Rapid development of domestic brake pad industry but poor understanding of core technology

Recently, the Ministry of Public Security announced that as of the end of 2012, the number of motor vehicles in the country had reached 240 million, of which 120 million were car ownership, an annual increase of 15.1 million. China has become one of the most important automotive consumers in the world.

The billions of car ownership have formed a huge consumer market. Surrounding the car has spawned numerous service projects. Among these projects, the most appreciable, least risky, quickest turnaround is the automotive wearing parts project, which is the most frequently used products that consumers usually switch to 4S stores, such as oil, three filters, light bulbs, spark plugs, and wipers. , belts, brake pads, brake discs, tires, refrigerant, glass water, speakers, etc.

Among the many products above, there is one type of product that deserves special attention. That is, brake pads and tires that directly affect the lives of consumers.

The earliest materials used by humans for vehicle braking were natural materials such as wood and leather. Due to low speed at the time, braking

The resulting temperature was also very low until 1897 when an Englishman named Aerbertfrood first invented a brake drum similar to today's and developed a brake band made of hair or cotton as the main material, soaked with asphalt. This material was used not only for carriages at the time but also for early motor vehicles. Since natural fibers such as cotton will become carbon at 270°C and lose their frictional properties and strength, their application is limited. Frood quickly recognized this shortcoming and in 1908 developed a winding asbestos friction lining. Until the late 1960s, asbestos friction material has been the main material for brake pads.

Roughly divided, brake pad friction material development has undergone the following stages:

Before 1930, mainly asbestos filaments and other types of wire (such as brass wire) were used to prepare impregnation methods. The impregnating material develops from bitumen to a mixture of oil and gum and begins to replace long fibers with short fibers. Later, there was no preparation of dry mixed hot pressing process.

In 1930, chemists developed a flexible resin adhesive with better thermal stability. This makes it possible to incorporate more filler into the dry process and gradually develop drum brake pads that we are familiar with today. In the following 30 years, asbestos has been the main raw material. At the same time, the research results of the rubber industry have also promoted the improvement of the friction material process. The coated preparation is brushed with a rubber mixture glue and then folded or stacked and hot pressed. This method is still widely used today.

In 1950, the United States SKWELLMAN company first developed a friction material made of iron powder, graphite and other fillers and resin as the adhesive heat press, the so-called semi-metallic friction material. In 1970, this material was used for disc brake pads and is still widely accepted today. A large number of semi-metal brake pads still occupy markets around the world.

Since 1960, with the continuous improvement of automotive design, the demand for brakes for automobiles has become higher and higher, forcing many friction material companies to begin to study the relationship between friction materials and brake drums and seek for alternative materials for asbestos. After analysis, people realized that the application of asbestos is subject to many restrictions. Asbestos resources are limited, and the quality of asbestos is very different. In particular, asbestos has great harm to human health and the environment. The existence of these problems has promoted the replacement of asbestos with glass fibers, mineral fibers, and metal fibers. More recently, aramid fibers, potassium titanate whiskers, and synthetic fibers have increasingly been used.

Looking at the history of brake pads, it is easy to see that the development of brake pads is gradual. It develops with the development of automotive technology and continues to meet the requirements of speed, temperature, comfort, stability, environmental protection and other changes brought about by new automotive technologies. The different regions and materials foster different formulations.

At present, there are three types of automotive brake pad formulations on the global market. One is a low-metal formula representing the European system, one is a semi-metallic formulation representing North America, and the other is a ceramic formulation represented by Japan. Each of these three formulations has its own advantages.

The BMW and Mercedes-Benz European models are basically based on low-metal formulas. This was because the friction material companies that were supplying these vehicles were all in Europe. When materials were selected, they were developed based on local materials in Europe. Its own unique formula system, this is the low-metal formula. Due to the heavy weight of the European car, it must require a large coefficient of friction. This greatly shortens the service life of the brake pads, and the drop of ash on these products is very serious. Therefore, we often see a lot of black and gray rims on the BMW Benz. This is the reason.

North American car bodies represented by GM and Ford are also very heavy, but in North America, they are speed-limiting. The difference in regional materials and car properties has created a new formula system, which is North America's semi-metal formula. Due to its moderateness, it can be used on relatively heavy European and North American vehicles, and it can also achieve good results on light bodies such as Japan and South Korea. Therefore, for a long time, semi-metal formulations have been the mainstream of the market.

The final piece is a ceramic brake pad. When it comes to ceramic brake pads, many consumers can easily think of the bowls and plates that we usually use to eat. Actually, these two are not the same thing at all. The reason why ceramic pads are called is because of the large amount of inorganic ceramic fiber materials used in materials. , and semi-metallic, less metal formulations are obviously different.

As mentioned above, the brake pads are designed to meet the performance requirements of automobiles. Europe, North America and Japan and South Korea have different automotive design styles, and the proposed brake pad design requirements are naturally different. Low-metal formulations and semi-metal formulations are well adapted to the weight and inertia requirements of European and American auto bodies, but at the same time they have their own unfavorable aspects. Low-metal formulations have a short life span and a lot of ash; semi-metal formulations contain a lot of metal fibers, heat conduction, high temperature recession. These lacks have also become the driving force for future research and development of brake pad formulations.

