Wet Clutch Friction Material Composition for Web Integrity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing friction materials for wet clutch applications face challenges in balancing performance properties with manufacturability, often resulting in insufficient wet strength that can lead to tearing or breaking during the manufacturing process, causing quality issues and downtime.
Innovation Solution
A friction material comprising structural fibers, friction particles, and polyvinyl alcohol fibers with specific dimensions, combined with a resin, which provides improved wet strength and porosity, allowing for efficient manufacturing and optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the friction material is made with porous structure and optimized composition for wet clutch performance, then the coefficient of friction and heat dissipation improve, but the wet strength decreases causing tearing or breaking during manufacturing
Solution Approach 1:
The patent changes the physical and chemical parameters of the friction material by incorporating specific fiber types (cellulose, aramid, carbon), particle sizes, and resin compositions. By adjusting these parameters within optimized ranges, the material achieves both high friction performance and sufficient wet strength to prevent manufacturing defects.
Solution Approach 2:
The patent uses a composite material structure combining multiple fiber types (cellulose, aramid, carbon), friction particles, and resin binders. This composite approach allows different components to contribute specific properties: cellulose provides bulk structure, aramid adds strength, carbon enhances friction, and resin binds everything together, achieving both performance and structural integrity.
2Duration of action of stationary object
If the friction material composition is optimized for wet clutch applications, then the durability and friction stability improve, but the manufacturing complexity increases
Solution Approach 1:
The patent optimizes specific parameters such as fiber length (5-20mm), particle size distributions, and resin content (15-30% by weight) to achieve durable friction material. These parameter optimizations are implemented through a continuous manufacturing process that, while complex, produces consistent results automatically.
Solution Approach 2:
The continuous manufacturing process is designed to automatically mix, layer, and cure the friction material composition without extensive manual intervention. The process self-regulates to maintain optimal fiber-to-particle ratios and resin distribution, reducing the need for complex quality control steps while ensuring durable product consistency.
3Productivity
If the fibrous web is moved through air in unsupported manner during manufacturing, then the production efficiency improves, but the web tears or breaks due to insufficient wet strength
Solution Approach 1:
The patent adjusts the wet strength parameters of the fibrous web by optimizing resin content and fiber composition before the web is moved through air during manufacturing. The resin acts as a temporary binder that provides sufficient strength during handling and curing, allowing the web to be transported unsupported without tearing.
Solution Approach 2:
The resin binder serves as an intermediary substance that temporarily holds the fibrous web together during manufacturing operations. This intermediary provides the necessary structural support during air transport and handling, after which the web is cured to achieve final product strength.
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 exhibits enhanced tensile strength, shear strength, and porosity, preventing tears and breaks during manufacturing while maintaining performance properties, such as coefficient of friction and heat dissipation, leading to improved durability and efficiency in wet clutch applications.
Implementation Method 1
The porous structure of the friction material allows the flow of lubricant through the friction material which cools the friction material
Implementation Method 2
A wet clutch is an assembly that interlocks two or more opposed, rotating surfaces in the presence of a lubricant by imposing selective interfacial frictional engagement between those surfaces
Data Source
AI summary
A friction material presents a friction generating surface and a bonding surface facing opposite said friction generating surface. The friction material includes structural fibers, friction particles, polyvinyl alcohol fibers, and a resin. A method of forming the friction material is also disclosed. The method comprises the steps of: combining the structural fibers, the friction particles, and the polyvinyl alcohol fibers having an average diameter of less than about 11 μm, an average length of less than about 4 mm, an average denier of less than about 1, to form a substrate material; impregnating the substrate material with the resin; and curing the resin to form the friction material.