Carbon-based friction material for automotive continuous slip service

A product comprising a friction material, said friction material comprising a plurality of fibers formed into strands woven or braided together into a fabric, said strands having a binder wicked along each of said fibers so that said fibers are bound together along points of contact thus leaving gaps between fibers substantially free of binder so that the friction material has a microtexture and microporosity that is open to provide a flow path for oil through the friction material substantially eliminating hydrodynamics across an engagement surface of the friction material whereby consistent and stable friction performance is achieved and shutter, chuggle and squawk is controlled, and wherein said binder in a dried state comprises about 18 to 40 weight percent of the binder and fiber together.

A product comprising:

• at least a first and second piece of friction material, each piece of friction material comprising a plurality of fibers spun into bundles, each bundle having a binder wicked along the fiber so that the fibers are bound together leaving gaps along the fibers substantially free of said binder, said bundles being twisted into strands and said strands being woven together to form a fabric, each piece of friction material being secured to a substrate and pieced together along an interlock seam, wherein said bundles are not bound together by said binder and are free to move so that upon application of force to the pieces of friction material said bundles elongate and fibers from each piece of friction material engage each other across the interlock seam providing improvement in the strength of the interlock seam between each piece of friction material, and wherein said binder in a dried state comprises about 18 to 40 weight percent of the binder and fiber together.