Disc Brake Friction Material Using Preceramic and Organic Resin Composites
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Solution Overview
Problem
Conventional ceramic matrix materials for disc brake friction components provide effective thermal resistance but generate noise due to vibration, requiring structural modifications to the brake system, which is undesirable.
Innovation Solution
A friction material composition comprising between 1% and 8% by weight of preceramic resin and between 2% and 10% by weight of organic resin, specifically silicone and phenolic resins, along with catalysts, abrasives, lubricants, and damping agents, to enhance heat resistance and quietness without altering the brake's structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic matrix materials are used for friction components, then thermal resistance is improved, but noise generation increases
Solution Approach 1:
The patent uses a composite material consisting of ceramic particles (for thermal resistance) embedded in an organic resin matrix (for noise reduction). This combines the advantages of both materials: ceramic provides high-temperature resistance while the organic resin dampens vibrations and reduces noise, resolving the contradiction between thermal performance and noise generation.
Solution Approach 2:
The patent applies different materials to different functional requirements within the same friction component. The ceramic particles are distributed throughout the organic resin matrix, with ceramic providing local thermal resistance where needed and the organic resin providing local vibration damping. This local differentiation allows simultaneous achievement of thermal resistance and noise reduction.
2Ease of manufacture
If conventional organic materials are used for friction components, then ease of manufacture is improved, but temperature resistance deteriorates
Solution Approach 1:
The patent creates a composite where organic resin (easy to manufacture) serves as the continuous matrix phase, while ceramic particles (high temperature resistance) are dispersed as the reinforcement phase. This allows the material to retain the ease of processing and manufacturing of organic materials while gaining the thermal resistance of ceramics, resolving the contradiction between manufacturability and temperature resistance.
3Reliability
If ceramic matrix materials are used for friction components, then friction performance is improved, but device complexity increases
Solution Approach 1:
The patent develops a composite friction material that combines ceramic particles with organic resin in a single integrated material system. This eliminates the need for complex multi-component brake assemblies or specialized ceramic matrix processing equipment, achieving high friction performance through a relatively simple composite material formulation and manufacturing process.
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 material achieves efficient and noiseless braking with improved heat resistance and performance, maintaining a consistent friction coefficient and reduced disc temperature, while maintaining a conventional brake structure and being cost-effective.
Implementation Method 1
submitting said green body to a pyrolysis process in order to achieve ceramization of the preceramic binder
Implementation Method 2
in which said mixture comprises a catalyst suitable for favouring reticulation of said ceramic precursor during said hot-pressing phase
Implementation Method 3
the braking action is produced by braking means, like for example a piston and cylinder group, which act through friction components on opposite surfaces of a rotating disc
Data Source
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AI summary
The invention illustrates a material for friction components of disc brakes comprising between 1% and 8% by weight of at least one preceramic resin and between 2% and 10% by weight of at least one organic resin. It also illustrates a friction component for a disc brake, a disc brake, and a process for producing such a material.