Phosphate-Dispersed Friction Material for Wet Noise Suppression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing friction materials require a costly coating step to suppress abrasion powder aggregate formation, leading to abnormal noise during wet conditions.
Innovation Solution
Incorporating a phosphate-based dispersant, such as sodium hexametaphosphate, as a friction modifier within the friction material to prevent abrasion powder aggregate formation without the need for a special coating step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a coating step is applied to filler or inorganic friction modifier with fatty acid or metal soap, then abnormal noise during wetting is suppressed, but manufacturing cost increases
Solution Approach 1:
The patent extracts the essential functional property (dispersion prevention of abrasion powder) from the complex coating process and achieves it through compositional design of the friction material itself, using phosphate-based dispersant in the friction modifier composition to prevent aggregate formation without requiring separate coating operations
Solution Approach 2:
The friction material composition itself provides the dispersion prevention function through the phosphate-based dispersant contained in the friction modifier, making the material self-sufficient to prevent abnormal noise during wetting without requiring external coating processes or additional protective layers
2Object-generated harmful factors
If a coating step is applied to filler or inorganic friction modifier, then abrasion powder aggregate formation is suppressed, but manufacturing process complexity increases
Solution Approach 1:
The patent merges the dispersion prevention function into the friction modifier composition by incorporating phosphate-based dispersant, combining multiple functions (friction modification and aggregate prevention) into a single integrated material system that eliminates separate coating process steps
3Object-affected harmful factors
If phosphate-based dispersant is used as friction modifier, then abnormal noise during wetting is suppressed without coating step, but dispersant content must be precisely controlled
Solution Approach 1:
The patent defines specific parameter ranges for phosphate-based dispersant content (0.1-5 mass%, preferably 0.5-3 mass%) to optimize the balance between dispersion prevention effectiveness and manufacturing controllability, ensuring abnormal noise suppression while maintaining practical manufacturability
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 effectively suppresses abnormal noise during wet conditions by promoting dispersion of abrasion powder in water, reducing the formation of aggregates and maintaining moldability.
Implementation Method 1
a phosphate-based dispersant is contained as the friction modifier... promoting dispersion of abrasion powder in water
Data Source
AI summary
There is provided a friction material including: a friction modifier; a binder; and a fibrous material. A phosphate-based dispersant is contained as the friction modifier. Preferably, a content of the phosphate-based dispersant is 0.2 mass % to 2.0 mass %. Preferably, the phosphate-based dispersant is at least one selected from a group consisting of sodium hexametaphosphate, sodium polyphosphate, and sodium pyrophosphate.