ENVIRONMENT-FRIENDLY FRICTION MATERIAL AND PRODUCT THEREOF

Abstract

The invention relates to an environment-friendly friction material, which consists of the following components in parts by weight: 8-15 parts of a binding material, 3-8 parts of an organic fiber, 3-8 parts of an inorganic fiber, 3-8 parts of an anti-friction material, 15-25 parts of granite powder, 35-40 parts of marble powder, 6-10 parts of a modified organic filling material, 5-10 parts of an acidity or alkalinity regulating material, and 0.5-4.5 parts of a non-copper metal material, wherein the modified organic filling material consists of the following components in parts by weight: 25-50 parts of tyre powder, 15-25 parts of a shoe sole waste, 10-15 parts of a sepiolite fiber, 2-3 parts of a silane coupling agent, 2-5 parts of a cashew nut shell liquid, and 0.5-2 parts of an activator, with the shoe sole waste including 15-30% of POE and 5-15% of EPDM. The invention is reasonable in compatibility, and has excellent properties such as reduced noise, heat resistance and little damage to mating plates while ensuring a moderate and stable friction coefficient, thereby changing waste materials into objects of value and achieving energy conservation and environmental protection effects.

Claims

1. An environment-friendly friction material, consisting of the following components in parts by weight: 8-15 parts of a binding material, 3-8 parts of an organic fiber, 3-8 parts of an inorganic fiber, 3-8 parts of an anti-friction material, 15-25 parts of granite powder, 35-40 parts of marble powder, 6-10 parts of a modified organic filling material, 5-10 parts of an acidity or alkalinity regulating material, and 0.5-4.5 parts of a non-copper metal material.

2. The environment-friendly friction material according to claim 1, wherein the binding material is one or a combination of some of phenolic resin, boron modified phenolic resin, cashew nut shell liquid modified phenolic resin and natural rubber.

3. The environment-friendly friction material according to claim 1, wherein the organic fiber is one or a combination of some of an aramid fiber and a polyacrylic fiber.

4. The environment-friendly friction material according to claim 1, wherein the inorganic fiber is one or a combination of some of a potassium titanate fiber, a glass fiber, a ceramic fiber, and a basalt fiber.

5. The environment-friendly friction material according to claim 1, wherein the anti-friction material is one or a combination of some of graphite, tin sulfide, and molybdenum disulfide.

6. The environment-friendly friction material according to claim 1, wherein the acidity or alkalinity regulating material is one or a combination of some of calcium hydroxide, gypsum powder, lime, and slaked lime.

7. The environment-friendly friction material according to claim 1, wherein the non-copper metal material is one or a combination of some of titanium, iron, nickel, zinc, and heat-resistant duralumin.

8. The environment-friendly friction material according to claim 1, wherein the modified organic filling material consists of the following components in parts by weight: 20-50 parts of tyre powder, 15-25 parts of a shoe sole waste, 10-15 parts of a sepiolite fiber, 2-3 parts of a silane coupling agent, 2-5 parts of a cashew nut shell liquid, and 0.5-2 parts of an activator, with the shoe sole waste comprising 15-30% of POE and 5-15% of EPDM.

