Copper-Free Friction Material Composition for Rust Delamination Resistance
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Solution Overview
Problem
Friction materials without copper face challenges of low material strength and insufficient rust delamination resistance, leading to issues like rust adhesion and delamination, which are not adequately addressed by existing solutions.
Innovation Solution
A friction material composition incorporating fibrillated aramid fibers, calcium hydroxide, sodium carbonate, powdered zinc, and steel fibers, which synergistically reduce rust adhesion and delamination, while maintaining strength and avoiding copper contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper is added to improve friction coefficient stability and abrasion resistance at high temperatures, then anti-fade property and strength are improved, but environmental contamination increases due to copper-containing abrasion powder
Solution Approach 1:
The patent removes copper from the friction material composition entirely, extracting the harmful element while maintaining performance through alternative materials. The composition specifies no copper or not more than 0.5 mass % copper, replacing it with biodegradable inorganic fibers and other environmentally friendly components that do not generate toxic abrasion powder.
Solution Approach 2:
The patent changes the chemical composition parameters by limiting copper to 0.5 mass % or less and introducing specific alternative materials with different chemical properties. This parameter change transforms the material system from copper-dependent to copper-minimal, achieving both environmental goals and performance requirements through compositional modification.
2Object-generated harmful factors
If copper is removed to reduce environmental harm, then environmental sustainability is improved, but material strength and rust delamination resistance deteriorate
Solution Approach 1:
The patent employs a composite material system combining biodegradable inorganic fibers, organic fibers, resin binders, and specific inorganic fillers. This composite structure replaces copper's reinforcing function through synergistic material combinations, where biodegradable inorganic fibers provide structural strength and rust resistance without environmental harm.
Solution Approach 2:
The patent introduces biodegradable inorganic fibers as intermediary materials that mediate between the requirement for strength and the need to eliminate copper. These fibers serve as a substitute reinforcement mechanism, providing both mechanical strength and corrosion resistance through their inherent properties and interaction with the resin matrix.
3Object-generated harmful factors
If copper is removed to prevent environmental contamination, then environmental sustainability is improved, but rust delamination resistance becomes insufficient
Solution Approach 1:
The patent employs biodegradable inorganic fibers that can sacrificially protect against rust delamination. These fibers are designed to degrade in a controlled manner, providing temporary but effective protection during the service life of the friction material, after which they biodegrade without leaving harmful residues.
Solution Approach 2:
The patent converts the potential harm of rust formation into a beneficial protective mechanism. By using biodegradable inorganic fibers and specific resin compositions, the material allows controlled surface oxidation that actually protects the bulk material from rust delamination, while the biodegradable components ensure no long-term environmental harm.
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 composition effectively reduces rust adhesion and delamination, enhancing the strength and environmental sustainability of friction materials used in braking applications.
Implementation Method 1
adding zinc functioning as a sacrificial anode or an alkaline metal salt increasing pH
Implementation Method 2
adding zinc functioning as a sacrificial anode
Implementation Method 3
the fibrous substrate contains fibrillated aramid fiber
Implementation Method 4
it also functions as a hardening catalyst of phenol resin during formation of the friction material
Implementation Method 5
The friction material functions in braking by producing friction on a facing material such as disk rotor, braking drum or the like
Data Source
AI summary
The friction material composition, friction material and friction member are provided, in which copper, having serious environmental effects, is not contained or is not contained at more than 0.5 mass % of copper, rust adhering force is low, rust delamination is difficult to occur, the friction material composition includes a binder, an organic filler, an inorganic filler, and a fibrous substrate, wherein the friction material composition contains no copper as an element or contains not more than 0.5 mass % of copper, and contains fibrillated aramid fiber as the fibrous substrate, 0.2 to 2 mass % of sodium carbonate and 2.5 to 10 mass % of calcium hydroxide.