Sintered Friction Lining Composition for Low Vibration Dry Clutches
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Solution Overview
Problem
Existing dry-running drive systems face challenges with friction linings that either have low energy and thermal load capacity or high frictional vibrations, which affect driving comfort and efficiency, due to limitations in material composition and installation space.
Innovation Solution
A binder-free, sintered friction lining with a metallic matrix, incorporating multiple solid lubricants such as hexagonal boron nitride and metal sulfides, and optionally graphite, to enhance friction behavior and reduce vibrations, allowing for improved temperature resistance and reduced drag torque without oil dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If resin-bonded friction linings are used, then frictional vibrations are reduced, but energy and thermal load capacity is limited
Solution Approach 1:
The patent employs a composite material system consisting of a metallic matrix (copper, iron, or steel base material) combined with specifically selected solid lubricants (graphite, molybdenum disulfide, tungsten disulfide, tin sulfide, iron sulfide) and abrasives (aluminum oxide, silicon carbide, boron carbide). This composite structure integrates the vibration-damping properties of the metallic matrix with the high-temperature stability of inorganic solid lubricants, resolving the contradiction between reducing frictional vibrations and increasing thermal load capacity.
Solution Approach 2:
The patent specifies precise compositional parameters: the metallic matrix contains 5-30 wt.% solid lubricants and 70-95 wt.% metallic base material, with the solid lubricants comprising specific ratios of different compounds (e.g., graphite 2-10 wt.%, molybdenum disulfide 2-15 wt.%, tungsten disulfide 2-10 wt.%, tin sulfide 3-15 wt.%, iron sulfide 3-10 wt.%). These parameter optimizations enable the material to simultaneously achieve low frictional vibrations and high thermal load capacity by tuning the composition to balance vibration damping and heat resistance.
2Temperature
If metallic friction linings are used, then energy and thermal load capacity is increased, but frictional vibrations increase
Solution Approach 1:
The patent creates a composite material where a metallic matrix (提供高能量和热负载能力) is combined with multiple solid lubricants including graphite, molybdenum disulfide, tungsten disulfide, tin sulfide, and iron sulfide. This composite structure maintains the high thermal load capacity of metallic materials while the solid lubricants reduce frictional vibrations through their low-shear-strength layers.
Solution Approach 2:
The patent optimizes the composition parameters by specifying that solid lubricants constitute 5-30 wt.% of the total material, with the metallic matrix making up 70-95 wt.%. The solid lubricants are further optimized with specific ratios (graphite 2-10 wt.%, molybdenum disulfide 2-15 wt.%, tungsten disulfide 2-10 wt.%, tin sulfide 3-15 wt.%, iron sulfide 3-10 wt.%). These parameter adjustments enable the material to simultaneously achieve high thermal load capacity and reduced frictional vibrations.
3Weight of moving object
If clutch frame size is reduced to decrease vehicle weight, then installation space is reduced, but energy and temperature loads on friction lining increase
Solution Approach 1:
The patent employs a composite material system with a metallic matrix combined with high-temperature-resistant solid lubricants (graphite, molybdenum disulfide, tungsten disulfide, tin sulfide, iron sulfide) and abrasives. This composite structure enables the friction lining to withstand higher temperature and energy loads that result from the reduced clutch frame size, allowing vehicle weight reduction without compromising thermal performance.
Solution Approach 2:
The patent optimizes the material composition with solid lubricants at 5-30 wt.% and metallic matrix at 70-95 wt.%, with specific ratios of different solid lubricants (graphite 2-10 wt.%, molybdenum disulfide 2-15 wt.%, tungsten disulfide 2-10 wt.%, tin sulfide 3-15 wt.%, iron sulfide 3-10 wt.%). These parameter optimizations enable the friction lining to handle increased temperature and energy loads resulting from the smaller clutch frame size, allowing vehicle weight reduction while maintaining thermal performance.
4Object-generated harmful factors
If solid lubricants are added to friction lining, then friction behavior is improved and vibrations are reduced, but material complexity increases
Solution Approach 1:
The patent employs a composite material system consisting of a metallic matrix combined with specifically selected solid lubricants (graphite, molybdenum disulfide, tungsten disulfide, tin sulfide, iron sulfide) and abrasives (aluminum oxide, silicon carbide, boron carbide). This composite structure integrates the vibration-damping properties of the metallic matrix with the high-temperature stability of inorganic solid lubricants, resolving the contradiction between reducing frictional vibrations and increasing thermal load capacity.
Solution Approach 2:
The patent specifies precise compositional parameters: the metallic matrix contains 5-30 wt.% solid lubricants and 70-95 wt.% metallic base material, with the solid lubricants comprising specific ratios of different compounds (e.g., graphite 2-10 wt.%, molybdenum disulfide 2-15 wt.%, tungsten disulfide 2-10 wt.%, tin sulfide 3-15 wt.%, iron sulfide 3-10 wt.%). These parameter optimizations enable the material to simultaneously achieve low frictional vibrations and high thermal load capacity by tuning the composition to balance vibration damping and heat resistance.
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 lining exhibits improved friction behavior, reduced vibrations, and enhanced long-term temperature resistance, leading to increased stability and reduced wear, making it suitable for high-load, dry-running applications with reduced construction volume.
Implementation Method 1
Solid lubricants used in embodiments of friction lining bodies according to the present disclosure may be formed by at least two different solid lubricants, which are selected from a group consisting of hexagonal boron nitride and metal sulfides
Implementation Method 2
a binder-free, sintered friction lining having a friction lining body, which may include a metallic matrix
Data Source
AI summary
Embodiments of the disclosure relate to a binder-free, sintered friction lining, for a friction component of a friction assembly, having a friction lining body, which comprises a metallic matrix, at least one abrasive, solid lubricants, and optionally at least one filling material, wherein the solid lubricants are formed by at least two different solid lubricants, which are selected from a group consisting of hexagonal boron nitride and metal sulfides with at least one metal from the group of tungsten, iron, tin, copper, bismuth, antimony, chromium, zinc, silver, manganese, molybdenum.