9. The environment-friendly friction material according to claim 8, wherein a process for preparing the modified organic filling material comprises the following steps: S1, modification of the sepiolite fiber: adding 10-15 parts of the dried sepiolite fiber and deionized water at a solid-to-liquid ratio of 1:5 to a dispersant, dispersing at 1500 r/min-1800 r/min for 5 min, then adding 2-3 parts of the silane coupling agent, dispersing at an increased revolving speed of 2500 r/min for 60 min to obtain a slurry, which is then dried in a constant-temperature drying oven at 110° C., and then finely grinding the dried modified sepiolite fiber by a ball mill for later use; S2, activation of the tyre powder: mixing the 20-50 parts of tyre powder, the 2-5 parts of a cashew nut shell liquid, and the 0.5-2 parts of an activator in a high-speed mixer at a revolving speed of 70 r/min-100 r/min for 5 min-10 min to obtain premixed powder, which is then activated and modified in a torque rheometer with a revolving speed of 70 r/min-100 r/min and a temperature of 120° C-160° C. for 5 min-30 min to obtain modified tyre powder, and finally, cooling the modified tyre powder under natural conditions to normal temperature for later use; S3, preprocessing of the shoe sole waste: stripping to remove miscellaneous substances and keep EVA insoles, physically shredding the EVA insoles in a shredding machine, and washing and drying the shredded EVA insoles to obtain the shoe sole waste for later use; and S4, mixing the modified sepiolite fiber from Step S1, the modified tyre powder from Step S2 and the shoe sole waste from Step S3 fully and evenly, feeding to a double-screw extruder for melting, extruding and granulating.

10. An environment-friendly friction material product, comprising a friction layer prepared from the environment-friendly friction material according to claim 1.

11. An environment-friendly friction material product, comprising a friction layer prepared from the environment-friendly friction material according to claim 2.

12. An environment-friendly friction material product, comprising a friction layer prepared from the environment-friendly friction material according to claim 3.

13. An environment-friendly friction material product, comprising a friction layer prepared from the environment-friendly friction material according to claim 4.

14. An environment-friendly friction material product, comprising a friction layer prepared from the environment-friendly friction material according to claim 5.

15. An environment-friendly friction material product, comprising a friction layer prepared from the environment-friendly friction material according to claim 6.

16. An environment-friendly friction material product, comprising a friction layer prepared from the environment-friendly friction material according to claim 7.

17. An environment-friendly friction material product, comprising a friction layer prepared from the environment-friendly friction material according to claim 8

18. An environment-friendly friction material product, comprising a friction layer prepared from the environment-friendly friction material according to claim 9.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0022] The following Examples 1-8 and Comparative Examples 1-4 are proposed for the environment-friendly friction material according to the invention. Among them, Comparative Example 1 is a control experiment of Example 1, with a difference in that the chemical component POE has a content of 12% the shoe sole waste used in Comparative Example 1; Comparative Example 2 is also the control experiment of Example 1, with a difference in that a mixture of the tyre powder and the shoe sole waste at the same mass ratio are only used in the modified organic filling material in Comparative Example 2, without an modification; Comparative Example 3 is also the control experiment of Example 1, with a difference in that the parts by weight of the modified organic filling material in Comparative Example 3 is 5 and the process for preparing the modified organic filling material is the same as that in Example 1; and Comparative Example 4 is also the control experiment of Example 1, with a difference in that the modified organic filling material, the granite powder and the marble powder are not used and substituted with zirconium silicate, alumina, calcium carbonate, mica, polytetrafluoroethylene, friction powder of cashew nut shell liquid. References may be made to Tables 1, 2, 3 and 4 for the component composition in Examples 1-8 and Comparative Examples 1-4.

TABLE-US-00001 TABLE 1 Specific composition of the modified organic filling materials according to Examples 1-8 and Comparative Examples 1-3 of the invention Modified organic filler material Tyre shoe sole Sepiolite Silane coupling Cashew nut Activator powder waste fiber agent Si-998 shell liquid 450 Example 1 20 20 10 2 2 0.5 Example 2 25 20 12 3 4.5 1 Example 3 22 15 10 2.5 3 1 Example 4 25 25 15 3 5 2 Example 5 22 18 12 2.5 3 1 Example 6 20 25 15 3 3 0.5 Example 7 25 18 10 2 3 2 Example 8 20 15 12 2 3 0.8 Comparative 20 20 10 2 2 0.5 Example 1 Comparative 20 20 — — — — Example 2 Comparative 20 20 10 2 2 0.5 Example 3

