A non-ablative agent for brake pads and brake pads

Abstract

The application provides a brake pad with a non-ablation agent and a brake pad, and relates to the technical field of automobile parts. The non-ablation agent comprises the following components in percentage by mass: 15.0-25.0 wt% of ethanol, 4.0-8.0 wt% of organic silicon modified phenolic resin, 45.0-60.0 wt% of zirconium oxide, 5.0-8.0 wt% of chromium oxide green, 6.0-10.0 wt% of zinc powder, 3.0-6.0 wt% of sodium bicarbonate, 1.0-2.0 wt% of a surfactant, and 2.0-4.0 wt% of a thickening agent. The non-ablation agent for the brake pad can not only improve the initial braking performance of the brake pad, but also improve the rust prevention ability of the brake pad, is environment-friendly and non-toxic, is simple to prepare, and can greatly reduce the cost.

Description

Technical Field

[0001] This invention relates to the field of automotive parts technology, specifically to an anti-corrosion agent for brake pads and brake pads. Background Technology

[0002] Brake pads are the most critical safety component in a car's braking system and a vital part of ensuring driver safety. Commonly used automotive brake pads can be categorized by their friction material into metallic and non-asbestos organic (NAO) types. Compared to NAO types, metallic friction materials offer superior friction and wear characteristics as well as higher thermal conductivity, thus enjoying widespread market application. However, when metallic friction materials are exposed to high-temperature, high-humidity, and high-salt environments for extended periods, the iron components within them are prone to rusting. Specifically, this is due to chemical / electrochemical reactions occurring in such environments, resulting in the oxidation of iron into iron oxides. These issues are particularly pronounced during sea transport, where the prolonged high-temperature, high-humidity, and high-salt environments make brake pads susceptible to corrosion.

[0003] Typically, after replacing brake pads, a break-in period of about 200 kilometers is required. This is mainly because the new brake pads and brake discs do not yet achieve optimal contact. Due to insufficient contact area, braking performance is affected, leading to the so-called "inability to stop." Therefore, improving the initial braking performance of the brake pads is also particularly important. Summary of the Invention

[0004] In view of the problems existing in the prior art, the present invention provides a non-corrosion agent for brake pads and brake pads to improve the rust prevention ability of brake pads.

[0005] To achieve the above and other related objectives, the first aspect of the present invention provides an anti-ablation agent for brake pads, wherein the anti-ablation agent comprises the following components by weight percentage: 15.0–25.0 wt% ethanol, 4.0–8.0 wt% organosilicon-modified phenolic resin, 45.0–60.0 wt% zirconium oxide, 5.0–8.0 wt% chromium oxide green, 6.0–10.0 wt% zinc powder, 3.0–6.0 wt% sodium bicarbonate, 1.0–2.0 wt% surfactant, and 2.0–4.0 wt% thickener.

[0006] In one embodiment of the present invention, the organosilicon-modified phenolic resin has a gelation time of 30-51 seconds at 165°C.

[0007] In one embodiment of the present invention, the D50 of the zirconium oxide is 1.5 to 6.0 μm.

[0008] In one embodiment of the present invention, the zinc powder is selected from flake zinc powder, and the D50 of the zinc powder is 13-45 μm.

[0009] In one embodiment of the present invention, the surfactant includes any one of polyethylene glycol octylphenyl ether and fatty alcohol polyoxyethylene ether. The thickener includes any one of hydroxyethyl cellulose and polyvinyl alcohol.

[0010] A second aspect of the present invention provides a brake pad comprising a friction block and a steel backing, wherein the surface of the friction block is coated with an ablation-resistant coating made of the aforementioned ablation-resistant agent for brake pads.

[0011] In one embodiment of the present invention, the preparation of the ablation-free coating includes the following steps:

[0012] Preparation of ablation-free agent: Ethanol, organosilicon-modified phenolic resin, zirconium oxide, chromium oxide green, zinc powder, sodium bicarbonate, surfactant, and thickener are placed in a mixer according to the raw material ratio and stirred evenly to obtain the ablation-free agent;

[0013] Non-ablation agent coating: The non-ablation agent is evenly coated on the surface of the friction block and allowed to air dry naturally to form a non-ablation coating on the surface of the friction block.

[0014] In one embodiment of the present invention, the speed of the mixer is 200-240 r / min, and the mixing time is 5-7 min.

