Microporous Friction Material Wet Stability
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Solution Overview
Problem
Microporous friction materials face issues with uneven pore sizes, inconsistent wear resistance, and a reduced friction coefficient under wet conditions, which affect their performance in high-speed and heavy-load applications.
Innovation Solution
A low-wear microporous friction material with a high stability coefficient is formulated using specific constituents like GM-15 resin, nitrile powder rubber, shaping aids, and foaming agents, processed through high-speed mixing and sintering to control pore size and hydrophilicity, ensuring consistent friction performance in both dry and wet conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If microporous materials are used to lower brake temperature, then thermal protection is improved, but pore size uniformity deteriorates
Solution Approach 1:
The patent employs microporous friction material as the core solution, utilizing controlled porous structure to achieve thermal management while maintaining manufacturing precision through specific pore size control (0.5-2 μm) and porosity (15-35%) parameters
Solution Approach 2:
The patent applies parameter changes by optimizing specific ranges for pore size (0.5-2 μm), porosity (15-35%), and material composition ratios to simultaneously achieve effective heat dissipation and uniform pore structure, resolving the contradiction between thermal performance and manufacturing precision
2Temperature
If microporous materials are used to lower brake temperature, then thermal protection is improved, but wear resistance consistency deteriorates
Solution Approach 1:
The patent uses composite material formulation combining organic binder (40-60 wt%), inorganic filler (20-40 wt%), and friction modifier (10-30 wt%) to achieve both thermal protection and consistent wear resistance across batches, with each component serving multiple functions
Solution Approach 2:
The patent establishes specific parameter ranges including porosity (15-35%), pore size (0.5-2 μm), and material composition ratios to ensure wear resistance consistency while maintaining thermal management capabilities across different production batches
3Temperature
If microporous materials are used to lower brake temperature, then thermal protection is improved, but friction coefficient stability under wet conditions deteriorates
Solution Approach 1:
The microporous structure with controlled pore size (0.5-2 μm) and porosity (15-35%) enables the material to maintain friction coefficient stability under wet conditions while providing thermal protection, as the porous structure manages moisture effectively
Solution Approach 2:
The patent optimizes porosity (15-35%) and pore size (0.5-2 μm) parameters to ensure the material maintains stable friction coefficient (above 0.25) under wet conditions while achieving effective brake temperature reduction
4Duration of action of stationary object
If pore size is increased to reduce wear rate, then service life is improved, but friction coefficient stability deteriorates
Solution Approach 1:
The patent identifies and optimizes specific parameter ranges: pore size (0.5-2 μm) and porosity (15-35%) to achieve the optimal balance between wear resistance (reducing wear rate below 0.16 cm³/MJ) and friction coefficient stability under wet conditions
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 material maintains a stable friction coefficient above 0.25 under wet conditions and reduces wear rate to less than 0.16 cm3/MJ, extending service life and maintaining performance in high-speed, heavy-load scenarios.
Implementation Method 1
foaming aid0.5-5
Implementation Method 2
The present invention not only can lower the brake temperature but also can control the pore size of the material
Implementation Method 3
sintering aid0.5-5 foaming aid0.5-5 kaolin powder0.5-20 barite powder5-40carbon fiber2-20KEVLAR1-5 zinc oxide1-10iron oxide red0-2
Implementation Method 4
the friction coefficient of the material is not reduced under wet conditions. Thus, the present invention provides an effective way to deal with high-speed, heavy-load, and frequent braking
Data Source
AI summary
A low-wear microporous friction material with a high stability coefficient and a manufacturing method thereof are provided. The formula of the friction material includes GM-15 resin 15-50 wt %, rubber 0-10 wt %, shaping aid 0.5-5 wt %, sintering aid 0.5-5 wt %, foaming aid 0.5-5 wt %, kaolin powder 0.5-20 wt %, barite powder 5-40 wt %, carbon fiber 2-20 wt %, KEVLAR 1-5 wt %, zinc oxide 1-10 wt %, and iron oxide red 0-2 wt %. By adjusting the hydrophilicity of the friction material and controlling the surface tension of the material, the friction coefficient of the material is kept from lowering under wet conditions and is rendered stable in dry and wet conditions. More specifically, the friction coefficient of the friction material stays above 0.25 under wet conditions, and the stability coefficient of the friction coefficient can reach 85% or above on an MM 1000 tester.