Eco-Friendly Brake Friction Composite Material for Vehicles.

Abstract

The present invention relates to an environmentally friendly friction composite material for manufacturing brake pads, brake shoes, and clutch discs for automotive braking systems. The composite material comprises predominantly recycled bio-waste and industrial waste materials including processed animal bone powder, ceramic waste powder, marble powder, leather fibers, metallic reinforcing fibers, and a thermosetting phenolic resin binder. Approximately 74.2% of the raw materials are obtained from locally available recycled waste resources. The manufacturing method includes cleaning and processing animal bones, pulverizing ceramic and marble waste, preparing leather fibers, blending the constituents with metallic fibers and phenolic resin, curing the mixture, molding, heat treatment, machining, bonding onto a backing plate, and surface finishing. The resulting friction material exhibits improved wear resistance, stable friction coefficient, high thermal stability, reduced brake dust emissions, enhanced mechanical strength, and environmentally sustainable waste utilization while reducing dependence on imported brake friction materials.