TABLE-US-00002 TABLE 2 Specific composition of the environment-friendly friction materials according to Examples 1-4 of the invention Material Specific components Example Example Example Example composition (parts) 1 2 3 4 Binding material Phenolic Resin 12 10 10 — (8-15 parts) Boron modified — — 2 — phenolic resin Cashew nut shell liquid — 5 — 6 modified phenolic resin Natural rubber — — 3 2 Organic fiber Aramid fiber 3 3 2 — material (3-8 Polyacrylic fiber 2 — 3 5 parts) Inorganic fiber Potassium titanate fiber — 2 2 — material Glass fiber — — 2 — (3-8 parts) Ceramic fiber 4 2 — 3 Basalt fiber 4 2 3 3 Anti-friction Graphite 2 3 2 — material (3-8 Tin sulfide — — 2 2 parts) Molybdenum disulfide 3 — — 6 Granite powder (15-25 parts) 20 25 15 20 Marble powder (35-40 parts) 35 40 35 40 Modified organic filler material (6-10 parts) 8 10 6 8 Acidity or Calcium hydroxide 5 3 2 — alkalinity Gypsum powder — — 3 — regulating Lime — 5 — 2 material (5-10 Slaked lime — — — 3 parts) Non-copper metal Titanium — 1 1.5 — material (0.5-4.5 Iron 0.5 — — — parts) Nickel 0.5 1 — 0.5 Zinc — 0.5 0.5 1 Heat-resistant 1 1 0.5 1 duralumin

TABLE-US-00003 TABLE 3 Specific composition of the environment-friendly friction materials according to Examples 5-8 of the invention Material Specific components Example Example Example Example composition (parts) 5 6 7 8 Binding material Phenolic Resin 10 — 8 — (8-15 parts) Boron modified — — 5 8 phenolic resin Cashew nut shell liquid 2 8 — — modified phenolic resin Natural rubber 3 — — 2 Organic fiber Aramid fiber 5 3 3 3 material (3-8 Polyacrylic fiber — 3 5 — parts) Inorganic fiber Potassium titanate fiber 1 — 1.5 1 material Glass fiber — 1 — 0.5 (3-8 parts) Ceramic fiber 1 — 0.5 — Basalt fiber 1.5 3.5 1 2 Anti-friction Graphite — 1 1 2 material (3-8 Tin sulfide 1.5 — 0.5 — parts) Molybdenum disulfide 2.5 3 5 3 Granite powder (15-25 parts) 25 25 15 20 Marble powder (35-40 parts) 35 40 35 40 Modified organic filler material (6-10 parts) 10 10 8 8 Acidity or Calcium hydroxide 5 5 2 5 alkalinity Gypsum powder — — — — regulating Lime — — — — material (5-10 Slaked lime — — 3 — parts) Non-copper metal Titanium 0.5 1 — — material (0.5-4.5 Iron — 0.5 — — parts) Nickel 1.5 1 2 1 Zinc — 0.5 — — Heat-resistant 1 — 2 1.5 duralumin

TABLE-US-00004 TABLE 4 Specific composition of the environment-friendly friction materials according to Comparative Examples 1-4 of the invention Specific Material components Comparative Comparative Comparative Comparative composition (parts) Example 1 Example 2 Example 3 Example 4 Binding material Phenolic Resin 12 12 12 12 Boron modified — — — — phenolic resin Cashew nut — — — — shell liquid modified phenolic resin Natural rubber — — — — Organic Aramid fiber 3 3 3 3 fiber Polyacrylic fiber 2 2 2 2 material Inorganic Potassium titanate — — — — fiber fiber material Glass fiber — — — — Ceramic fiber 4 4 4 4 Basalt fiber 4 4 4 4 Anti-friction Graphite 2 2 2 2 material Tin sulfide — — — — Molybdenum 3 3 3 3 disulfide Granite powder 20 20 20 — Marble powder 35 35 35 — Zirconium Silicate — — — 20 Alumina — — — 15 Calcium carbonate — — — 25 Mica — — — 5 Polytetrafluoroethylene — — — 5 Friction powder of cashew — — — 8 nut shell liquid Modified organic filler 8 8 5 — material (6-10 parts) Acidity or Calcium hydroxide 5 5 5 5 alkalinity Gypsum powder — — — — regulating Lime — — — — material Slaked lime — — — — Non-copper Titanium — — — — metal Iron 0.5 0.5 0.5 0.5 material Nickel 0.5 0.5 0.5 0.5 Zinc — — — — Heat-resistant 1 1 1 1 duralumin

