Friction Material with Aggregated Particles for Wet Clutch Permeability
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Solution Overview
Problem
Current friction materials used in wet clutch applications have evenly distributed ingredient fillers, which do not adequately address the need for increased permeability and resistance to extreme temperatures and high-energy conditions.
Innovation Solution
The friction material incorporates aggregated particles and fibers, such as aramid and carbon fibers, along with diatomaceous earth and graphite particles, to create regions of grouped particles, enhancing permeability by 2 to 10 times compared to uniformly distributed particles, and includes a resin bonding agent and chemical binder for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If particles are evenly distributed throughout the friction material, then the material structure is simple and easy to manufacture, but the permeability is insufficient for high-speed applications
Solution Approach 1:
The friction material is segmented into distinct regions: densely packed particle regions and low-density porous regions. This segmentation creates interconnected pores that enhance permeability while maintaining structural integrity, resolving the contradiction between manufacturing simplicity and permeability requirements.
Solution Approach 2:
Different regions of the friction material are assigned different particle densities and compositions. The low-density regions provide high permeability for oil flow, while densely packed regions provide friction material strength. This local differentiation allows the material to simultaneously achieve good permeability and manufacturability.
2Reliability
If particles are aggregated into regions of groups, then the permeability increases by 2 to 10 times, but the material structure becomes more complex
Solution Approach 1:
The material is divided into discrete particle groups separated by porous regions. This segmentation naturally creates the aggregated particle structure that enhances permeability without requiring complex manufacturing processes, as the segmentation can be achieved through conventional mixing and molding techniques.
Solution Approach 2:
Multiple particles are merged into grouped regions that maintain internal density while being separated from other particle groups by porous spaces. This merging approach creates the desired permeability structure using standard friction material manufacturing methods, avoiding excessive structural complexity.
3Ease of manufacture
If uniformly distributed particles are used, then the manufacturing process is straightforward, but the resistance to extreme temperatures and high-energy conditions is insufficient
Solution Approach 1:
Densely packed particle regions are strategically positioned to provide thermal and mechanical strength where needed, while low-density porous regions are placed to facilitate oil flow and heat dissipation. This local quality differentiation enables the material to withstand extreme conditions while maintaining manufacturing simplicity.
Solution Approach 2:
The friction material employs a composite structure combining densely packed particle regions with low-density porous regions. This composite architecture provides both the thermal and mechanical resistance required for extreme conditions and can be manufactured using conventional friction material processes.
4Reliability
If aggregated particle regions are created, then oil flow resistance is improved and permeability increases, but the arrangement and distribution control becomes more difficult
Solution Approach 1:
The particle distribution is segmented into discrete groups rather than requiring continuous uniform distribution. This segmentation relaxes manufacturing precision requirements, as the particle groups can form naturally during conventional mixing and molding processes without needing precise control over individual particle placement.
Solution Approach 2:
The invention changes the distribution parameter from uniform density throughout to variable density with clustered regions. This parameter change allows oil flow resistance to be optimized through natural particle aggregation during manufacturing, reducing the need for precise distribution control while improving permeability.
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 solution significantly increases the average permeability and resistance to extreme temperatures, making the friction material more suitable for high-speed and high-energy applications by creating interconnected pores and improving oil flow resistance.
Implementation Method 1
the amount and arrangement of regions of groups of particles results in an increase in average permeability of 2 to 10 times compared to a composition with single particles instead of regions of groups particles
Implementation Method 2
resistance to extreme temperatures and high-energy conditions
Data Source
AI summary
One variation includes a friction material wherein the friction material may be fabricated from fibers, particles, a chemical binder, and a resin bonding agent wherein the particles are aggregated.