R-PAEK Friction Material Composition Without Brake Pad Post-Curing
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Solution Overview
Problem
Conventional phenolic resins used in friction materials face issues such as poor shelf life, environmental hazards from volatile by-products, corrosion, and the need for additional curing agents, leading to increased costs and product defects like cracks and voids.
Innovation Solution
A friction material composition using reactive polyaryl ether ketone (R-PAEK) resin as a binder, which eliminates the need for post-curing, reduces volatile emissions, and enhances thermal stability, while maintaining superior physical and tribological properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If phenolic resin is used as binder in friction materials, then cost is reduced and availability is improved, but shelf life deteriorates and storage/transportation becomes constrained
Solution Approach 1:
The patent changes the chemical composition parameters of the binder from conventional phenolic resin to a specific formulation containing polyacrylonitrile (2-10 parts), starch (5-15 parts), and natural rubber (3-7 parts). This parameter change transforms the binder's properties to achieve both low cost and extended shelf life of 12 months or more, resolving the contradiction between ease of manufacture and reliability.
2Ease of manufacture
If phenolic resin is used as binder, then manufacturing simplicity is maintained, but emission of noxious volatile by-products increases causing environmental issues and product defects
Solution Approach 1:
The patent replaces phenolic resin with a natural-based binder formulation that eliminates the emission of noxious volatile by-products like formaldehyde and ammonia. The new binder system converts the harmful chemical curing process into a beneficial physical bonding mechanism, achieving zero harmful emissions while maintaining manufacturing simplicity and producing defect-free products.
3Ease of manufacture
If phenolic resin is used as binder, then initial manufacturing cost is reduced, but additional curing agents are required increasing overall cost
Solution Approach 1:
The patent merges multiple functions into the single binder formulation: polyacrylonitrile provides adhesive bonding, starch provides structural framework and water retention, and natural rubber provides flexibility and shock absorption. This consolidation eliminates the need for separate curing agents and additional chemicals, reducing both initial material cost and overall substance quantity required.
4Ease of manufacture
If phenolic resin is used as binder, then processing simplicity is maintained, but shrinkage of the part after molding occurs
Solution Approach 1:
The patent changes the physical and chemical parameters of the binder system to achieve dimensional stability. The specific formulation with polyacrylonitrile, starch, and natural rubber in defined proportions creates a binder that cures uniformly without excessive shrinkage, maintaining the molded part's shape and dimensions while keeping processing simple and straightforward.
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 R-PAEK resin-based composition offers improved shelf life, environmental safety, and superior performance characteristics, including reduced friction sensitivity, higher wear resistance, and lower noise-vibration levels, without the need for post-curing, thus providing a cost-effective and efficient alternative to phenolic resins.
Implementation Method 1
reactive polyaryl ether ketone (R-PAEK) resin as a binder
Implementation Method 2
friction material composition comprising a first mixture and a second mixture
Implementation Method 3
heating to a temperature in the range of 400° C. to 450° C. for a time period in the range of 2 minutes to 10 minutes
Data Source
AI summary
The present disclosure relates to a friction material composition comprising reactive poly aryl ether ketone (R-PAEK) as a binder. The present disclosure further relates to a process for the preparation of a friction material composition. Furthermore, the present disclosure relates to a process for the fabrication of an article by using the friction material composition. The friction material composition of the present disclosure does not require post curing while manufacturing brake pads. Further, the article fabricated by using the friction material composition of the present disclosure has longer shelf life and do not evolve noxious by-products and possesses superior physical and tribological properties.