[0023] A process for preparing the modified organic filling material according to each of the above Examples 1-8 and Comparative Examples 1 and 3 includes the following steps:

[0024] S1, modification of the sepiolite fiber: adding 10-15 parts of the dried sepiolite fiber and deionized water at a solid-to-liquid ratio of 1:5 to a dispersant, dispersing at 1500 r/min-1800 r/min for 5 min, then adding 2-3 parts of the silane coupling agent, dispersing at an increased revolving speed of 2500 r/min for 60 min to obtain a slurry, which is then dried in a constant-temperature drying oven at 110° C., and then finely grinding the dried modified sepiolite fiber by a ball mill for later use;

[0025] S2, activation of the tyre powder: mixing the 20-50 parts of tyre powder, the 2-5 parts of a cashew nut shell liquid, and the 0.5-2 parts of an activator in a high-speed mixer at a revolving speed of 70 r/min-100 r/min for 5 min-10 min to obtain premixed powder, which is then activated and modified in a torque rheometer with a revolving speed of 70 r/min-100 r/min and a temperature of 120° C-160° C. for 5 min-30 min to obtain modified tyre powder, and finally, cooling the modified tyre powder under natural conditions to normal temperature for later use;

[0026] S3, preprocessing of the shoe sole waste: stripping to remove miscellaneous substances and keep EVA insoles, physically shredding the EVA insoles in a shredding machine, and washing and drying the shredded EVA insoles to obtain the shoe sole waste for later use; and

[0027] S4, mixing the modified sepiolite fiber from Step S1, the modified tyre powder from Step S2 and the shoe sole waste from Step S3 fully and evenly, feeding to a double-screw extruder for melting, extruding and granulating.

[0028] In addition, the invention further provides an environment-friendly friction material product, which includes a friction layer prepared from the environment-friendly friction material according to each of the above Examples 1-8.

[0029] According to the respective formulas shown in Tables 1-4, the respective components of the friction material are mixed for 10 min by using a mixer to obtain an evenly mixed friction material mixture; then, the friction material mixture is pressurized for 5 seconds under 16 Mpa at the temperature of 160° C., exhausted for 5 seconds and circulated 5 times to obtain a press-formed product; then, the press-formed product is thermally treated for 2 hours at the temperature of 190° C.; and finally, the thermally treated product is sprayed with protective paint and cured for 20 min at the temperature of 160° C.

[0030] Next, braking efficiency tests are performed in terms of second effectiveness, third effectiveness, third effectiveness, and fourth effectiveness respectively according to the bench test method of passenger car braking devices under JASO C406-2000; and the average wear extent tests are performed for the brake pad and brake disc respectively according to the bench wear test method for automobile parts-drum brake pads and disc brake pads-under JASO C427-2009. Test results are shown in Tables 5 to 6.

[0031] For the occurrence frequency of noise, when tests are performed on the bench test equipment for passenger car braking devices under JASO C406-2000, the number of occurrences of unacceptable human noise (≥55 dB) is calculated, divided by the number of occurrences of sound, and evaluated in percentage as a noise occurrence rate.

[0032] Next, a service noise test is performed as follows: service tests are performed under the following conditions of the initial speed of 30 km/h and 50 km/h, the deceleration of 0.49-1.96 m/s2, the temperature of 50-200° C., and the repetition number of 200 times, and the occurrence rate of the noises (≥55 dB) generated during all the braking is evaluated according to the following criteria.

