Friction Material with Binder-Bound Friction Modifying Particles
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Solution Overview
Problem
Existing friction materials for applications like slip clutches and torque converters face challenges in withstanding thermal and physical forces, and in providing adequate friction and wear resistance, especially with the use of organic fibers which are not suitable for heavy-duty service.
Innovation Solution
A friction material with an open-pore structure comprising aramid fibers, flowable uncured binder particles, and smaller friction modifying particles such as silica or carbon particles, bound to the binder particles, which improves wear resistance and oil flow through the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If organic fibers are used in friction material, then ease of manufacture is improved, but thermal and physical resistance deteriorates
Solution Approach 1:
The patent employs a composite material structure combining organic fibers with inorganic friction modifying particles (silica, carbon, oxide particles) and binder particles. This composite approach allows the organic fibers to provide structural integrity and ease of manufacture while the inorganic particles contribute thermal and physical resistance, resolving the contradiction between manufacturing ease and thermal/physical durability in heavy-duty friction applications
2Reliability
If friction modifying particles are added to improve friction performance, then friction characteristics are improved, but wear resistance deteriorates
Solution Approach 1:
The patent applies local quality by creating a layered structure where friction modifying particles are concentrated at the engagement surface to optimize friction characteristics, while binder particles and fiber matrix provide structural support and wear resistance in the bulk material. This spatial differentiation allows each component to perform its specialized function without compromising overall durability
Solution Approach 2:
The composite material system combines friction modifying particles (for friction performance) with binder particles containing polymers like phenolic, silicone, polyamide, or polyimide (for wear resistance and thermal stability). This composite structure enables simultaneous achievement of good friction characteristics and wear resistance that neither component could achieve alone
3Reliability
If binder particles are used to hold friction modifying particles, then friction modifying particle retention is improved, but oil flow through the material deteriorates
Solution Approach 1:
The patent utilizes porous materials by incorporating binder particles with controlled porosity and creating an open-pore structure within the friction material matrix. This porous architecture allows the binder particles to retain friction modifying particles through adsorption and physical entrapment while simultaneously maintaining adequate pore channels for oil flow, thus resolving the contradiction between particle retention and fluid 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 friction material exhibits improved wear resistance, oil flow, and heat dissipation, reducing uneven lining wear and maintaining consistent friction performance under high energy operations.
Implementation Method 1
a plurality of friction modifying particles at the engagement surface of the base material, the friction modifying particles having a particle size less than the binder particles, and the weight ratio of friction modifying particles to binder particles ranging from 50/50 to 90/10, wherein the friction modifying particles comprise carbon particles, oxide particles, resin powders, silica particles or cashew oil modified particles and wherein a plurality of the friction modifying particles are bound to each binder particle
Implementation Method 2
A friction material having an open-pore structure comprising a base material comprising a plurality of fibers
Implementation Method 3
a plurality of friction modifying particles at the engagement surface of the base material... maintaining consistent friction performance under high energy operations
Data Source
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AI summary
One exemplary embodiment includes a friction material including a base including a plurality of fibers. The base including an engagement surface, and a plurality of binder particles and friction modifying particles at the engagement surface.