Copper-Free Friction Material Composition for Brake Noise and Wear
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Copper-free friction materials often compromise on noise resistance and heat radiation properties, limiting their application to specific vehicle types, and existing solutions do not adequately enhance wear resistance during high-temperature braking.
Innovation Solution
A friction material composition containing a fiber base material, a binder, and a combination of partially graphitized coke and muscovite, where the copper content is 0.5% by mass or less, with muscovite ranging from 1% to 6% and partially graphitized coke from 2% to 8% by mass, to achieve enhanced wear resistance and noise resistance without copper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If copper is removed from friction material to address environmental concerns, then environmental compatibility is improved, but noise resistance and heat radiation properties deteriorate
Solution Approach 1:
The patent introduces zinc powder as an intermediary substance to replace copper's functions. Zinc serves as a mediator that provides both noise resistance and heat radiation properties without the environmental harm of copper. The zinc particles are specifically controlled in size (2-20 μm) and content (1-5% by mass) to optimize their mediating effect between the friction material and the environment.
Solution Approach 2:
The patent changes the chemical composition parameters by removing copper and adding zinc powder with specific characteristics. The particle size parameter of zinc (2-20 μm) and its content parameter (1-5% by mass) are precisely controlled to achieve the desired noise resistance and heat radiation properties while maintaining environmental compatibility.
2Object-affected harmful factors
If copper is removed from friction material, then environmental compatibility is improved, but wear resistance during high-temperature braking deteriorates
Solution Approach 1:
The patent creates a composite friction material system combining organic fibers, inorganic fillers, zinc powder, and resin binder. This composite structure provides wear resistance through the synergistic effect of multiple components: aramid/glass/ceramic fibers provide structural strength, while zinc powder and inorganic fillers contribute to high-temperature stability and wear resistance without relying on copper.
Solution Approach 2:
Zinc powder acts as an intermediary substance that maintains wear resistance during high-temperature braking. The zinc particles distribute heat and reduce direct contact wear between friction surfaces, compensating for the removal of copper while maintaining environmental compatibility.
3Object-affected harmful factors
If copper is removed from friction material, then environmental compatibility is improved, but heat radiation property deteriorates
Solution Approach 1:
Zinc powder serves as a thermal mediator with high thermal conductivity that replaces copper's heat radiation function. The zinc particles (2-20 μm size) distribute and radiate heat efficiently throughout the friction material, maintaining effective heat dissipation while eliminating the environmental harm of copper.
Solution Approach 2:
The patent changes the thermal properties by substituting copper with zinc powder at controlled concentrations (1-5% by mass). This parameter change maintains the heat radiation property through zinc's thermal conductivity while improving environmental compatibility by eliminating heavy metal copper.
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 combination of muscovite and partially graphitized coke maintains wear resistance at high temperatures comparable to copper-containing materials, while improving noise resistance and brake effectiveness for a wide range of vehicle types, making it suitable for industrial and passenger vehicles.
Implementation Method 1
a friction material composition excellent in wear resistance, noise resistance, brake effect, etc.
Implementation Method 2
Friction material composition and friction material
Implementation Method 3
maintains wear resistance at high temperatures comparable to copper-containing materials
Implementation Method 4
improving noise resistance and brake effectiveness
Data Source
AI summary
The present invention provides a friction material that is used in friction members such as disc brake pads and drum brake shoes of braking equipment for vehicles, does not contain copper or copper-containing metals, improves abrasion resistance during high-temperature braking, and improves noise resistance and the effectiveness of brakes in a wide range of models. Further provided is friction material composition: containing a fiber base material, a friction modifier and a binder; having a copper content of not more than 0.5 mass%; and containing partially graphitized coke and muscovite. The friction material is obtained by molding the friction material composition.