NAO Disc Brake Friction Material for High-Temperature Vibration Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional disc brake friction materials containing copper components face environmental pollution issues, and their elimination leads to reduced thermal conductivity, increased wear, and brake vibrations due to uneven friction surface temperatures.
Innovation Solution
A Non-Asbestos-Organic (NAO) friction material composition for disc brake pads is developed, incorporating cashew dust as an organic friction modifier, muscovite as an inorganic friction modifier, and aluminum particles to control tar-like substance formation and improve heat dissipation, thereby reducing brake vibrations during high-temperature braking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If copper components are eliminated from friction material, then environmental pollution is reduced, but thermal conductivity decreases and brake vibrations increase
Solution Approach 1:
The patent changes the material composition parameters by completely eliminating copper components (reducing copper content to 0%) and simultaneously adjusting the proportions of alternative materials (steel fibers: 2-5%, organic friction modifiers: 3-8%, inorganic friction modifiers: 5-15%) to achieve both environmental compliance and adequate thermal conductivity
Solution Approach 2:
The patent creates a composite friction material formulation combining multiple materials with complementary properties: steel fibers for structural integrity and thermal conductivity, organic friction modifiers for surface friction control, inorganic friction modifiers for heat dissipation, and lubricants for wear reduction, achieving a balance between environmental safety and thermal performance
2Object-affected harmful factors
If copper components are eliminated from friction material, then environmental pollution is reduced, but wear resistance decreases
Solution Approach 1:
The patent adjusts the formulation parameters by eliminating copper (0%) and optimizing the content of wear-resistant alternatives: steel fibers (2-5%) for structural strength, lubricants (5-15%) for reduced friction and wear, and inorganic friction modifiers (5-15%) for surface stability, achieving wear resistance without copper pollution
Solution Approach 2:
The patent replicates the functional properties of copper (thermal conductivity, wear resistance, friction control) using alternative materials组合, where steel fibers copy the structural reinforcement function, and lubricants copy the wear protection function, achieving equivalent performance without copper
3Object-affected harmful factors
If copper components are eliminated from friction material, then environmental pollution is reduced, but brake vibrations increase due to uneven friction surface temperature
Solution Approach 1:
The patent modifies the composition parameters by eliminating copper and adjusting the ratios of thermally conductive materials (steel fibers: 2-5%, inorganic friction modifiers: 5-15%) to ensure uniform heat distribution across the friction surface, preventing hot spots and brake vibrations while maintaining environmental compliance
Solution Approach 2:
The patent employs a composite formulation where steel fibers provide structural framework for heat conduction, inorganic friction modifiers (such as alumina, silica) provide additional thermal pathways and surface stability, and organic friction modifiers regulate surface friction characteristics, collectively ensuring uniform temperature distribution without copper
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 NAO friction material effectively reduces brake vibrations and maintains braking effectiveness by controlling tar-like substance formation and enhancing heat dissipation, while adhering to environmental regulations by excluding copper components.
Implementation Method 1
aluminum particles to control tar-like substance formation and improve heat dissipation
Implementation Method 2
the cashew dust that is contained in the friction material is thermally decomposed, which generates a tar-like substance
Implementation Method 3
muscovite as an inorganic friction modifier
Data Source
AI summary
[Object]To provide the friction material for the disc brake such as an automobile, which is manufactured by forming the NAO friction material composition, enabling to restrain the brake vibration during braking in a high temperature.[Means to Resolve]In the friction material for the disc brake pad, which is manufactured by forming the NAO friction material composition that does not contain the copper component but contains the binder, the fiber base, the organic friction modifier, the inorganic friction modifier, and the lubricant, the friction material composition contains 1-4 weight % of the cashew dust as the organic friction modifier relative to the entire amount of the friction material composition, 7-12 weight % of the muscovite as the inorganic friction modifier relative to the entire friction material composition, and 0.5-5 weight % of the aluminum particle as the inorganic friction modifier relative to the entire amount of the friction material composition.