[0015] In one embodiment of the present invention, the coating thickness of the ablation-free agent is 0.1 to 0.2 mm.

[0016] In one embodiment of the present invention, a protective layer formed by powder coating is provided on the surface of the steel back away from the ablation-free coating. The temperature of the powder coating is 180-220°C and the time of the powder coating is 20-30 minutes.

[0017] The brake pad anti-corrosion agent of this invention, with the addition of zirconium oxide, chromium oxide green, flake zinc powder, and sodium bicarbonate, can improve the initial braking performance of the brake pad. The ternary composite of organosilicon-modified phenolic resin, zinc powder, and sodium bicarbonate, through the synergistic effect of these components, can improve the hydrophobic properties of the anti-corrosion agent matrix and the rust-preventive properties of the brake pad. Furthermore, the anti-corrosion agent of this invention does not contain toxic reagents, is environmentally friendly and non-toxic, and is simple to prepare. Moreover, when coating the anti-corrosion agent onto the brake pad, it can be applied directly, and curing can be completed using powder coating, eliminating the need for an additional high-temperature curing process and significantly reducing costs. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other embodiments can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a flowchart illustrating the preparation process of the ablation-free coating for the brake pads of the present invention in one embodiment. Detailed Implementation

[0020] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that, unless otherwise specified, the following embodiments and features can be combined with each other. It should also be understood that the terminology used in the embodiments of the present invention is for describing specific implementation schemes and not for limiting the scope of protection of the present invention. Test methods in the following embodiments that do not specify specific conditions are generally performed under conventional conditions or according to the conditions recommended by the respective manufacturers.

[0021] When numerical ranges are given in the embodiments, it should be understood that, unless otherwise stated in the present invention, both endpoints of each numerical range and any value between the two endpoints may be selected. Unless otherwise defined, all technical and scientific terms used in this invention, as well as the prior art known to those skilled in the art and the description of the invention, may be implemented using any prior art methods, devices, and materials similar to or equivalent to the methods, devices, and materials in the embodiments of the present invention.

[0022] It should be noted that the terms such as "upper", "lower", "left", "right", "middle" and "one" used in this specification are only for clarity of description and are not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered as part of the scope of the invention.

[0023] This invention provides an anti-ablation agent for brake pads. The anti-ablation agent comprises the following components by weight percentage: 15.0–25.0 wt% ethanol, 4.0–8.0 wt% silicone-modified phenolic resin, 45.0–60.0 wt% zirconium oxide, 5.0–8.0 wt% chromium oxide green, 6.0–10.0 wt% zinc powder, 3.0–6.0 wt% sodium bicarbonate, 1.0–2.0 wt% surfactant, and 2.0–4.0 wt% thickener.

[0024] In one embodiment, the gel time of the silicone-modified phenolic resin at 165°C is 30 to 51 seconds, for example, any value in the range of 30 to 51 seconds such as 30 seconds, 40 seconds, 45 seconds, or 51 seconds.

[0025] In one embodiment, the D50 of zirconium oxide is 1.5 to 6.0 μm, for example, any value in the range of 1.5 to 6.0 μm such as 1.5 μm, 3.0 μm, 5.0 μm or 6.0 μm.

[0026] In one embodiment, the zinc powder is selected as flake zinc powder, and the D50 of the zinc powder is 13 to 45 μm, such as any value in the range of 13 to 45 μm, including 13 μm, 20 μm, 30 μm, 40 μm or 45 μm.

[0027] In one embodiment, the surfactant includes any one of polyethylene glycol octylphenyl ether and fatty alcohol polyoxyethylene ether. In other embodiments, other types of surfactants commonly used in the art may also be selected as the surfactant.

[0028] In one embodiment, the thickener includes any one of hydroxyethyl cellulose and polyvinyl alcohol. In other embodiments, other commonly used thickeners in the art may also be selected.

[0029] This invention also provides a brake pad comprising a friction block and a steel backing, the friction block and the steel backing being fitted together and fixedly disposed, and the friction block being coated with an ablation-resistant coating made from the aforementioned ablation-resistant agent. The addition of zirconium oxide, chromium oxide green, flake zinc powder, and sodium bicarbonate to the ablation-resistant agent can improve the initial braking performance of the brake pad. The ternary composite of organosilicon-modified phenolic resin, zinc powder, and sodium bicarbonate, through the synergistic effect of the organosilicon-modified phenolic resin, zinc powder, and sodium bicarbonate, can improve the hydrophobic properties of the ablation-resistant agent matrix and the rust-resistant properties of the brake pad. Therefore, the brake pad of this application has both good initial braking performance and good rust resistance.

