Ferrous Brake Friction Material With Low Dust and Rotor Wear
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Solution Overview
Problem
Existing friction materials for brake systems deteriorate moving parts like the rotor and generate excessive brake dust or powder, and there is a need for a material that provides high braking performance without these drawbacks.
Innovation Solution
A friction material comprising ferrous metals, non-carbonaceous lubricants such as molybdates and tungsten compounds, and micro-particulated materials to enhance lubrication and reduce wear, while being asbestos and copper-free.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If steel and abrasives are used to generate high friction, then braking performance is improved, but brake dust and powder generation increases
Solution Approach 1:
The patent introduces non-carbonaceous lubricants as intermediary substances between the steel/abrasive friction material and the rotor surface. These lubricants (such as molybdenum disulfide, tungsten disulfide, or zinc sulfide) form a protective film that mediates the friction interaction, allowing high friction force to be generated while significantly reducing direct metal-to-metal contact and thereby reducing brake dust generation
Solution Approach 2:
The friction material is formulated as a composite containing multiple components: steel (for friction), abrasives (for wear resistance), and non-carbonaceous lubricants (for dust reduction). This composite structure allows the material to simultaneously achieve high braking performance while minimizing brake dust generation through the synergistic effect of its constituents
2Reliability
If friction material composition is adjusted to increase one property, then that property is improved, but another property deteriorates
Solution Approach 1:
The patent systematically adjusts the parameters of the friction material composition, specifically the ratios and types of steel, abrasives, and non-carbonaceous lubricants. By changing these compositional parameters within optimized ranges, the material achieves reliable braking performance while maintaining composition stability under various operating conditions
Solution Approach 2:
The friction material exhibits local quality variations where different regions or components serve specific functions: steel provides friction, abrasives provide wear resistance, and non-carbonaceous lubricants provide dust reduction. This localized functional distribution allows each component to optimize its performance while contributing to overall material stability
3Force
If copper is used in friction material, then braking performance is improved, but harmful effects increase
Solution Approach 1:
The patent extracts copper from the friction material composition entirely, eliminating the source of harmful effects (such as rotor deterioration and excessive brake dust). Instead of using copper, the patent employs alternative materials like steel combined with non-carbonaceous lubricants to achieve the necessary friction force without the associated harmful side effects
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 high braking performance with reduced wear on moving parts and minimal brake dust or powder generation, maintaining system integrity and efficiency.
Implementation Method 1
one or more lubricating components present in an amount from about 2 to about 30 percent by weight of the friction material, the one or more lubricating components including: one or more lubricants that are a non-carbonaceous lubricant and (i) a molybdate or an alkali metal molybdate; (ii) a tungsten containing compound; (iii) a zinc sulfide; (iv) a fluoride and metal containing compound; (v) alkali earth metals which are magnesium, calcium, or both that are combined with a phosphate, sulfate, or both
Implementation Method 2
the friction material gradually slows the moving part until a complete stop is achieved. During the contact between the friction material and the moving part wear occurs
Data Source
Figure 1~2
Figure 3
AI summary
A friction material comprising: (a) at least one metal containing constituent, wherein the at least one metal containing constituent includes a ferrous metal; (b) one or more lubricating components including: one or more lubricants that are a non-carbonaceous lubricant and (i) a molybdenum containing compound; (ii) a tungsten containing compound; (iii) a zinc sulfide; (iv) a fluoride and metal containing compound; (v) an alkali earth metal phosphate, sulfate, or both; (vi) or a combination of (i) through (v); (c) one or more filler materials; (d) optionally at least one processing aid; (e) an organic binder; and wherein the friction material is free of asbestos and substantially devoid of copper.