Multi-Layer Wet Friction Material Lamination With Tunable Interface
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Solution Overview
Problem
Existing methods for producing asbestos-free friction materials are limited in flexibility and efficiency, as the multi-layering process restricts the independent selection and processing of materials for the bottom and top layers, leading to suboptimal performance in friction lining applications.
Innovation Solution
A method where the bottom and top layers are produced independently using different formulations and then bonded through a decoupled process involving temperature and pressure, with the option of using a binder material to create a tight or porous interface, allowing for greater freedom in material selection and processing without restricting the multi-layering process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the multi-layering process is integrated with material manufacturing, then the process structure is simplified, but the flexibility in material selection and processing is restricted
Solution Approach 1:
The patent divides the manufacturing process into two independent segments: material manufacturing and multi-layering. Each layer (bottom layer and top layer) is manufactured separately with independent process parameters, then bonded together in a subsequent multi-layering step. This segmentation allows each segment to be optimized independently, resolving the contradiction between process simplicity and material flexibility.
Solution Approach 2:
The patent performs preliminary actions by manufacturing and preparing each layer independently before the multi-layering process. The layers are produced with their specific material properties and characteristics already established, then brought together for bonding. This preliminary preparation enables greater flexibility in material selection without complicating the overall process structure.
2Adaptability or versatility
If the bottom layer and top layer are produced independently with different formulations, then material flexibility is improved, but the manufacturing process complexity increases
Solution Approach 1:
The manufacturing process is segmented into independent production lines for the bottom layer and top layer, each capable of producing materials with different formulations. This segmentation allows material flexibility while keeping each production segment relatively simple and manageable.
Solution Approach 2:
The patent introduces an intermediary bonding process that connects the independently produced layers. This intermediary step (laminating process) uses a binder material and controlled temperature/pressure to join the layers, adding minimal complexity while enabling great material flexibility.
3Strength
If a binder material is applied to the interface between layers, then bonding strength is enhanced, but the manufacturing steps increase
Solution Approach 1:
A binder material is introduced as an intermediary substance at the interface between layers to enhance bonding strength. The binder acts as a mediator that creates strong adhesion between the bottom and top layers during the laminating process, justifying the additional manufacturing step.
Solution Approach 2:
The bonding process utilizes parameter changes (temperature and pressure) during the laminating step to activate the binder material and achieve strong bonding. By controlling these parameters, the process achieves high bonding strength with a single integrated bonding operation rather than multiple separate steps.
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
This approach enables the production of multi-layered wet friction materials with desirable thickness and basis weights, providing improved performance in applications such as double clutch transmissions and synchronizers, with the ability to customize the interface permeability and enhance bonding strength.
Implementation Method 1
The different materials are connected to one another by means of temperature and pressure in a continuous or in a discontinuous process. The connection is established either by a binder material already present in some materials or by a binder material specifically applied to the interface between two layers.
Data Source
AI summary
A method for producing a multi-layered wet friction material includes providing a bottom layer, providing a top layer produced independently of the bottom layer from different materials, and bonding the bottom layer to the top layer. The bottom layer and the top layer may be produced from different formulations and supplied as raw papers. A formulation of the top layer may include twenty to sixty percent (20%-60%) filler, ten to forty percent (10%-40%) wood pulp, five to ten percent (5%-10%) aramid, and twenty-five to thirty-five percent (25%-35%) phenolic resin. A formulation of the bottom layer may include ten to fifty percent (10%-50%) filler, ten to forty percent (10%-40%) wood pulp, five to ten percent (5%-10%) aramid, five to fifteen percent (5%-15%) carbon, and twenty-five to thirty-five percent (25%-35%) phenolic resin.