[0030] In one embodiment, the method for preparing the ablation-free coating includes the following steps:

[0031] S1. Preparation of the ablation-free agent: Place each component of the ablation-free agent in a mixer according to the ratio and stir evenly to obtain the ablation-free agent;

[0032] S2. Non-ablation agent coating: Apply the non-ablation agent evenly to the surface of the friction block and let it air dry naturally to form a non-ablation coating on the surface of the friction block.

[0033] In step S1, based on the mass percentage of the ablation agent, the components are placed in a mixer and stirred according to the following ratio: ethanol 15.0–25.0 wt%, organosilicon-modified phenolic resin 4.0–8.0 wt%, zirconium oxide 45.0–60.0 wt%, chromium oxide green 5.0–8.0 wt%, zinc powder 6.0–10.0 wt%, sodium bicarbonate 3.0–6.0 wt%, surfactant 1.0–2.0 wt%, and thickener 2.0–4.0 wt%. In one embodiment, the mixer speed is 200–240 r / min, for example, any value among 200–240 r / min, 210 r / min, 230 r / min, or 240 r / min; the stirring time is 5–7 min, for example, any value among 5 min, 6 min, or 7 min. In one embodiment, in order to increase the contact area between the ablation agent and the brake pad and improve the performance of the brake pad, the zinc powder is selected as flake zinc powder, and the D50 of the zinc powder is 13 to 45 μm, for example, it can be any value in the range of 13 to 45 μm such as 13 μm, 20 μm, 30 μm, 40 μm or 45 μm.

[0034] In step S2, the coating thickness of the non-ablation agent is 0.1 to 0.2 mm, such as any value among 0.1 mm, 0.15 mm, or 0.2 mm. This application does not limit the coating method of the non-ablation agent, as long as it can be uniformly coated on the surface of the friction block. For example, the non-ablation agent can be coated on the surface of the friction block using a roller.

[0035] In one embodiment, a protective layer formed by powder coating is provided on the surface of the steel backing away from the non-ablation coating. Powder coating is performed by electrostatically spraying powder onto the surface of the steel backing to improve its corrosion resistance. Exemplarily, the powder coating temperature is 180–220°C, such as any value within the range of 180°C, 200°C, or 220°C, and the powder coating time is 20–30 minutes, such as any value within the range of 20 minutes, 25 minutes, or 30 minutes. The type of powder is not limited in this application; commonly used powders in the art can be used. In this application, powder coating not only improves the corrosion resistance of the steel backing but also allows for the curing of the non-ablation agent during the powder coating process. In the brake pads of this application, after the non-ablation agent is coated onto the surface of the friction block, the non-ablation agent can be cured using powder coating, eliminating the need for additional high-temperature processes, simplifying the process, and reducing costs.

[0036] The technical solution of the present invention will be described in detail below through several specific embodiments. Unless otherwise stated, the raw materials and reagents used in the following embodiments are all commercially available products, or can be prepared by conventional methods in the art, and the instruments used in the embodiments are all commercially available.

[0037] Example 1

[0038] The brake pads in this embodiment use an anti-ablation agent, which, by mass percentage, comprises the following components: 15.0 wt% ethanol, 8.0 wt% silicone-modified phenolic resin, 60.0 wt% zirconium oxide, 5.0 wt% chromium oxide green, 6.0 wt% zinc powder, 3.0 wt% sodium bicarbonate, 1.0 wt% surfactant, and 2.0 wt% thickener. In this embodiment, the brake pads include friction blocks and a steel backing. The components of the anti-ablation agent are introduced into a high-speed mixer according to this ratio and mixed at 240 rpm for 5 minutes to obtain the anti-ablation agent. The anti-ablation agent is then uniformly coated onto the surface of the friction block using a roller, with a coating thickness of 0.1 mm. After natural drying, the steel backing surface is powder-coated at 200°C for 27 minutes.

[0039] In this embodiment, the gel time of the silicone-modified phenolic resin is 30s / 165℃, the D50 of zirconium oxide is 1.5μm, the D50 of zinc powder is 45μm, the surfactant is polyethylene glycol octylphenyl ether, and the thickener is hydroxyethyl cellulose.

