Ceramic Brake Pad Composition Without Copper or Antimony
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Solution Overview
Problem
Current brake friction materials, such as those containing asbestos and copper, pose safety and environmental concerns due to hazardous emissions and carcinogenic properties, necessitating the development of alternative materials that balance performance and environmental friendliness.
Innovation Solution
A friction material composition comprising 1.0% to 6.0% boron-containing solid lubricants, 5.0% to 15.0% fibrous or powdered metal materials, abrasives, organic fillers, inorganic fillers, and a binder, which is free of antimony and copper, forming a thermosetting matrix for brake applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper-based friction materials are used, then braking performance is improved, but harmful emissions into the environment worsen
Solution Approach 1:
The patent removes copper entirely from the friction material composition, extracting the harmful element while maintaining performance through alternative materials including iron powder, steel wool, and organic polymers that provide equivalent friction and wear characteristics without environmental harm
Solution Approach 2:
The invention uses a composite formulation combining multiple materials (iron powder, steel wool, organic polymers, inorganic fillers) to achieve the complex functional requirements of brake friction materials, replacing the simpler copper-based formulations while eliminating harmful emissions
2Reliability
If antimony trisulfide is used as lubricant, then friction control is improved, but carcinogenic emissions worsen
Solution Approach 1:
The patent eliminates antimony trisulfide and all antimony-containing compounds from the friction material composition, removing the source of carcinogenic antimony oxide emissions while maintaining lubrication and friction control through alternative materials
Solution Approach 2:
The invention introduces alternative lubricating materials such as polyethylene glycol and other organic polymers that serve as intermediaries to provide the necessary friction control and lubrication functions previously achieved by antimony trisulfide, without producing harmful emissions
3Duration of action of stationary object
If asbestos-based friction materials are used, then durability is improved, but carcinogenic properties worsen
Solution Approach 1:
The patent completely removes asbestos and all asbestos-containing materials from the friction material composition, eliminating the carcinogenic hazard while maintaining the desired durability and wear resistance through alternative materials such as steel wool, aramid fibers, and reinforced organic polymers
Solution Approach 2:
The invention employs a composite material system combining multiple durable components (metal fibers, organic polymers, inorganic fillers) to achieve the long-term durability and structural integrity previously provided by asbestos, without the associated health risks
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 provides a high-performance, environmentally friendly brake friction material with reduced wear and longer pad life, maintaining effective friction coefficients without hazardous emissions, as demonstrated in comparative testing against copper-free materials with antimony trisulfide.
Implementation Method 1
about 1.0% to about 6.0% by weight of a boron-containing solid lubricant
Implementation Method 2
about 5.0% to about 15.0% by weight of a fibrous or powdered metal material
Data Source
AI summary
Provided is a friction material that includes a boron-containing solid lubricant. The friction material may be used to form a brake pad for automotive vehicles. The friction material may include, by weight, about 1.0% to about 6.0% of the boron-containing solid lubricant, about 5.0% to about 15.0% of a fibrous or powdered metal material, an abrasive, an organic filler, an inorganic filler, and a binder. Advantageously, an antimony free and copper free friction material of the present disclosure may still achieve high friction performance and long pad life, providing a more environment friendly solution to brake systems.