Low-Copper Friction Material Composition for Stable Braking
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Solution Overview
Problem
Existing friction materials with reduced copper content face challenges in maintaining stable braking performance, wear resistance, and noise suppression, especially under high temperature or high load conditions.
Innovation Solution
A friction material composition with a copper content of less than 5 wt % is developed, incorporating a titanic acid salt with 1-8 wt % content, a cryolite powder with 0.5-5 wt % content, and an iron oxide powder with a median diameter of 15-30 μm and 1-10 wt % content, to form a stable transfer film and enhance wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If copper content is reduced to less than 5 wt%, then environmental compatibility is improved, but braking performance stability and wear resistance deteriorate under high temperature or high load conditions
Solution Approach 1:
The patent changes the chemical composition parameters by reducing copper content to less than 5 wt% and introducing specific alternative materials (titanic acid salt at 1-8 wt%, cryolite powder at 0.5-5 wt%, iron oxide powder at 1-10 wt%) to maintain braking performance while improving environmental compatibility
Solution Approach 2:
The patent creates a composite friction material composition combining multiple inorganic fillers (titanic acid salt, cryolite powder, iron oxide powder) with organic binders and lubricants to replace copper's functional roles while reducing environmental impact
2Strength
If a large amount of hard raw material is used to increase attacking property on rotor, then wear resistance is improved, but rotor wear increases and judder (brake vibration) deteriorates
Solution Approach 1:
The patent applies local quality by using iron oxide powder with a specific median diameter of 15-30 μm, creating optimal local abrasive characteristics that provide sufficient attacking property while minimizing rotor wear and vibration compared to using only coarse hard materials
Solution Approach 2:
The patent optimizes the particle size parameter of iron oxide powder (median diameter 15-30 μm) to achieve the right balance between attacking property and minimizing harmful effects like rotor wear and judder
3Reliability
If titanic acid salt content is increased to form appropriate transfer film, then braking effect is improved, but friction coefficient becomes unstable and noise increases
Solution Approach 1:
The patent optimizes the content parameter of titanic acid salt to a specific range (1-8 wt%) and combines it with cryolite powder (0.5-5 wt%) to achieve stable transfer film formation that provides consistent braking effect while suppressing noise and friction coefficient instability
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 stable braking performance, excellent wear resistance, and suppressed noise generation even under high temperature or high load conditions, while reducing environmental impact by minimizing copper content.
Implementation Method 1
an iron oxide powder having a median diameter of 15 to 30 μm (D50) and a content of 1 wt % or more and 10 wt % or less
Implementation Method 2
a titanic acid salt having a content of 1 wt % or more and 8 wt % or less, a cryolite powder having a content of 0.5 wt % or more and 5 wt % or less
Implementation Method 3
a friction material having a copper content of less than 5 wt %, the friction material including a titanic acid salt
Data Source
AI summary
A friction member according to an embodiment is a friction material having a copper content of less than 5 wt %, the friction material including a titanic acid salt having a content of 1 wt % or more and 8 wt % or less, a cryolite powder having a content of 0.5 wt % or more and 5 wt % or less, and an iron oxide powder having a median diameter of 15 to 30 μm (D50) and a content of 1 wt % or more and 10 wt % or less.