Friction Material Silicone Rubber Particle Adhesion
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Solution Overview
Problem
Conventional friction materials for automotive brakes face issues with silicone rubber particles falling off and dislocating due to friction impact, leading to accelerated wear and reduced lifespan, despite efforts to enhance adhesive properties with silane coupling agents, which are ineffective when worn during the mixing process.
Innovation Solution
Dispersing silane coupling agents within silicone rubber particles during manufacturing, combined with the addition of rigid inorganic particles, to maintain adhesive effectiveness and prevent particle dislocation during braking, while using a suitable binder and fiber base materials for improved wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If silane coupling agent is coated on the surface of silicone rubber particles to improve adhesive property, then adhesive property between silicone rubber particle and thermosetting resin is improved, but the silane coupling agent effectiveness is reduced due to wear during mixing process
Solution Approach 1:
The silane coupling agent is embedded within the silicone rubber particle structure rather than being coated on the surface. This nested configuration protects the silane coupling agent from wear during mixing while still allowing it to function when the particle contacts the thermosetting resin, resolving the contradiction between adhesive property and agent effectiveness
Solution Approach 2:
The silane coupling agent is incorporated into the silicone rubber particle during the particle formation process itself, before the particles are used in the friction material. This preliminary incorporation ensures the agent is protected during subsequent mixing operations and will be released to provide adhesion when needed
2Object-affected harmful factors
If silicone rubber particles are added to friction material to improve vibration absorption, then brake noise generation is reduced, but particle fall off and dislocation occur due to friction impact, accelerating wear
Solution Approach 1:
The invention creates a composite structure where silicone rubber particles are embedded within a matrix containing thermosetting resin and silane coupling agent. This composite configuration provides both the vibration absorption benefits of silicone rubber and the wear resistance of the crosslinked resin matrix, resolving the contradiction between noise reduction and wear prevention
Solution Approach 2:
The thermosetting resin acts as an intermediary material that bonds the silicone rubber particles to the friction material matrix. The silane coupling agent enhances this bonding interface, allowing the soft silicone particles to remain embedded during braking operations while still providing vibration absorption, thus preventing particle loss while maintaining noise reduction
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 solution effectively inhibits silicone rubber particle dislocation and enhances wear resistance, resulting in a friction material with improved durability and reduced brake noise generation, suitable for both disc and drum brakes.
Implementation Method 1
the condensation polymerization reaction of the silanol group is repeated by the evaporation of a solvent and heating, a siloxane bond is formed and is hardened
Implementation Method 2
In order to inhibit the brake noise occurrence, improving a vibration absorption performance is found to be effective
Implementation Method 3
Disc brakes and drum brakes are conventionally used as automotive brake devices
Data Source
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AI summary
This friction material, including the silicone rubber particles as the friction modifier, inhibits fall off and dislocation of the silicone rubber particles from the friction surface to provide effective abrasive resistance. For the friction material including the fiber base material, the binder, the abrasive material, and the friction modifier, the silane coupling agent dispersed silicone rubber particles, in which the silane coupling agent is dispersed, can be used as the friction modifier.