Sintered Brake Pad Composition Without Copper or Nickel
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Solution Overview
Problem
Existing sintering processes for manufacturing brake pads often rely on environmentally damaging heavy metals like copper and nickel, which are undesirable due to their environmental impact and potential for metal release during wear.
Innovation Solution
A method of manufacturing a friction element using a sintering composition that excludes environmentally harmful heavy metals, comprising a friction modifying metal in the range of 0 wt% to 5 wt%, a fibre component, metal phosphide, lubricant, filler, abrasive, processing aid, and iron to balance, applied to a back plate with protrusions and subjected to pressure and temperature conditions in a conductive sintering process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper or nickel are used in sintered brake pads, then good brake performance properties are achieved, but environmental damage occurs due to heavy metal release
Solution Approach 1:
The patent removes copper and nickel from the sintered brake pad composition entirely, replacing these harmful heavy metals with alternative materials such as iron-based alloys, organic binders, and ceramic particles that provide comparable friction and wear properties without the environmental toxicity
Solution Approach 2:
The patent modifies the chemical composition parameters of the brake pad material by adjusting the ratios of iron, carbon, and other alloying elements to achieve the desired friction coefficient and wear resistance without relying on copper or nickel, thereby maintaining performance while eliminating environmental harm
2Object-affected harmful factors
If copper-free brake pad materials are used, then environmental impact is reduced, but brake performance may deteriorate
Solution Approach 1:
The patent employs a composite material system combining iron-based particles, organic binders, and ceramic additives to replicate the functional properties of copper-containing materials, where each component contributes specific properties such as friction, lubrication, and structural integrity to achieve overall brake performance without harmful metals
3Object-affected harmful factors
If nickel-free sintered metal friction material is used, then environmental safety is improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes readily available, inexpensive raw materials such as iron powder, common organic binders, and standard ceramic particles that can be easily sourced and processed, simplifying the supply chain and manufacturing operations while achieving the goal of eliminating nickel and other expensive or difficult-to-handle specialty materials
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 method achieves improved braking performance without the use of environmentally damaging heavy metals, ensuring effective friction generation while minimizing environmental impact.
Implementation Method 1
a method of manufacturing a friction element using a sintering composition that excludes environmentally harmful heavy metals, comprising a friction modifying metal in the range of 0 wt% to 5 wt%, a fibre component, metal phosphide, lubricant, filler, abrasive, processing aid, and iron to balance, applied to a back plate with protrusions and subjected to pressure and temperature conditions in a conductive sintering process
Implementation Method 2
the friction material of the friction element is pressed against a rotating rotor to cause friction and thereby stopping the rotation of the rotor
Implementation Method 3
simultaneously applying a pressure between the sintering vice plate and the sintering carrier, the pressure being in the range of 10 kg/cm2 to 200 kg/cm2
Implementation Method 4
increasing the temperature between the sintering vice plate and the sintering carrier to a sintering temperature in the range of 800° C. to 950° C.
Data Source
AI summary
The present disclosure relates to a method of manufacturing a friction element, the method comprising the steps of providing a back plate, the back plate having a connection surface comprising a plurality of protrusions; providing a sintering composition and applying the sintering composition to the connection surface and shaping the sintering composition to form an intermediary friction element; positioning the intermediary friction elements between a sintering plates; and simultaneously applying a pressure between the sintering plates, the pressure being in the range of 10 kg/cm2 to 200 kg/cm2; increasing the temperature to a sintering temperature in the range of 800° C. to 950° C., optionally by applying an electrical current between the sintering plates; and maintaining at least one of the applied pressure, the optionally applied electrical current and the sintering temperature for a sintering duration in the range of 1 hour to 10 hours to form a friction material on the back plate.