Dual-Material Wet Friction Segments for Heat-Durability Balance
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Solution Overview
Problem
Existing wet friction materials in torque converters and motor vehicle transmissions face challenges in balancing friction performance and durability under high energy and power conditions, particularly due to increased engagement temperatures.
Innovation Solution
A dual-material friction surface is formed by combining two different wet friction materials, where one material prioritizes high friction performance and the other prioritizes durability, with specific fiber and filler compositions, to create a balanced performance layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single wet friction material composition is used, then the manufacturing process is simple, but the friction performance and durability cannot be simultaneously optimized under high energy and power conditions
Solution Approach 1:
The friction material is divided into different radial zones with distinct compositions. The inner radius region contains a first composition optimized for high-temperature durability, while the outer radius region contains a second composition optimized for friction performance. This local differentiation allows each zone to perform its specific function optimally without compromising the other.
Solution Approach 2:
The invention uses composite material structures with at least two different friction material compositions. Each composition contains specific ratios of organic fibers, inorganic fibers, resin binder, and friction modifiers. The composite structure combines materials with complementary properties to achieve both high friction performance and durability simultaneously.
2Reliability
If high friction performance material is used, then friction performance is improved, but durability under high engagement temperatures deteriorates
Solution Approach 1:
The friction material is divided into different radial zones with distinct compositions. The inner radius region contains a first composition optimized for high-temperature durability, while the outer radius region contains a second composition optimized for friction performance. This local differentiation allows each zone to perform its specific function optimally without compromising the other.
3Reliability
If high durability material is used, then durability is improved, but friction performance under high energy conditions deteriorates
Solution Approach 1:
The friction material is divided into different radial zones with distinct compositions. The inner radius region contains a first composition optimized for high-temperature durability, while the outer radius region contains a second composition optimized for friction performance. This local differentiation allows each zone to perform its specific function optimally without compromising the other.
4Power
If uniform friction material composition is used, then manufacturing is simple, but performance cannot meet high energy and power demands
Solution Approach 1:
The friction material is divided into different radial zones with distinct compositions. The inner radius region contains a first composition optimized for high-temperature durability, while the outer radius region contains a second composition optimized for friction performance. This local differentiation allows each zone to perform its specific function optimally without compromising the other.
Solution Approach 2:
The invention uses composite material structures with at least two different friction material compositions. Each composition contains specific ratios of organic fibers, inorganic fibers, resin binder, and friction modifiers. The composite structure combines materials with complementary properties to achieve both high friction performance and durability simultaneously.
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 dual-material friction surface enhances friction performance and durability, meeting high energy and power demands while maintaining material integrity.
Implementation Method 1
a first axially facing surface configured as a friction contacting surface configured for being brought in and out of contact with a further surface for frictional engagement with the further surface
Data Source
AI summary
A wet friction assembly includes a part; and at least one first arc shaped wet friction material segment and at least one second arc shaped wet friction material segment to the part to form an annular wet friction material layer on the part. Each first arc shaped wet friction material segment has a first composition including a binder, fibers and filler particles. Each second arc shaped wet friction material segment has a second composition including a binder, fibers and filler particles. The first composition is different from the second composition.