 1,000*C AND 1,100*C AND A PARTICLE SIZE BETWEEN 20- MESH AND +325 MESH COMPRISING FROM 1% TO 50% BY VOLUME OF THE TOTAL FRICTION MATERIAL FOR CONTROLLING THE FORMATION OF A SURFACE OF GLAZE ON THE FRICTION MATERIAL CREATED BY THERMAL ENERGY DURING ENGAGEMENT WITH A CORRESPONDING FRICTION ELEMENT TO REDUCE THE WEAR RATE OF THE FRICTION MATERIAL.

Claim 3

The friction material, as recited in claim 1, wherein said silicate glass powder particles comprise 10% by volume and said graphite powder particles comprise 15% by volume of the total friction material.

Claim 4

The friction material, as recited in claim 1 wherein said silicate glass powder particles comprise between 2% to 15% by volume of the total friction material.

Claim 5

The friction material, as recited in claim 3 wherein said graphite powder particles comprise from 5% to 15% by volume of the total friction material.

Claim 6

The friction material, as recited in claim 4, wherein said selected crystalline ceramic powder material is mullite.

Claim 7

The friction material, as recited in claim 5, wherein said selected metallic powder is copper which comprise from 45% to 50% by volume of the total friction material.

Claim 8

A friction material having a surface resistant to wear with a substantially uniform coefficient of friction at a temperature above 1,000*C, said friction material consisting of: metallic elements selected from a group consisting of copper, iron, nickel and mixtures thereof for forming a matrix upon being sintered at a temperature above 925*C, said selected metallic elements comprising from 40% to 80% by volume of the total friction material; ceramic elements combined with said selected metallic elements and selected from a group consisting of aluminum oxide, crystalline silicon oxide, mullite, kyanite, sillimanite, cordierite, forsterite, and mixtures thereof for providing a modifier to enhance the frictional characteristics of the friction material, said selected ceramic elements comprising from 0 to 30% by volume of the total friction material; graphite elements combined with said metallic elements and comprising from 0 to 30% by volume of the total friction material for controlling oxidation of the friction material in temperatures above 1,000*C; and silicate glass particles having a viscosity above 102.5 poises at temperatures between 1,000*C and 1,100*C and a particle size between -20 mesh and +325 mesh being combined with said metallic elements and comprising from 1% to 50% by volume of the total friction material for forming a glaze coating with a controlled thickness on said surface during frictional engagement with a corresponding element to reduce the wear rate of the friction material.

Claim 9

A friction material having a surface resistant to wear with a substantially uniform coefficient of friction at a temperature above 1,000*C, said friction material consisting of: metallic elements selected from a group consisting of copper, iron, nickel and mixtures thereof for forming a matrix upon being sintered at a temperature above 925*C, said selected metallic elements comprising from 40% to 80% by volume of the total friction material; ceramic elements combined with said selected metallic elements and selected from a group consisting of aluminum oxide, crystalline silicon oxide, mullite, kyanite, sillimanite, cordierite, forsterite, and mixtures thereof for providing a modifier to enhance the frictional characteristics of the friction material, said selected ceramic elements comprising from 0 to 30% by volume of the total friction material; graphite elements combined with said metallic elements and comprising from 0 to 30% by volume of the total friction material for controlling oxidation of the friction material in temperatures above 1,000*C; and silicate glass particles having a viscosity above 102.5 poises at temperatures between 1,000*C and 1,100*C and a particle size between -20 mesh and +325 mesh being combined with said metallic elements and comprising from 1% to 50% by volume of the total friction material for forming a glaze coating with a controlled thickness on said surface during frictional engagement with a corresponding element to reduce the wear rate of the friction material.

Claim 10

The friction material, as recited in claim 7, wherein said silicate glass powder particles comprise 10% by volume and said graphite powder particles comprise 15% by volume of the total friction material.

Claim 11

The friction material, as recited in claim 7, wherein said silicate glass powder particles comprise betWeen 2% to 15% by volume of the total friction material.

Claim 12

The friction material, as recited in claim 7, wherein said graphite powder particles comprise from 5% to 15% by volume of the total friction material.

Claim 13

The friction material, as recited in claim 7, wherein said selected crystalline ceramic powder material is mullite.

Claim 14

The friction material, as recited in claim 7, wherein said selected metallic powder is copper which comprise from 45% to 50% by volume of the total friction material.