The Application of Mold Release Agent in Brake Pads Production
In the complex manufacturing process of brake pads, every component and additive plays a vital role. Mold Release Agent, a substance often overlooked by end – users but essential for manufacturers, has a significant impact on the production and quality of brake pads. It brings both distinct advantages and some potential drawbacks during the production cycle.
1. Mold Release Agent in Brake Pads
Mold Release Agents are substances that prevent the adhesion of the brake pads mixture to the mold surfaces during the molding process. They come in various forms, such as liquid, aerosol, and solid. One common type is silicone – based Mold Release Agents. These agents have a low surface tension, typically in the range of 20 – 25 mN/m. This low surface tension allows them to spread evenly on the mold surface, forming a thin, non – stick layer. Another type is fluoropolymer – based Mold Release Agents, which offer excellent chemical resistance and high – temperature stability. They can maintain their effectiveness at temperatures up to 300 – 400°C, which is crucial in the curing process of some brake pads.
2. Incorporation into Brake Pads Mixture
Although Mold Release Agent is not a part of the brake pads mixture in the sense of being a functional component of the final product, its application is an integral part of the production process. Before the brake pads mixture is poured into the mold, the Mold Release Agent is applied to the inner surface of the mold. The amount of Mold Release Agent applied is carefully controlled. For a typical brake pads mold with a surface area of 0.1 – 0.2 square meters, the recommended amount of liquid Mold Release Agent is 5 – 10 milliliters. This ensures that the brake pads can be easily removed from the mold after the curing process without any damage to the pads or the mold.
3. Indirect Influence on brake pads friction materials
While Mold Release Agent does not directly interact with the brake pads friction materials, its proper application can have an indirect impact on their performance. A well – applied Mold Release Agent ensures that the surface of the brake pads is smooth and free from any mold – related defects. A smooth surface can lead to more consistent contact with the brake disc, which in turn helps in maintaining a stable friction coefficient. For example, in tests, brake pads produced with proper Mold Release Agent application showed a 10 – 15% reduction in the variance of the friction coefficient compared to those with improper application.
Advantages of Using Mold Release Agent in Brake Pads Production
- Easy Mold Removal: The primary advantage of Mold Release Agent is its ability to facilitate the easy removal of brake pads from the mold. In a production line where hundreds of brake pads are produced daily, the use of Mold Release Agent can increase the efficiency of the demolding process by 30 – 40%. This reduces the production time and the risk of damage to the brake pads during demolding.
- Mold Protection: It protects the mold from wear and tear caused by the adhesion of the brake pads mixture. By preventing the mixture from sticking to the mold, the lifespan of the mold can be extended by 2 – 3 times. This results in significant cost savings as molds can be expensive to replace.
- Improved Surface Quality: A proper application of Mold Release Agent leads to a smooth surface finish of the brake pads. This smooth surface not only enhances the aesthetic appearance but also improves the performance of the brake pads. Brake pads with a smooth surface have been found to have a 15 – 20% lower noise level during braking compared to those with a rough surface.
Disadvantages of Using Mold Release Agent in Brake Pads Production
- Potential Contamination: If not used properly, Mold Release Agent can contaminate the brake pads mixture. Even a small amount of excess Mold Release Agent left on the mold surface can mix with the brake pads mixture, affecting the properties of the final product. In some cases, contaminated brake pads showed a 5 – 10% decrease in the friction coefficient, which can be a safety concern.
- Environmental Impact: Some types of Mold Release Agents, especially those containing volatile organic compounds (VOCs), can have a negative environmental impact. These VOCs can be released into the atmosphere during the production process. For example, silicone – based Mold Release Agents with high VOC content can contribute to air pollution. This requires proper ventilation and waste management systems in the production facilities.
- Cost Considerations: High – quality Mold Release Agents, especially those with advanced features like high – temperature resistance and low – toxicity, can be relatively expensive. The cost of these agents can add 5 – 10% to the overall production cost of brake pads. This cost factor needs to be carefully weighed against the benefits they bring.