Patent ID: 8906289

Claim:
A method for manufacturing a friction disk comprising preparing a mixture consisting of from 20 to 70% by mass based on the total mass of the mixture of a carbide-forming element having an average particle size less than or equal to 2,000 μm, from 30 to 80% by mass based on the total mass of the mixture of a resin having an average particle size less than or equal to 2,000 μm, and optionally a binder selected from the group consisting of a binder resin, a pitch, and combinations thereof, and from 0 to 50% by mass based on the total mass of the mixture of a component selected from the group consisting of fine carbon short carbon fibers, and combinations thereof; forming the mixture at a temperature of less than or equal to 280° C. to produce a molded body consisting of the components of the mixture and having a porosity of less than or equal to 15% measured as a volumetric proportion of pores in the molded body, wherein the forming step comprises compacting the mixture; heating the molded body to a temperature of from approximately 750° C. to approximately 1300° C. to form a porous carbon body comprising a carbon residue; heating the porous carbon body to a temperature above the melting point of the carbide forming element thereby reacting the carbide-forming element with at least a portion of the carbon residue to yield an alveolar structure; infiltrating the alveolar structure with silicon at a temperature above the melting point of silicon thereby filling at least one pore of the alveolar structure with silicon and reacting the silicon with an amount of unreacted carbon residue to form silicon carbide; and obtaining a friction disk, wherein the friction disk is one selected from the group consisting of brake disks and clutch driving disks.