Silicone-Cashew Friction Material for Cold Brake Squeal Control
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Solution Overview
Problem
Friction materials used in automotive brakes face challenges in maintaining stability of the friction coefficient, abrasion resistance, and low rust fixation properties, especially in cold environments, and tend to produce squeal, particularly low temperature squeal, especially when copper content is reduced or absent, making it difficult to achieve these properties without environmental contamination.
Innovation Solution
A non-asbestos-organic friction material composition containing cashew particles adhered with a silicone resin, with the silicone resin amount ranging from 0.5 to 3% by mass, and a bonding material selected from phenolic, modified phenolic, epoxy, polyimide, or melamine resins, which provides excellent stability, abrasion resistance, and suppressed rust fixation, even with minimal copper content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If copper content is reduced or eliminated to minimize environmental contamination, then environmental pollution decreases, but the stability of the friction coefficient, abrasion resistance, and squeal suppression deteriorate
Solution Approach 1:
The invention changes the chemical composition parameters by eliminating copper and copper alloys from the friction material, replacing them with alternative materials (such as iron-based fibers and organic binders) that can provide similar functional properties without the environmental harm. This parameter change resolves the contradiction by maintaining performance while reducing pollution.
Solution Approach 2:
The invention uses composite materials combining organic fibers, inorganic fillers, and specific binder systems to achieve the required friction characteristics without copper. The composite structure allows different components to contribute specific properties (friction, wear resistance, thermal stability) that collectively replace the functionality previously provided by copper-containing materials.
2Object-affected harmful factors
If copper content is reduced or eliminated to minimize environmental contamination, then environmental pollution decreases, but abrasion resistance deteriorates
Solution Approach 1:
The invention modifies the material composition parameters by substituting copper-based abrasion-resistant components with alternative materials such as high-strength organic fibers and inorganic fillers that provide comparable or superior wear resistance without the environmental drawbacks of copper.
Solution Approach 2:
The friction material employs a composite formulation where organic fibers provide structural integrity and wear resistance, inorganic fillers enhance friction characteristics, and binder materials ensure cohesive bonding. This composite approach achieves abrasion resistance without relying on copper content.
3Object-affected harmful factors
If copper content is reduced or eliminated to minimize environmental contamination, then environmental pollution decreases, but squeal and vibration increase
Solution Approach 1:
The invention adjusts the compositional parameters by removing copper and copper alloys that contribute to squeal and vibration, and replaces them with materials having different acoustic and damping properties. The new composition parameters are optimized to reduce unwanted noise and vibration while maintaining friction performance.
Solution Approach 2:
The composite material system incorporates components with complementary damping and noise-reduction properties. The combination of organic and inorganic materials creates a structure that naturally suppresses squeal and vibration through distributed energy dissipation mechanisms, replacing the acoustic properties previously associated with copper-containing formulations.
4Object-affected harmful factors
If copper content is reduced or eliminated to minimize environmental contamination, then environmental pollution decreases, but rust fixation properties deteriorate
Solution Approach 1:
The invention changes the chemical composition by eliminating copper (which provides rust fixation) and introduces alternative materials with rust-inhibiting properties. The new composition parameters include rust-preventive additives and materials that form protective layers, replacing the rust fixation function previously provided by copper without the environmental harm.
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 friction material composition effectively maintains stability of the friction coefficient, enhances abrasion resistance, and suppresses squeal and rust fixation, particularly low temperature squeal, while minimizing environmental contamination from copper, suitable for a wide range of environments from warm to cold regions.
Implementation Method 1
cashew particles adhered with a silicone resin
Implementation Method 2
the friction force generated at this time generates braking force
Data Source
AI summary
There are provided a friction material composition containing no copper or having a reduced content of copper that can provide a friction material in which the stability of the friction coefficient after standing in a cold environment, the abrasion resistance, and the low rust fixation properties are excellent, and squeal (particularly low temperature squeal) is suppressed, and a friction material obtained by molding the friction material composition, and a friction member using the friction material. The friction material composition is specifically a friction material composition comprising a bonding material, an organic filler, an inorganic filler, and a fiber substrate, in which the friction material composition comprises no copper, or has a content of copper of less than 0.5% by mass in terms of a copper element even if comprising the copper, and comprises, as the organic filler, cashew particles to which a silicone resin adheres.