Low-Copper Brake Pad Composition for Stable Friction Film Formation
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Solution Overview
Problem
Conventional friction materials used in vehicles with regenerative brakes experience reduced wear performance and instability in maintaining a stable friction coefficient over time, leading to inconsistent brake performance due to the infrequent formation of a coating film during high-load braking or environmental exposure.
Innovation Solution
A friction material composition with a copper content of 5% or less, incorporating a titanate with a layered crystal structure and lithium potassium titanate with a tunnel crystal structure, which enables continuous coating film formation and stable friction performance regardless of regenerative braking conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional friction material is used in a vehicle with regenerative brake, then wear of the pad is reduced and life is extended, but coating film cannot be continuously formed and friction performance becomes unstable
Solution Approach 1:
The patent changes the chemical composition parameters by limiting copper content to 5% or less and specifying precise proportions of iron oxide (2-10%), zinc oxide (1-5%), and titanate (5-20%). These parameter adjustments enable the friction material to maintain stable friction performance while extending pad life in regenerative brake systems.
Solution Approach 2:
The patent creates a composite friction material containing multiple components including iron oxide, zinc oxide, titanate, organic binder, and inorganic filler. This composite structure enables continuous coating film formation on the rotor surface, ensuring reliable friction performance while extending pad service life in vehicles with regenerative braking.
2Object-affected harmful factors
If copper content is reduced to minimize environmental burden, then environmental impact decreases, but friction performance stability may be affected
Solution Approach 1:
The patent reduces copper content to 5% or less by mass while adjusting the proportions of alternative materials including iron oxide (2-10%), zinc oxide (1-5%), and titanate (5-20%). This parameter optimization maintains friction performance stability and enables continuous coating film formation without relying on high copper content, thereby reducing environmental burden.
Solution Approach 2:
The patent replaces the traditional copper-based friction material formulation with an alternative composite formulation. This substitution copies the essential functions of copper (friction coefficient stability and coating film formation) using a combination of iron oxide, zinc oxide, and titanate, achieving similar performance with reduced environmental impact.
3Reliability
If coating film is formed during high-load braking, then rust prevention and friction stability are improved, but wear is increased and pad life is reduced
Solution Approach 1:
The patent optimizes the chemical composition parameters including iron oxide (2-10%), zinc oxide (1-5%), and titanate (5-20%) to enable coating film formation at lower braking loads. This allows the coating film to form during normal operation rather than requiring high-load braking, thereby protecting the pad from excessive wear while maintaining friction stability and rust prevention.
Data Source
AI summary
A friction material composition, which is for molding a friction material for a braking device of a vehicle provided with a regenerative brake, in which the content of copper is 5% by mass or less in terms of elemental copper based on the friction material composition, and which includes a titanate having a layered crystal structure and a lithium potassium titanate having a tunnel crystal structure.