Fibrous Friction Material with Particle Gradient for Hot Spot Resistance
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Solution Overview
Problem
Current friction materials fail to maintain consistent friction and heat resistance at high speeds and temperatures in advanced transmission and braking systems, leading to issues like 'hot spots' and reduced performance due to the absence of asbestos and inadequate heat dissipation.
Innovation Solution
A fibrous base material with a permeating or penetrating gradient of friction modifying particles, such as silica, is used, which is impregnated with a suitable resin to create a friction material that is elastic, porous, and has improved heat resistance and coefficient of friction stability, eliminating 'hot spots' and maintaining performance over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If asbestos fibers are used for temperature stability, then heat resistance is improved, but health and environmental problems occur
Solution Approach 1:
The patent removes asbestos fibers from the friction material composition entirely, extracting the harmful substance while maintaining the functional requirements through alternative materials and structural design
Solution Approach 2:
The patent uses a composite structure combining organic fibers (cotton, wood pulp) with inorganic fillers (metallic particles, ceramic particles) to achieve the temperature stability and friction characteristics previously provided by asbestos, without the associated health hazards
2Object-affected harmful factors
If phenolic or phenolic-modified resins are used to replace asbestos, then asbestos-free composition is achieved, but heat dissipation and heat resistance are insufficient
Solution Approach 1:
The patent combines phenolic resins with metallic particles (aluminum, copper, iron) and ceramic particles (alumina, silica) to create a composite material that achieves both asbestos-free composition and superior heat resistance and dissipation properties
Solution Approach 2:
The patent modifies the resin system by incorporating specific ratios of metallic and ceramic particles, changing the thermal parameters of the material to achieve rapid heat dissipation while maintaining structural integrity at high temperatures
3Speed
If high speeds are generated during engagement and disengagement, then transmission performance is improved, but friction consistency and torque curve stability deteriorate
Solution Approach 1:
The patent uses a composite friction material containing metallic particles, ceramic particles, and organic fibers that maintains consistent friction characteristics across a wide speed range, preventing squeak and ensuring stable torque curves during high-speed engagement and disengagement
Solution Approach 2:
The patent creates a friction material with heterogeneous composition where different materials are distributed to provide specific local functions: metallic particles for heat conduction, ceramic particles for friction stability, and fibers for structural integrity, achieving overall friction consistency at varying speeds
4Duration of action of stationary object
If fluid is used over a long period, then transmission operation continues, but fluid degradation particles form causing loss of coefficient of friction
Solution Approach 1:
The patent employs a porous friction material structure that can absorb and filter degradation particles from the transmission fluid, preventing these particles from interfering with the friction interface and maintaining coefficient of friction stability over extended operation periods
Solution Approach 2:
The composite friction material composition includes materials that are resistant to fluid degradation and can maintain their friction properties even in the presence of degraded fluid particles, ensuring long-term reliability
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 friction material exhibits improved 'hot spot' resistance, high heat resistance, durability, and porosity, ensuring consistent friction and efficient heat dissipation, even under high-energy conditions, thus enhancing the performance and longevity of transmission and braking systems.
Implementation Method 1
it must also be able to rapidly dissipate the high heat that is being generated during operating conditions
Implementation Method 2
The friction interface energy management is primarily concerned with controlling interface temperature and is affected by the pump capacity, oil flow path and control strategy
Implementation Method 3
a fibrous base material with a permeating or penetrating gradient of friction modifying particles, such as silica, is used
Implementation Method 4
The friction material exhibits improved 'hot spot' resistance, high heat resistance, durability, and porosity, ensuring consistent friction
Data Source
AI summary
The present invention relates to a friction material having a fully fibrous content fibrous base material. The base material has dispersed therethrough, in a penetrating gradient, a desired amount of friction modifying particles.