Pure iron fiber based friction material product

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.

What is claimed is:  
     
         1 . A braking element comprising a friction material, the friction material being entirely devoid of carbon steel and including: 
 a reinforcement material selected from a group consisting essentially of mineral fibers, non-carbon steel metal fibers, aramid fibers, cellulose fibers, and combinations thereof.    
     
     
         2 . The braking element of  claim 1 , wherein the metal fibers are iron fibers.  
     
     
         3 . The braking element of  claim 2 , wherein the iron fibers are annealed.  
     
     
         4 . The braking element of  claim 2 , wherein a length of the iron fibers is in a range of about 0.5 millimeters to about 6 millimeters.  
     
     
         5 . The braking element of  claim 4 , wherein the length of the iron fibers is in a range of about 2.2 millimeters to about 3.2 millimeters.  
     
     
         6 . The braking element of  claim 2 , wherein a width of the iron fibers is in a range of about 25 micrometers to about 200 micrometers.  
     
     
         7 . The braking element of  claim 6 , wherein the width of the iron fibers is in a range of about 60 micrometers to about 90 micrometers.  
     
     
         8 . The braking element of  claim 2 , wherein a length-to-width ratio of the iron fibers ranges between about 2.5 to 1 to about 240 to 1.  
     
     
         9 . The braking element of  claim 2 , wherein an amount of the iron fibers in the friction material ranges between about 0.5 v % to about 40 v %.  
     
     
         10 . The braking element of  claim 9 , wherein the amount of the iron fibers in the friction material ranges between about 2 v % to about 28 v %.  
     
     
         11 . The braking element of  claim 1 , wherein the non-carbon steel metal fibers are selected from a group consisting of brass fibers, copper fibers, bronze fibers, iron fibers and combinations thereof.  
     
     
         12 . A friction material being entirely devoid of carbon steel and including: 
 a reinforcement material selected from a group consisting essentially of mineral fibers, non-carbon steel metal fibers, aramid fibers, cellulose fibers, and combinations thereof.    
     
     
         13 . The friction material of  claim 12 , wherein the metal fibers are iron fibers.  
     
     
         14 . The friction material of  claim 13 , wherein the iron fibers are annealed.  
     
     
         15 . The friction material of  claim 13 , wherein a length of the iron fibers is in a range of about 0.5 millimeters to about 6 millimeters.  
     
     
         16 . The friction material of  claim 15 , wherein the length of the iron fibers is in a range of about 2.2 millimeters to about 3.2 millimeters.  
     
     
         17 . The friction material of  claim 13 , wherein a width of the iron fibers is in a range of about 25 micrometers to about 200 micrometers.  
     
     
         18 . The friction material of  claim 17 , wherein the width of the iron fibers is preferably in a range of about 60 micrometers to about 90 micrometers.  
     
     
         19 . The friction material of  claim 13 , wherein a length-to-width ratio of the iron fibers ranges between about 2.5 to 1 to about 240 to 1.  
     
     
         20 . The friction material of  claim 13 , wherein an amount of the iron fibers in the friction material ranges between about 0.5 v % to about 40 v %.  
     
     
         21 . The friction material of  claim 20 , wherein the amount of the iron fibers in the friction material ranges between about 2 v % to about 28 v %.  
     
     
         22 . The friction material of  claim 12 , wherein the non-carbon steel metal fibers are selected from a group consisting of brass fibers, copper fibers, bronze fibers, iron fibers, and combinations thereof.  
     
     
         23 . A clutch comprising a friction material, the friction material being entirely devoid of carbon steel and including: 
 a reinforcement material selected from a group consisting essentially of mineral fibers, non-carbon steel metal fibers, aramid fibers, cellulose fibers, and combinations thereof.    
     
     
         24 . The clutch of  claim 23 , wherein the metal fibers are annealed iron fibers.  
     
     
         25 . The clutch of  claim 24 , wherein a length-to-width ratio of the annealed iron fibers ranges between about 2.5 to 1 to about 240 to 1.  
     
     
         26 . The clutch of  claim 24 , wherein an amount of the annealed iron fibers in the friction material ranges between about 0.5 v % to about 40 v %.  
     
     
         27 . The clutch of  claim 24 , wherein an amount of the annealed iron fibers in the friction material ranges between about 2 v % to about 28 v %.  
     
     
         28 . A braking element comprising a friction material, the friction material comprising iron fibers and not carbon steel.  
     
     
         29 . The braking element of  claim 28 , wherein an amount of the iron fibers in the friction material ranges between about 0.5 v % to about 40 v %.  
     
     
         30 . The braking element of  claim 29 , wherein the amount of the iron fibers in the friction material ranges between about 2 v % to about 28 v %.  
     
     
         31 . The braking element of  claim 29 , wherein a length-to-width ratio of the iron fibers ranges between about 2.5 to 1 to about 240 to 1.