Friction Material Using Titanate and Magnesium Silicate
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Solution Overview
Problem
Conventional friction materials for automotive brakes face issues with unstable braking force due to temperature dependence and metal catch, and lack sufficient mechanical strength without metal fibers, while attempts to enhance wear resistance and braking force through increased titanate content lead to excessive film thickness and noise.
Innovation Solution
A friction material combining plate-like titanate with hydrous magnesium silicate, optimizing their volume ratio and particle size to control transferred film thickness and strength, thereby achieving stable braking force and mechanical strength without additional abrasive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If nonferrous metal fibers and particles are used to create adhesive friction, then braking force is generated, but braking force becomes unstable due to temperature dependence
Solution Approach 1:
The patent combines plate-like titanate particles with fibrous materials (organic and/or inorganic fibers) to create a composite friction material. This composite structure replaces the temperature-sensitive adhesive friction mechanism of nonferrous metals with a friction mechanism based on mechanical interlocking and abrasion, achieving stable braking force across varying temperatures.
Solution Approach 2:
The patent specifies precise particle size parameters for plate-like titanate (0.1-500 μm) and controls the volume ratio between plate-like titanate and fibrous materials. By optimizing these physical parameters, the friction material achieves consistent friction characteristics and stable braking force regardless of temperature changes.
2Strength
If plate-like titanate is increased to enhance wear resistance and braking force, then wear resistance improves, but transferred film becomes excessively thick causing noise
Solution Approach 1:
The patent precisely controls the particle size of plate-like titanate (0.1-500 μm) and the volume ratio between plate-like titanate and fibrous materials. This parameter optimization ensures the transferred film has appropriate thickness and structure, providing wear resistance while preventing excessive film buildup that causes noise.
Solution Approach 2:
The patent creates a friction material with heterogeneous structure where plate-like titanate particles are distributed among fibrous materials. This local distribution ensures that the transferred film has optimal properties at the friction interface (wear resistance) while the overall structure prevents excessive film accumulation (noise reduction).
3Object-affected harmful factors
If metal fibers are removed for environmental reasons, then heavy metal content is reduced, but mechanical strength becomes insufficient
Solution Approach 1:
The patent creates a composite structure combining plate-like titanate particles with a matrix of organic and/or inorganic fibers. The fibrous materials provide the necessary mechanical strength and structural integrity, while the plate-like titanate enhances friction and wear resistance, eliminating the need for heavy metal fibers.
Solution Approach 2:
The patent replaces expensive and environmentally problematic metal fibers with cost-effective organic and/or inorganic fibers that provide equivalent or superior mechanical properties. This substitution maintains structural strength while eliminating heavy metal content.
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 achieves balanced braking force and mechanical strength, reducing wear and noise issues, while adhering to environmental standards by avoiding heavy metals like copper and lead.
Implementation Method 1
When the friction material makes a frictional engagement with a mating member, a transferred film is formed on the frictional surface of the mating member, and the transferred film and components existing on the frictional surface of the friction material create friction, thereby enabling and creating a braking force
Implementation Method 2
the friction material formed by heat press forming a friction material compositions including 1-10 weight percent of zinc fiber with the length of 1-10mm relative to the total amount of the friction material compositions
Data Source
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AI summary
The present invention relates to the friction material for the use of disc brake pads and brake shoes for automotive brake devices, and an object of the present invention is to provide the friction material with sufficiently stable braking force and sufficient mechanical strength. In the friction material without a metal or a metal alloy, the friction material includes the plate-like titanate with average particle diameter of 10 to 50µm and the hydrous magnesium silicate. An amount of the plate-like titanate and the hydrous magnesium silicate is 20 to 30 volume percent relative to the total amount of the friction material, and the volume ratio of the plate-like titanate and the hydrous magnesium silicate is 12:1 to 5:1. Also, the average particle diameter of the plate-like titanate is 20 to 40µm, and the plate-like titanate is preferably potassium hexatitanate.