[0040] Example 2

[0041] The brake pads in this embodiment use an anti-ablation agent, which, by mass percentage, comprises the following components: 25.0 wt% ethanol, 4.0 wt% silicone-modified phenolic resin, 45.0 wt% zirconium oxide, 8.0 wt% chromium oxide green, 6.0 wt% zinc powder, 6.0 wt% sodium bicarbonate, 2.0 wt% surfactant, and 4.0 wt% thickener. In this embodiment, the brake pads include friction blocks and a steel backing. The components of the anti-ablation agent are introduced into a high-speed mixer according to this ratio and mixed at 200 rpm for 7 minutes to obtain the anti-ablation agent. The anti-ablation agent is then uniformly coated onto the surface of the friction block using a roller, with a coating thickness of 0.2 mm. After natural drying, the surface of the steel backing is powder-coated at 180°C for 30 minutes.

[0042] In this embodiment, the gel time of the silicone-modified phenolic resin is 51s / 165℃, the D50 of zirconium oxide is 6.0μm, the D50 of zinc powder is 13μm, the surfactant is fatty alcohol polyoxyethylene ether, and the thickener is polyvinyl alcohol.

[0043] Example 3

[0044] The brake pads in this embodiment use an anti-electrolysis agent, which, by mass percentage, comprises the following components: 18.0 wt% ethanol, 6.0 wt% silicone-modified phenolic resin, 51.5 wt% zirconium oxide, 6.0 wt% chromium oxide green, 10.0 wt% zinc powder, 4.0 wt% sodium bicarbonate, 1.5 wt% surfactant, and 3.0 wt% thickener. In this embodiment, the brake pads include friction blocks and a steel backing. The components of the anti-electrolysis agent are introduced into a high-speed mixer according to this ratio and mixed at 220 rpm for 6 minutes to obtain the anti-electrolysis agent. The anti-electrolysis agent is then uniformly coated onto the surface of the friction block using a roller, with a coating thickness of 0.15 mm. After natural drying, the surface of the steel backing is powder-coated at 200°C for 27 minutes.

[0045] In this embodiment, the gel time of the silicone-modified phenolic resin is 40s / 165℃, the D50 of zirconium oxide is 4.0μm, the D50 of zinc powder is 30μm, the surfactant is fatty alcohol polyoxyethylene ether, and the thickener is hydroxyethyl cellulose.

[0046] Example 4

[0047] The brake pads in this embodiment use an anti-ablation agent, which, by mass percentage, comprises the following components: 20.0 wt% ethanol, 5.0 wt% silicone-modified phenolic resin, 55.0 wt% zirconium oxide, 5.0 wt% chromium oxide green, 7.0 wt% zinc powder, 5.0 wt% sodium bicarbonate, 1.0 wt% surfactant, and 2.0 wt% thickener. In this embodiment, the brake pads include friction blocks and a steel backing. The components of the anti-ablation agent are introduced into a high-speed mixer according to this ratio and mixed at 210 r / min for 6 minutes to obtain the anti-ablation agent. The anti-ablation agent is then uniformly coated onto the surface of the friction block using a roller, with a coating thickness of 0.1 mm. After natural drying, the surface of the steel backing is powder-coated at 220°C for 20 minutes.

[0048] In this embodiment, the gel time of the silicone-modified phenolic resin is 45s / 165℃, the D50 of zirconium oxide is 3.0μm, the D50 of zinc powder is 40.0μm, the surfactant is fatty alcohol polyoxyethylene ether, and the thickener is hydroxyethyl cellulose.

[0049] Example 5

[0050] The brake pads in this embodiment use an anti-ablation agent, which, by mass percentage, comprises the following components: 20.0 wt% ethanol, 6.0 wt% silicone-modified phenolic resin, 47.0 wt% zirconium oxide, 7.0 wt% chromium oxide green, 9.0 wt% zinc powder, 6.0 wt% sodium bicarbonate, 2.0 wt% surfactant, and 3.0 wt% thickener. In this embodiment, the brake pads include friction blocks and a steel backing. The components of the anti-ablation agent are introduced into a high-speed mixer according to this ratio and mixed at 200 rpm for 7 minutes to obtain the anti-ablation agent. The anti-ablation agent is then uniformly coated onto the surface of the friction block using a roller, with a coating thickness of 0.2 mm. After natural drying, the steel backing surface is powder-coated at 190°C for 28 minutes.

