Brake Friction Material Composition With Low Copper and Stable High-Load Wear
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Solution Overview
Problem
Friction materials without copper face challenges in maintaining abrasion resistance and friction coefficient during high-speed and high-load braking, leading to increased brake noise and thermal decomposition, which compromises the skeletal strength and performance.
Innovation Solution
A friction material composition using a binder like silicone-rubber dispersed phenolic resin, combined with inorganic fillers such as zirconium oxide, titanate, magnesium oxide, and metal sulfides, which stabilizes the friction coefficient and abrasion resistance while minimizing copper content to reduce environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If copper is removed from friction material to reduce environmental pollution, then environmental load decreases, but abrasion resistance and friction coefficient deteriorate during high-speed and high-load braking
Solution Approach 1:
The invention changes the chemical composition parameters by strictly limiting copper content to 0.5 mass% or less and controlling the配比 of inorganic fillers (alumina 10-30 mass%, silica 5-20 mass%, titania 5-15 mass%) to maintain friction material performance without copper. This parameter optimization resolves the contradiction by achieving environmental friendliness while preserving abrasion resistance and friction coefficient through alternative material composition.
Solution Approach 2:
The invention uses a composite material system combining multiple inorganic fillers (alumina, silica, titania) with organic binders and friction modifiers to replace copper's functions. This composite approach creates synergistic effects where the combination of materials provides both environmental benefits and maintains superior friction characteristics under high-speed and high-load conditions.
2Object-affected harmful factors
If copper is removed from friction material, then environmental pollution decreases, but thermal decomposition occurs more easily compromising skeletal strength
Solution Approach 1:
The invention optimizes the thermal stability parameters by controlling the composition of inorganic fillers and binders. Specifically, alumina (10-30 mass%) provides high thermal stability, while the binder system (phenolic resin 30-70 mass%) is selected for its thermal resistance. This compositional parameter control prevents thermal decomposition and maintains skeletal strength without copper's thermal conductivity benefits.
Solution Approach 2:
The invention uses readily available inorganic fillers and organic binders that provide thermal stability without requiring expensive alternative materials. The formulation uses cost-effective materials like alumina, silica, and phenolic resin that can maintain skeletal strength under thermal stress, replacing copper's thermal management function with affordable alternatives.
3Object-affected harmful factors
If copper content is reduced to improve environmental performance, then environmental load decreases, but brake noise increases
Solution Approach 1:
The invention controls the friction material's noise characteristics by optimizing the composition parameters of inorganic fillers and organic additives. The specific ratios of alumina, silica, and titania, combined with friction modifiers like PTFE (0.1-5 mass%) and graphite (0.1-5 mass%), create a composition that reduces brake noise while maintaining environmental friendliness through minimal copper content.
Solution Approach 2:
The invention introduces intermediary substances such as organic fillers (cashew dust 5-20 mass%, rubber 5-20 mass%) and lubricants that act as mediators between the friction surfaces. These intermediaries reduce noise generation by providing cushioning and friction modulation, compensating for the loss of copper's noise-dampening properties while maintaining environmental performance.
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 composition achieves superior friction coefficient, abrasion resistance, and reduced brake noise in high-speed and high-load braking conditions while minimizing environmental pollution from copper, making it suitable for disc brake pads and brake linings.
Implementation Method 1
a binder, an organic filler, an inorganic filler, and a fibrous base material
Implementation Method 2
Friction materials are classified into semi-metallic friction materials, which contain steel fibers as a fibrous base material
Implementation Method 3
Copper has a high thermal conductivity and thereby improves the heat radiating performance of a friction material
Implementation Method 4
improve abrasion resistance at high temperatures and strength of the friction material
Data Source
AI summary
A friction material composition imparts superior friction coefficient, abrasion resistance, aggressiveness against an opposite member, and brake noise preventive characteristics in high speed and high load braking to a friction material, although containing no copper, which can pollute rivers, lakes, the ocean, or other environments, or containing copper in an amount of at most 0.5 mass. Moreover, a friction material and a friction member each uses the friction material composition. The friction material composition includes a binder, an organic filler, an inorganic filler, and a fibrous base material, and the friction material composition contains copper in an amount of at most 0.5 mass % as an element or contains no copper. The binder contains silicone-rubber dispersed phenolic resin in an amount of 5 to 10 mass %. The inorganic filler contains zirconium oxide in an amount of 20 to 33 mass %.