Friction Material Mixing Using Low-Frequency Acoustic Agitation
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Solution Overview
Problem
Existing methods for manufacturing friction materials using mechanical mixers are inefficient, leading to prolonged mixing times, contamination, and dust scattering due to complex internal structures and incomplete sealing, resulting in extended manufacturing cycles.
Innovation Solution
The use of low frequency acoustic agitation to mix and agitate raw materials at frequencies between 30 Hz to 1 kHz for 60 to 180 seconds, ensuring uniform mixing and preventing contamination and dust scattering by uniformly transferring energy throughout the container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mechanical mixer with blades and screws is used to mix raw materials, then the raw materials can be mixed, but the mixing occurs only in portions where raw materials contact the blades, resulting in prolonged mixing time
Solution Approach 1:
The patent replaces the traditional mechanical mixing system (blades and screws) with an acoustic field system. By applying acoustic waves to the raw materials, the invention achieves uniform mixing throughout the entire container without relying on mechanical contact, thereby eliminating the limitation of localized mixing and significantly reducing mixing time while maintaining or improving uniformity.
Solution Approach 2:
The invention utilizes acoustic vibration to agitate and mix the raw materials. The acoustic waves induce vibrational motion in the material particles, causing them to move and mix uniformly throughout the container. This vibrational approach replaces the mechanical blade rotation and achieves more efficient and uniform mixing compared to traditional mechanical mixing methods.
2Manufacturing precision
If a mechanical mixer with complex internal structure (blades, screws) is used, then mixing can be achieved, but cleaning becomes inadequate and contamination occurs, extending the cleaning cycle
Solution Approach 1:
By replacing the complex mechanical mixing system with an acoustic field-based system, the invention eliminates the need for blades, screws, and other mechanical components that are difficult to clean. The acoustic mixing device has a simple structure with no internal moving parts that contact the materials, making it extremely easy to clean and preventing contamination, thereby significantly improving cleaning efficiency while maintaining mixing uniformity.
3Manufacturing precision
If a mechanical mixer with air seal structure is used, then mixing can be performed, but the container is not completely sealed, causing dust scattering and deterioration of working environment
Solution Approach 1:
The invention replaces the mechanical mixing system with an acoustic field system that does not require a complex sealed container structure. The acoustic waves can effectively mix materials in a sealed container without requiring complex air seal mechanisms, thereby achieving complete sealing and preventing dust scattering while maintaining effective mixing capability.
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
This approach allows for rapid and efficient mixing of friction materials, reducing manufacturing cycles, preventing contamination and dust scattering, and ensuring uniformity, as demonstrated by improved shear strength and friction coefficient measurements.
Implementation Method 1
mixing and agitating the raw materials by low frequency acoustic agitation at a frequency of 30 Hz to 1kHz
Data Source
AI summary
The present invention addresses the problem of providing a novel method which is for manufacturing a friction material and with which raw materials can be mixed in a short time, the scattering of contamination or powder dust is prevented, and the friction material can be manufactured in short cycles. The present invention pertains to a method for manufacturing a friction material that contains, as raw materials, a friction adjustment material, a fiber base material, and a binding material, the method including a step for mixing and stirring the raw materials by performing low-frequency acoustic stirring and mixing.