Layered Titanate Friction Modifier for Rotor Rust Reduction
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Solution Overview
Problem
Conventional friction materials face challenges in achieving both good formability and reduced rust formation, especially when moisture-absorbed materials are left pressed against a rotor for long periods, and they often contain copper, which is environmentally harmful and reduces rust removal effectiveness.
Innovation Solution
A friction modifier made from a titanate compound with a layered crystal structure and controlled chlorine ion dissolution rates, combined with a thermosetting resin, to enhance formability and reduce rust formation without using copper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper is added to friction material composition, then the friction material can maintain high coefficient of friction at high temperatures through copper transfer film formation, but the friction material causes environmental pollution and fails to effectively remove rust from rotors
Solution Approach 1:
The invention extracts copper from the friction material composition entirely, replacing it with alternative materials (titanium oxide, zinc oxide, magnesium hydroxide) that do not cause environmental pollution or rust formation, while maintaining the friction material's functional performance through other mechanisms
Solution Approach 2:
The invention changes the chemical composition parameters by eliminating copper and introducing alternative inorganic additives with specific properties (titanium oxide for friction stability, zinc oxide and magnesium hydroxide for rust prevention), fundamentally altering how the friction material achieves its protective functions
2Duration of action of moving object
If conventional friction materials are left pressed against the rotor for long periods, then the friction material can provide sustained braking force, but rust formation occurs between the friction material and rotor causing sticking
Solution Approach 1:
The invention incorporates rust-preventing additives (zinc oxide, magnesium hydroxide) into the friction material composition before use, which proactively prevent rust formation during prolonged contact periods, eliminating the need for subsequent rust removal operations
Solution Approach 2:
The invention introduces zinc oxide and magnesium hydroxide as intermediary substances between the friction material and rotor surface, which act as protective barriers preventing direct rust formation while allowing sustained contact for braking force application
3Ease of manufacture
If the friction material has good formability during manufacturing, then the friction material can be easily shaped and produced, but the curing of thermosetting resin is inhibited reducing manufacturing quality
Solution Approach 1:
The invention changes the chemical composition by using specific inorganic additives with controlled particle sizes and surface properties that do not interfere with thermosetting resin curing reactions, enabling both good formability and complete curing
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 solution provides a friction material with improved formability and reduced rust formation on rotors, while being environmentally friendly by minimizing copper content and maintaining high frictional properties.
Implementation Method 1
a titanate compound having a layered crystal structure, the titanate compound having a rate of chlorine ion dissolution of 0.5 ppm to 400 ppm
Implementation Method 2
Friction materials for use in brakes, such as disc brakes or drum brakes, constituting parts of braking devices
Data Source
AI summary
Provided is a friction modifier giving excellent formability in producing a friction material and capable of reducing rust formation on a rotor even when the moisture-absorbed friction material is left pressed against the rotor for a long. The friction modifier is made of a titanate compound having a layered crystal structure, wherein the titanate compound has a rate of chlorine ion dissolution of 0.5 ppm to 400 ppm.