Disc Brake Pad Friction Material for Copper-Free Noise Suppression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge is to develop a friction material for disc brake pads that suppresses noise occurrence just before a vehicle stops, while adhering to regulations limiting copper content, and maintains braking effectiveness and wear resistance under high-speed and high-load conditions.
Innovation Solution
The solution involves a non-asbestos-organic friction material composition that includes 15-25 weight % non-whisker-like titanate, 15-25 weight % zirconium oxide, 4-6 weight % mica or vermiculite, and 2-4 weight % flaky graphite particles, which form a protective film and facilitate abrasion powder ejection, preventing rust and abrasive wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper component is added to NAO friction material to secure braking effectiveness and wear resistance, then braking performance is improved, but environmental pollution increases and regulatory compliance deteriorates
Solution Approach 1:
The invention extracts and removes the copper component from the NAO friction material composition entirely, replacing it with alternative materials (specifically iron oxide and organic friction modifiers) that provide similar braking performance without the environmental pollution associated with copper discharge during braking operations
Solution Approach 2:
The invention changes the compositional parameters of the friction material by eliminating copper and introducing iron oxide (0.1-5.0 wt%) combined with specific organic friction modifiers, thereby achieving the same functional objectives (braking effectiveness and wear resistance) through different material parameters that do not contribute to environmental pollution
2Object-affected harmful factors
If copper component is reduced or eliminated from NAO friction material to comply with regulations, then environmental compliance is improved, but braking effectiveness and wear resistance deteriorate
Solution Approach 1:
The invention introduces iron oxide and organic friction modifiers as intermediary materials that mediate between the requirement for copper-free composition and the need for maintaining braking effectiveness, providing a functional substitute that achieves similar performance without the harmful environmental effects of copper
Solution Approach 2:
The invention creates a composite friction material system combining iron oxide particles with specific organic friction modifiers (such as polyacetal resin, polyester resin, or polyamide resin) to achieve synergistic effects that maintain or improve braking effectiveness and wear resistance while eliminating copper content
3Object-affected harmful factors
If NAO friction material without copper is used to reduce pollution, then environmental compliance is improved, but low frequency vibration noise increases
Solution Approach 1:
The invention changes the compositional parameters by introducing iron oxide (0.1-5.0 wt%) and adjusting the types and amounts of organic friction modifiers, thereby altering the friction material's vibrational characteristics to suppress low frequency noise while maintaining the copper-free composition required for environmental compliance
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 composition effectively suppresses low-frequency noise and maintains stable braking performance without copper, ensuring compliance with environmental regulations and reducing noise issues during low-load braking.
Implementation Method 1
2-4 weight % flaky graphite particles, which form a protective film and facilitate abrasion powder ejection
Implementation Method 2
a friction material used for a disc brake pad... securing the braking effectiveness... under the high speed and high load braking conditions
Data Source
AI summary
[OBJECT] The present invention provides a friction material used for a disc brake pad, which is manufactured by forming a non-asbestos-organic (NAO) friction material composition, which is able to suppress an occurrence of noise just before a vehicle stops, while satisfying laws and regulations relating to the required amount of the content of the copper component. [MEANS TO SOLVE THE PROBLEM] The friction material for the disc brake pad is manufactured by forming the NAO friction material composition that is free of the copper component, the friction material composition practically does not include an iron component but includes 15 - 22 weight % of a non-whisker-like titanate, relative to the total amount of the friction material composition, as a titanate, 15 -25 weight % of zirconium oxide with the average particle diameter of 1.0-4.0 µm, relative to the total amount of the friction material composition, as the inorganic friction modifier, and 4 - 6 weight % of cleavable mineral particles, relative to the total amount of the friction material composition, as the inorganic friction modifier.