Copper-Reduced Sintered Friction Material for High-Speed Braking
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Solution Overview
Problem
Sintered friction materials with copper components face environmental concerns due to copper abrasion and lack evaluation in high-speed ranges, necessitating a copper-reduced, environmentally friendly alternative with sufficient friction performance.
Innovation Solution
A sintered friction material with a titanate and metal material matrix, where the metal material is primarily iron-based, and tungsten is included, with a copper content of 0.5 mass % or less, processed at 900°C to 1300°C, ensuring sufficient friction performance in high-speed ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper component is used in friction material, then friction performance is improved, but environmental contamination increases
Solution Approach 1:
The patent changes the chemical composition parameters by limiting copper component to 0.5 mass% or less and introducing specific metal materials (iron-based: 8-32 vol%, tungsten: 1-15 vol%, aluminum: 2-20 vol%) to replace copper's friction functions while minimizing environmental harm
Solution Approach 2:
The patent creates a composite material system combining multiple metal materials (iron-based, tungsten, aluminum) with titanate and ceramic matrix, where each component contributes different properties: iron-based provides friction coefficient, tungsten provides wear resistance, and aluminum provides oxidation resistance, collectively replacing copper's multiple functions
2Manufacturing precision
If sintering temperature is increased to improve material density, then manufacturing cost and energy consumption increase
Solution Approach 1:
The patent optimizes the sintering temperature parameter to a specific range (900-1300°C) that achieves sufficient material density and mechanical properties while minimizing energy consumption, avoiding excessive heating that would waste energy without providing proportional benefits
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 an environmentally friendly sintered friction material with improved friction performance and reduced environmental impact, suitable for high-speed applications while minimizing copper content.
Implementation Method 1
a sintering step of sintering, at 900°C to 1300°C, a molded product molded in the molding step
Data Source
AI summary
The present invention pertains to a sintered friction material that has a copper component content of 0.5 mass % or less, contains a metal material other than copper and a titanate as a matrix, and has a metal material content of 10.0-34.0 vol% for the metal material other than copper. This sintered friction material is environmentally friendly and has adequate friction performance even in a high-speed range.