The earliest solution to the heat conduction of semi-metal formulations in the world is to adopt two kinds of mixture. The surface is a functional friction material, and a layer of specially developed material with a thickness of 2 mm is located near the bottom of the steel back plate. The role of this layer of material is to increase the shear area, reduce noise, and block heat conduction. Due to the increase in technology and cost, at present, only a few brands such as Lutheran Braxcel adopt this technology. Generally, they use only one type of friction material and do not have special materials at the bottom.

By analyzing the shortcomings of low-metal and semi-metal formulations and combining the performance characteristics of Japanese cars, Akibono Japan has developed a new material formulation system. It is based on the realization of a number of traditional technical requirements such as high temperature resistance, low thermal conductivity, wear-resistance, non-ash deposition, and environmental protection, and it is a good solution to the deficiencies of low-metal and semi-metal formulations. Theoretically, half-metal heat conduction is faster because of more metal fibers. Instead of metal fibers, it uses aramid fibers (material used for body armor); but only aramid fibers are not wear-resistant, so a new material was invented: Potassium hexatitanate whiskers (whiskers: single crystal grains. The metal we are talking about is composed of individual grains, like animals and plants are composed of countless cells, and metal fractures are mainly from intergranular fractures. However, it is basically not broken from the middle of the grains, so the grain strength is extremely high.Whisker is controlled by the process, so that the grain grows unidirectionally, like a whisker, similar to the ice flower on the window we see in winter, ice flower. At the beginning, it grew in one direction. Titanium, a precious metal, is commonly found in nuclear submarine shells and aero engine blades). As a binder resin, considering that it needs to meet the high-temperature performance, and the traditional resin is unstable at high temperatures, it has developed a high-temperature model. This alone is not enough, because in the semi-metal formula, the metal fiber plays a role similar to the beam used for building the house. The friction material consists of 10 to 20 kinds of materials, in addition to fiber reinforcements, resin adhesives. , There are some process modifiers, friction modifiers and other particulate fillers. When a metal fiber such as a whisker is replaced with a small fiber such as a whisker, the space is small, and the original large-size filler cannot be put in, and only small-grained materials can be used. The purity of various fillers must be high, so as to ensure the stability of performance.

From the above introduction, it can be understood that this formula is completely different from the less metal and semimetal formulations. Because of the improvement of technical requirements, qualitative changes have taken place from materials to structures, thus forming a completely new formula for friction materials. Because a large number of inorganic ceramic fiber materials are used in materials, they are defined as ceramic brake pads. This is the origin of ceramic brake pads.

The Japanese invented the ceramic formula and also invented the key material in the ceramic formula: potassium hexatitanate whiskers. Therefore, before 2008, except for Japan, other countries did not have ceramic brake pads.

And China. We have been catching up with foreign countries quickly through the 30 years of reform and opening up. We started by relying on human resources, relying on others to work or OEM to produce brake pads. While helping others to process, their own level has also been tempered and improved. A large number of brake brands and manufacturers have started to emerge in the country, especially in recent years. A large number of factories have mushroomed due to the optimistic view of the market's inventory and brake pads' simple process and low equipment investment.

At the same time as the rapid development of the domestic brake pad industry, we have neglected to precipitate in our studies. We are always seeking to make quick money. After the bosses have money to buy equipment, engage in exhibitions, do promotion, do high imitations, and give fakes a good name: they are packaged, but few people calm down and delve into the core of the brake pads: recipes. Look at the current market, fakes, high imitation, the so-called factory deputy factory, make people dizzy. Some dealers are superstitious about the foreigner's brand, and the manufacturer also took the opportunity to slog through the "non-domestic" gimmick.

At present, there are many brands on the domestic market that have hit the banner of ceramics. However, it is rarely similar to Japan's Akibono's materials, processes and technical formulas. One is that there is no such technology, and the other is that it cannot afford such a combination of materials. Ceramic brake pads have special effects. The friction coefficient is stable under all kinds of road conditions and environments; the high temperature resistance is excellent; the wear of the disc is minimal; there is no black ash; the service life is 30% longer than the semi-metal formula; the brakes are comfortable Basically no noise. These are good perspectives for authenticating pure ceramic formulations. On the market, if we use these criteria to judge, many can only be called: "the addition of sporadic aramid fibers of low metal formula brake pads" only, can not be considered pure ceramic brake pads.

Japan's Akibono was the originator of ceramic brake pads because it created and controlled the core material: potassium hexatitanate whiskers, creating new processes and technologies. In 2008, China Dongying Xinyi Co., Ltd. and the Chinese Academy of Sciences cooperated to complete the development of potassium hexatitanate whiskers and wafers, breaking the monopoly of Japanese companies. Promoting ceramic formulation technology has achieved synchronization with the international community. On the market, the ceramic and semi-metal formulas of the “braxcel Brasil” brand, which is sold exclusively through franchise stores, are used to support more than 20 car manufacturers’ original vehicles, using Lutheran potassium hexatitanate whiskers and DuPont’s aramid fibers. Ceramic fiber from Sweden, high-purity graphite from Termigahl, imported high-purity barium sulfate, mineral fiber from Finland, and high-temperature resistant resin from Itochu Japan. Although the use of high-end materials has substantially increased the cost, it has fundamentally ensured the authenticity of the ceramic formula.

Of course, ceramic brake pads are not a panacea. When consumers choose, they can freely choose according to their own conditions. The three formula systems are good. Try to choose the original car or brand with the original car supporting strength will be the best insurance.

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