Dual-Layer Clutch Friction Material Bonding Without Papermaking
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Solution Overview
Problem
Existing methods for manufacturing dual layer friction materials in motor vehicle drivetrain components face challenges, particularly for facilities lacking paper making equipment, and there is a need for improved bonding techniques to enhance adhesion and durability.
Innovation Solution
A method involving the application of a colloid, such as a polysaccharide mixture, to align and bond two wet friction material layers, followed by curing with a binder, using a hot press to form grooves and create a strong bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional paper making equipment is used to manufacture dual layer friction materials, then manufacturing precision and adhesion are improved, but device complexity and manufacturing cost increase due to equipment requirements
Solution Approach 1:
The patent introduces a colloid as an intermediary substance applied to the interface between the first friction material layer and the second friction material layer. This colloid acts as a mediator that enhances adhesion between the layers, allowing dual layer friction materials to be manufactured without complex paper making equipment. The colloid creates a bonding interface that achieves reliable adhesion through a simplified process.
2Device complexity
If dual layer friction material is manufactured without paper making equipment, then device complexity is reduced, but manufacturing precision and alignment of layers deteriorate
Solution Approach 1:
The colloid serves as a positioning intermediary that facilitates precise alignment of the second friction material layer on the first layer. By applying the colloid to the interface, manufacturers can achieve accurate layer positioning without requiring complex paper making equipment, thus maintaining manufacturing precision while reducing device complexity.
3Strength
If binder is applied to bond friction material layers, then strength of bonding is improved, but manufacturing process time and energy consumption increase due to curing requirements
Solution Approach 1:
The patent applies the colloid to the interface between friction material layers before the bonding process. This preliminary action prepares the surface for bonding, creating a ready-to-bond interface that reduces the overall curing time. By pre-applying the colloid and allowing it to prepare the interface, the subsequent binder application and curing process is accelerated, reducing total manufacturing time while maintaining bonding strength.
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 method enables effective bonding of dual layer friction materials, even in facilities without paper making equipment, resulting in enhanced adhesion and durability, suitable for clutch assemblies in motor vehicles.
Implementation Method 1
the colloid aiding in the arranging and aligning of the second wet friction material layer on the first wet friction material layer by causing adhesion of the second wet friction material layer to the first wet friction material layer
Implementation Method 2
bonding the second wet friction material layer and the first wet friction material layer together by a binder
Implementation Method 3
the heating of the binder evaporating a liquid of the colloid
Implementation Method 4
the curing of the binder is performed by heating the binder, the heating of the binder evaporating a liquid of the colloid
Data Source
AI summary
A method of making a clutch assembly for a motor vehicle is provided. The method includes applying a colloid to at least one of a first wet friction material layer and a second wet friction material layer; arranging and aligning the second wet friction material layer on the first wet friction material layer with the colloid an interface between the first wet friction material layer and the second wet friction material layer, the colloid aiding in the arranging and aligning of the second wet friction material layer on the first wet friction material layer by causing adhesion of the second wet friction material layer to the first wet friction material layer; and then bonding the second wet friction material layer and the first wet friction material layer together by a binder.