Disc Brake Pad Friction Material With Controlled Alkali Elution
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Solution Overview
Problem
Existing friction materials for disc brake pads face challenges in achieving optimal braking effectiveness, crack resistance, and fade resistance, particularly due to high alkali elution rates from titanates used in these materials.
Innovation Solution
The friction material composition is optimized by adjusting the alkali elution rate of layer crystal structure titanates to between 0.1 mass % and 2.5 mass %, and incorporating monoclinic crystal zirconium oxide and fibrillated organic fibers to enhance performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional titanates with high alkali elution rates are used in friction material, then fade resistance is improved, but braking effectiveness and crack resistance deteriorate
Solution Approach 1:
The patent applies parameter changes by precisely controlling the alkali elution rate of titanate within 0.1-15 mass%, and more specifically 0.1-10 mass%. This parameter optimization resolves the contradiction by selecting a moderate alkali elution rate that provides sufficient fade resistance while avoiding the excessive alkali generation that causes crack propagation and reduces braking effectiveness.
2Reliability
If layer crystal structure titanate is used to increase alkali elution, then fade resistance is improved, but braking effectiveness deteriorates
Solution Approach 1:
The patent resolves this contradiction by changing the alkali elution rate parameter to a controlled range of 0.1-15 mass%. This moderate level provides enough alkali to improve fade resistance through transfer film formation while preventing excessive alkali that would decompose organic constituents and reduce braking effectiveness.
3Reliability
If high alkali elution rate titanate is used, then transfer film formation is enhanced, but decomposed gas generation increases
Solution Approach 1:
The patent applies parameter changes by limiting the alkali elution rate to 0.1-15 mass%, and preferably 0.1-10 mass%. This controlled parameter range generates sufficient alkali for transfer film formation and fade resistance while preventing excessive alkali that would decompose organic constituents and generate harmful gases.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a friction material that provides excellent braking effectiveness, improved crack resistance, and enhanced fade resistance, while also meeting regulatory requirements regarding copper content.
Implementation Method 1
The magnesium potassium titanate is known to have a layer crystal structure and a high alkali elution rate. The alkali elution rate with respect to the titanate compound may be 15 mass % or less, preferably 0.1-15 mass %, more preferably 0.1-10 mass % and further more preferably 0.1-6 mass %. Utilizing the titanate compound inhibits the fading phenomenon and improves the wear resistance.
Implementation Method 2
This invention relates to a friction material used for a disc brake pad such as for an automobile, which is made from a friction material composition.
Data Source
AI summary
This invention relates to a friction material used for a disc brake pad, which is manufactured by forming a non-asbestos-organic (NAO) friction material composition that contains a binder, a fiber base material, a friction modifier, a lubricant, a pH adjuster, and a filler, which satisfies requirements for the required braking effectiveness, crack resistance, and fade resistance. The friction modifier contains 5-30 mass % of a magnesium potassium titanate, which has the alkali elution rate of 0.1-2.5 mass %, relative to the total amount of the friction material composition. Preferably, the titanate that may be contained in the friction modifier is a magnesium potassium titanate and 5-25 mass % of a monoclinic crystal zirconium oxide relative to the total amount of the friction material composition, and the fiber base contains 1-5 mass % of a fibrillated organic fiber relative to the total amount of the friction material composition.