[0033] Among them, “good” indicates the occurrence rate of noise is less than 1% (including 1%); “excellent” indicates the occurrence rate of noise is more than 1% (excluding 1%) and less than 30% (including 30%); and “poor” indicates the occurrence rate of noise is more than 30% (excluding 30%).

TABLE-US-00005 TABLE 5 Physical test results of the friction layers prepared from the environment- friendly friction materials according to Examples 2-7 of the invention Test item Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Example 8 Braking Second 50 KM/h 0.37 0.38 0.35 0.36 0.37 0.37 0.38 efficiency effectiveness 100 KM/h 0.35 0.37 0.37 0.36 0.37 0.37 0.36 130 KM/h 0.37 0.37 0.37 0.38 0.35 0.38 0.35 Third 100 KM/h 0.36 0.36 0.37 0.36 0.37 0.36 0.38 effectiveness Fourth 50 KM/h 0.36 0.37 0.37 0.36 0.38 0.36 0.37 effectiveness 100 KM/h 0.35 0.38 0.38 0.36 0.36 0.38 0.37 130 KM/h 0.37 0.35 0.37 0.35 0.36 0.35 0.35 Wear Brake pad AVG 0.4 0.48 0.42 0.52 0.55 0.6 0.55 extent (mm) Brake pad AVG 0.001 0.002 0.001 0.002 0.003 0.003 0.001 Heat fade First time AVG 0.35 0.37 0.36 0.35 0.37 0.36 0.36 MIN 0.26 0.26 0.24 0.21 0.24 0.25 0.23 Second time AVG 0.35 0.36 0.36 0.34 0.36 0.35 0.35 MIN 0.24 0.23 0.22 0.24 0.22 0.25 0.21 Bench brake noise (≥55 dB) 50 KM/h 0.37 0.38 0.35 0.36 0.37 0.37 0.38 Service brake noise (≥55 dB) 100 KM/h 0.35 0.37 0.37 0.36 0.37 0.37 0.36

TABLE-US-00006 TABLE 6 Physical test results of the friction layers prepared from the friction materials according to Comparative Examples 1-4 and Example 1 of the invention Comparative Comparative Comparative Comparative Test item Example 1 Example 2 Example 3 Example 4 Example 1 Braking Second 50 KM/h 0.38 0.34 0.35 0.37 0.36 efficiency effectiveness 100 KM/h 0.36 0.37 0.37 0.35 0.37 130 KM/h 0.33 0.34 0.36 0.35 0.36 Third 100 KM/h 0.34 0.35 0.36 0.37 0.36 effectiveness Fourth 50 KM/h 0.35 0.33 0.35 0.38 0.35 effectiveness 100 KM/h 0.37 0.37 0.35 0.35 0.37 130 KM/h 0.34 0.34 0.33 0.36 0.38 Wear Brake pad AVG 0.46 0.61 0.53 0.5 0.48 extent (mm) Brake disc AVG 0.001 0.002 0.002 0.003 0.001 Heat fade First time AVG 0.35 0.34 0.36 0.36 0.36 MIN 0.22 0.25 0.26 0.26 0.25 Second time AVG 0.36 0.31 0.32 0.36 0.35 MIN 0.24 0.21 0.2 0.24 0.24 Bench brake noise (≥ 55 dB) 0.2 0.5 0.3 0.3 0.2 Service brake noise (≥ 55 dB) Good Poor Excellent Excellent Good

[0034] The above illustration and description provide the basic principles and main features as well as the advantages of the invention. Those skilled in the art should understand that the invention is not limited by the embodiments described above. The embodiments described above and the description in the specification are merely for the purpose of explaining the principle of the invention. There may be a variety of variations and improvements made to the invention without departing from the inventive spirit and scope of the invention. These variations and improvements shall be construed as falling within the scope claimed by the invention. The scope claimed by the invention should be defined by the appended claims and equivalents thereof.