The Application of Mineral Fibers in Brake Pads Production
In the highly competitive and technologically – driven field of brake pads manufacturing, the selection and utilization of appropriate materials are of paramount importance. Mineral Fibers, with their distinct physical and chemical properties, have become an integral part of brake pads production, bringing both remarkable advantages and certain limitations.
1. Mineral Fibers in Brake Pads
Mineral Fibers are a class of fibrous materials derived from natural minerals. They come in various forms, such as basalt fibers, glass fibers, and ceramic fibers. Each type has its own unique characteristics. For example, basalt fibers have a density of around 2.6 – 3.0 g/cm³, which is relatively lightweight compared to some metals. They also possess high tensile strength, typically in the range of 2000 – 4000 MPa, and excellent heat – resistance, being able to withstand temperatures up to 800 – 1000°C without significant degradation. Glass fibers, on the other hand, are known for their high chemical resistance and relatively low cost. They have a density of approximately 2.4 – 2.7 g/cm³ and can be produced in different diameters to suit various applications.
2. Incorporation into brake pads mixture
When formulating brake pads mixtures, Mineral Fibers are combined with a wide array of other components. Binders, like phenolic resins or rubber – based binders, are used to bind the mineral fibers and other ingredients together. These binders form a matrix that holds the structure of the brake pads. Fillers such as graphite, mica, or clay are often added to adjust the mechanical and frictional properties of the mixture. In a typical brake pads mix, Mineral Fibers usually account for 10 – 20% by weight. This proportion is carefully determined as the right amount of mineral fibers can enhance the overall performance of the brake pads. For instance, increasing the amount of mineral fibers can improve the mechanical strength of the mixture, but too much can lead to brittleness and affect the wear – resistance.
3. Role in brake pads friction materials
As a key component in brake pads friction materials, Mineral Fibers play a crucial role in determining the friction and wear behavior. A well – designed friction material with an appropriate amount of Mineral Fibers can maintain a stable friction coefficient. Under normal braking conditions, brake pads with optimized Mineral Fibers content can maintain a friction coefficient in the range of 0.4 – 0.6. This stability is essential for ensuring a consistent braking force, whether for a small – sized vehicle in urban traffic or a large – scale industrial vehicle.
Advantages of Using Mineral Fibers in Brake Pads
- High Mechanical Strength: Mineral Fibers, especially those like basalt and ceramic fibers, contribute significantly to the mechanical strength of brake pads. Brake pads with mineral fibers have been shown to have a 20 – 30% increase in flexural strength compared to those without them. This increased strength helps the brake pads withstand the high – stress forces during braking, reducing the risk of breakage or deformation.
- Excellent Heat Resistance: Their ability to withstand high temperatures makes Mineral Fibers ideal for brake pads. In high – speed braking scenarios, brake pads with mineral fibers can maintain their structural integrity even when the temperature on the friction surface reaches 600 – 700°C. This heat – resistance property helps prevent brake fade, ensuring reliable braking performance under extreme conditions.
- Improved Wear Resistance: Incorporating Mineral Fibers into brake pads can enhance their wear resistance. Laboratory – tested brake pads with mineral fibers exhibited a wear rate that was 15 – 25% lower than those without them. This extended lifespan not only reduces the frequency of brake pad replacements but also improves the overall safety of the braking system.
Disadvantages of Using Mineral Fibers in Brake Pads
- Potential Health Risks: Some types of Mineral Fibers, such as asbestos – like fibers (although asbestos is now widely banned), can pose health risks if inhaled. Even non – asbestos mineral fibers, in fine particulate form, may cause respiratory problems over long – term exposure. This requires strict safety measures during the production and handling of brake pads containing mineral fibers.
- High Cost in Some Cases: High – performance mineral fibers, such as certain ceramic fibers, can be relatively expensive. This can increase the production cost of brake pads. For example, the use of advanced ceramic fibers can raise the production cost of brake pads by 20 – 30% compared to using more common materials. This cost factor may limit their widespread use in some price – sensitive markets.
- Difficulties in Processing: Mineral Fibers can be challenging to process in the brake pads production. Their high – strength nature may require specialized equipment and techniques for cutting, mixing, and shaping. In some cases, improper processing can lead to uneven distribution of the fibers in the brake pads mixture, resulting in inconsistent performance.