Lignin-Modified Underlayer Material for Low-Squeal Friction Members
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Solution Overview
Problem
Existing friction members suffer from reduced strength and heat resistance, and are prone to brake squeal, as seen in techniques using silane coupling agent-dispersed silicone rubber particles.
Innovation Solution
Incorporating a plant-derived resin, specifically a lignin-modified phenol resin, into the underlayer material of friction members, which includes a friction material and a pressure plate, to enhance strength and heat resistance while minimizing brake squeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If silane coupling agent-dispersed silicone rubber particles are used as friction modifier, then brake squeal is reduced, but strength and heat resistance deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the binder by replacing conventional organic binders with plant-derived resins (lignin, tannin, starch) and inorganic binders (alumina sol, silica sol). This parameter change maintains the friction modifier's squeal-reducing function while improving the overall strength and heat resistance of the friction material.
Solution Approach 2:
The patent creates a composite binder system combining plant-derived resins with inorganic binders. This composite approach allows the friction material to simultaneously achieve low squeal (from the friction modifier) and high strength/heat resistance (from the composite binder structure containing alumina sol, silica sol, and plant-derived resins).
2Ease of manufacture
If conventional organic binders are used in friction material, then manufacturing is easy, but environmental compatibility and performance deteriorate
Solution Approach 1:
The patent changes the binder composition from conventional organic resins to a new formulation using plant-derived resins (lignin, tannin, starch) combined with inorganic binders. This parameter change improves environmental compatibility and performance while maintaining manufacturability through established molding processes.
Solution Approach 2:
The patent uses abundant, renewable plant-derived materials (lignin from wood waste, tannin from plant extracts, starch from crops) as binders. These inexpensive, readily available materials replace costly synthetic organic binders, improving both environmental sustainability and cost-effectiveness without sacrificing performance.
Data Source
AI summary
The present invention relates to an underlayer material to be used in a friction member, the underlayer material including a plant-derived resin, in which the friction member includes a friction material and a pressure plate, and the friction material includes a friction modifier, a binder, and a fiber base material. The plant-derived resin may be a lignin-modified phenol resin.