Friction Material with Diatomaceous Earth for Wet Stability
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Solution Overview
Problem
Existing friction materials for applications like brake and clutch systems face challenges in achieving excellent friction stability, wear-resistance, noise-resistance, pressure-resistance, and temperature-resistance, especially when submerged in lubricants, due to insufficient structural strength and porosity.
Innovation Solution
A friction material comprising a resin-impregnated fibrous base material with a specific composition of aramid fibers, polyacrylonitrile-based carbon fibers, and diatomaceous earth, where the fibrous base material includes a higher amount of diatomaceous earth than aramid or carbon fibers, and is free from activated carbon, providing enhanced porosity, strength, and lubricant compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional friction materials are used in wet applications, then lubrication is provided, but friction stability and wear-resistance deteriorate due to insufficient structural strength and porosity
Solution Approach 1:
The friction material uses a composite fibrous base material combining aramid fibers (15-35 parts), polyacrylonitrile-based carbon fibers (5-25 parts), and diatomaceous earth (45-65 parts) to achieve both structural strength and porosity. This composite structure provides the necessary mechanical strength while maintaining lubricant retention capability for stable friction performance in wet applications.
Solution Approach 2:
The friction material incorporates diatomaceous earth as a porous filler material that retains lubricant within the friction material structure. The porous structure allows the material to absorb and hold lubricant, ensuring consistent friction performance and preventing fade during operation while maintaining adequate structural integrity.
2Reliability
If diatomaceous earth content is increased to improve porosity and lubricant retention, then friction stability improves, but manufacturing complexity increases due to precise composition requirements
Solution Approach 1:
The invention specifies precise parameter ranges for each component: aramid fibers (15-35 parts), polyacrylonitrile-based carbon fibers (5-25 parts), and diatomaceous earth (45-65 parts) based on 100 parts of fibrous base material. These defined parameter ranges optimize the balance between porosity, structural strength, and friction stability while providing clear manufacturing guidelines.
3Reliability
If activated carbon is used in friction material, then friction performance is enhanced, but noise-resistance deteriorates
Solution Approach 1:
The invention explicitly excludes activated carbon from the friction material composition to eliminate the noise problem associated with its use. Instead, the formulation relies on aramid fibers, polyacrylonitrile-based carbon fibers, and diatomaceous earth to achieve the desired friction performance without the harmful noise effect produced by activated carbon in wet applications.
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 friction stability, noise-resistance, and wear-resistance, maintaining a positive coefficient of friction slope across varying speeds, reducing shuddering and noise, and maintaining structural integrity under pressure and temperature conditions.
Implementation Method 1
the fibrous base material has a single ply and includes a plurality of aramid fibers present in a first amount, a plurality of polyacrylonitrile-based carbon fibers present in a second amount that is less than the first amount, and diatomaceous earth present in a third amount that is greater than the first amount
Data Source
Figure 1~2
AI summary
A friction material (18) includes a resin and a fibrous base material impregnated with the resin. The fibrous base material has a single ply, and includes a plurality of aramid fibers present in a first amount, a plurality of polyacrylonitrile-based carbon fibers present in a second amount that is less than the first amount, and diatomaceous earth present in a third amount that is greater than the first amount. The fibrous base material is substantially free from activated carbon. A friction member for operatively contacting a lubricated surface (12) includes a substrate (16) and a friction material (18). The friction material (18) defines a first surface (20) bonded to the substrate (16) and a second surface (22) configured for operatively contacting the lubricated surface (12).