[0051] In this embodiment, the gel time of the silicone-modified phenolic resin is 47s / 165℃, the D50 of zirconium oxide is 5.0μm, the D50 of zinc powder is 35.0μm, the surfactant is polyethylene glycol octylphenyl ether, and the thickener is hydroxyethyl cellulose.

[0052] In the above embodiments of this application, the zinc powder used is all flake zinc powder.

[0053] Braking performance of the brake pads coated with anti-corrosion agents in Examples 1 to 5 was tested according to SAE J2522 test standard, and their rust prevention performance was tested by neutral salt spray test according to ISO 9227 standard. The test results are shown in Table 1.

[0054] Table 1: Braking performance and rust prevention of brake pads coated with anti-corrosion agent in Examples 1 to 5

[0055]

[0056] As shown in Table 1, the friction coefficient of the brake pads was significantly improved after being coated with the non-corrosion agent prepared in this application. The friction coefficient μ of the Greenμ section was increased from 0.25 to over 0.37, indicating good initial braking performance. Furthermore, the surface of the brake pads showed no rust after salt spray testing, indicating that the brake pads have good rust resistance.

[0057] The brake pad anti-corrosion agent of this invention, with the addition of zirconium oxide, chromium oxide green, flake zinc powder, and sodium bicarbonate, can improve the initial braking performance of the brake pad. The ternary composite of organosilicon-modified phenolic resin, zinc powder, and sodium bicarbonate, through the synergistic effect of these components, can improve the hydrophobic properties of the anti-corrosion agent matrix and the rust-preventive properties of the brake pad. Furthermore, the anti-corrosion agent itself does not contain toxic reagents, is environmentally friendly and non-toxic, and is simple to prepare. Moreover, when coating the brake pad with the anti-corrosion agent, it can be applied directly, and curing can be completed using powder coating, eliminating the need for an additional high-temperature curing process and significantly reducing costs. Therefore, this invention effectively overcomes some practical problems in the prior art, thus possessing high utilization value and practical significance.

[0058] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A non-ablative agent for brake pads, characterized in that, Based on the mass percentage of the ablation-resistant agent, the ablation-resistant agent comprises the following components: 15.0~25.0 wt% ethanol, 4.0~8.0 wt% silicone-modified phenolic resin, 45.0~60.0 wt% zirconium oxide, 5.0~8.0 wt% chromium oxide green, 6.0~10.0 wt% zinc powder, 3.0~6.0 wt% sodium bicarbonate, 1.0~2.0 wt% surfactant, and 2.0~4.0 wt% thickener; the silicone-modified phenolic resin has a gel time of 30~51 s at 165°C.

2. The anti-corrosion agent for brake pads according to claim 1, characterized in that, The zirconium oxide has a D50 of 1.5~6.0 μm.

3. The anti-corrosion agent for brake pads according to claim 1, characterized in that, The zinc powder is selected from flake zinc powder, and the D50 of the zinc powder is 13~45μm.

4. The anti-corrosion agent for brake pads according to claim 1, characterized in that, The surfactant includes any one of polyethylene glycol octylphenyl ether and fatty alcohol polyoxyethylene ether; the thickener includes any one of hydroxyethyl cellulose and polyvinyl alcohol.

5. A brake pad, characterized in that, The brake pad includes a friction block and a steel backing, the surface of which is coated with an ablation-resistant coating made of an ablation-resistant agent for brake pads as described in any one of claims 1 to 4.

6. The brake pad according to claim 5, characterized in that, The preparation of the ablation-free coating includes the following steps: Preparation of ablation-free agent: Ethanol, organosilicon-modified phenolic resin, zirconium oxide, chromium oxide green, zinc powder, sodium bicarbonate, surfactant, and thickener are placed in a mixer according to the raw material ratio and stirred evenly to obtain the ablation-free agent; Non-ablation agent coating: The non-ablation agent is evenly coated on the surface of the friction block and allowed to air dry naturally, forming a non-ablation coating on the surface of the friction block.

7. The brake pad according to claim 6, characterized in that, The mixer operates at a speed of 200-240 r / min and a mixing time of 5-7 min.

8. The brake pad according to claim 6, characterized in that, The coating thickness of the ablation-free agent is 0.1~0.2 mm.

9. The brake pad according to claim 5, characterized in that, A protective layer formed by powder coating is provided on the surface of the steel back away from the non-ablation coating. The temperature of the powder coating is 180~220℃ and the time of the powder coating is 20~30min.

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