Resin Bonded Carbonaceous Brush Conductivity
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Solution Overview
Problem
The resin bonded carbonaceous brush has high electrical resistivity due to its large resin content, which hinders motor output improvement.
Innovation Solution
Incorporating metallic powder with an average particle diameter of 0.3 mm or more into the carbonaceous material, with a ratio of 1% to 30% by weight, to form a three-dimensional metal network, reducing electrical resistivity while maintaining bonding force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If resin content is increased to improve flexibility and lubrication ability, then friction noise is reduced, but electrical resistivity increases
Solution Approach 1:
The invention uses a composite material system consisting of carbonaceous material particles, resin, and metallic powder. The metallic powder (silver, copper, or aluminum) is dispersed within the resin-bonded carbonaceous structure, creating a multi-phase composite that simultaneously provides lubrication (from resin and carbon), flexibility (from resin bonding), and electrical conductivity (from metallic powder network), thereby resolving the contradiction between noise reduction and electrical resistivity
Solution Approach 2:
The invention applies local quality by distributing metallic powder specifically within the resin matrix and at particle interfaces, rather than uniformly throughout. This localized placement of conductive material creates conductive pathways where needed while maintaining the overall resin-bonded structure's lubrication and flexibility properties, thus reducing electrical resistivity without sacrificing noise reduction capabilities
2Reliability
If metallic powder ratio is increased to decrease electrical resistivity, then conductivity is improved, but bonding force among particles decreases
Solution Approach 1:
The invention optimizes the metallic powder content parameter within a specific range (1-30 wt%) to achieve the desired balance. This parameter optimization ensures sufficient conductive pathways are formed while maintaining adequate resin content to provide bonding force between carbonaceous particles, thus resolving the contradiction between conductivity improvement and bonding strength maintenance
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
The solution effectively decreases electrical resistivity and ensures sufficient conductivity, preventing a decrease in bonding force, thus enhancing motor efficiency.
Implementation Method 1
conductivity is increased by arrangement of the metallic powder among the particles of the carbonaceous material, and thus the electrical resistivity is decreased
Implementation Method 2
A resin bonded carbonaceous brush that includes carbon and is formed by resin bonding
Data Source
AI summary
A carbonaceous material is fabricated by kneading of carbon powder and a binder. The carbonaceous material is granulated such that an average particle diameter of the carbonaceous material is 0.3 mm or more. A brush material is fabricated by mixing of the granulated carbonaceous material and metallic powder. A ratio of the metallic powder to a total weight of the brush material is adjusted to 1% by weight or more and 30% by weight or less. Pressure molding is performed on the fabricated brush material, and thermal processing is further performed on the brush material at a temperature at which a resin in the brush material is not carbonized.