The Application of Rubber Accelerator (MBTS/DM) in Brake Pads Production
In the complex landscape of brake pads manufacturing, every component plays a crucial role in determining the performance, durability, and safety of the final product. Rubber Accelerator (MBTS/DM), a chemical compound with unique properties, has found its application in brake pads production, bringing both advantages and disadvantages to the table.
1. Rubber Accelerator (MBTS/DM) Basics
MBTS (2,2′-Dibenzothiazyl disulfide) and DM (4,4′-Dithiomorpholine) are widely used rubber accelerators. MBTS is a yellow – brown powder with a melting point around 175 – 185°C. DM, on the other hand, is a white to light – yellow crystal with a melting point in the range of 126 – 129°C. These accelerators are known for their ability to speed up the vulcanization process of rubber compounds. In the context of brake pads, they interact with the rubber components in the brake pads mixture to enhance the overall performance.
2. Incorporation into Brake Pads Mixture
In a brake pads mixture, Rubber Accelerator (MBTS/DM) is combined with various other materials. The main components typically include binders, such as phenolic resins, which hold the entire mixture together. Fillers like kaolin, mica, or graphite are added to adjust the mechanical and thermal properties. Rubber components, which are crucial for providing elasticity and some level of friction modulation, are also present. In a typical brake pads mix, the amount of Rubber Accelerator (MBTS/DM) usually ranges from 0.5 – 2% by weight. This relatively small proportion is carefully optimized as it can significantly impact the properties of the final brake pads.
3. Role in brake pads friction materials
As part of the brake pads friction materials, Rubber Accelerator (MBTS/DM) plays an important role in the vulcanization of rubber components. Vulcanization transforms the rubber from a soft, sticky material into a more durable and stable one. In brake pads, this process improves the heat resistance and wear resistance of the friction materials. For example, a well – vulcanized rubber component in the friction material can maintain its integrity even at temperatures up to 250 – 300°C, which is common during moderate – to – high – speed braking. This enhanced heat resistance helps in preventing the degradation of the friction coefficient and ensures consistent braking performance.
Advantages of Using Rubber Accelerator (MBTS/DM) in Brake Pads Production
- Enhanced Vulcanization Efficiency: Rubber Accelerator (MBTS/DM) significantly speeds up the vulcanization process. In laboratory tests, the use of MBTS or DM reduced the vulcanization time by 30 – 40% compared to non – accelerated rubber compounds in brake pads mixtures. This not only improves the production efficiency but also reduces the overall manufacturing cost.
- Improved Wear Resistance: Brake pads with Rubber Accelerator (MBTS/DM) show enhanced wear resistance. A study on commercial vehicle brake pads found that the addition of MBTS/DM reduced the wear rate by 15 – 20% over a 100,000 – kilometer driving distance. This extended lifespan means fewer brake pad replacements, which is cost – effective for vehicle owners.
- Stable Friction Performance: By optimizing the vulcanization process, the friction coefficient of brake pads containing Rubber Accelerator (MBTS/DM) remains more stable. Under normal braking conditions, the friction coefficient can be maintained within a range of 0.4 – 0.55, with a variation of less than ±0.03. This stability ensures predictable braking performance, whether in city driving or on the highway.
Disadvantages of Using Rubber Accelerator (MBTS/DM) in Brake Pads Production
- Potential for Over – Vulcanization: If the amount of Rubber Accelerator (MBTS/DM) is not carefully controlled, over – vulcanization can occur. In some cases, an over – vulcanized brake pad can become too hard, leading to a decrease in the friction coefficient. Laboratory experiments showed that when the accelerator content exceeded 2.5% by weight, the friction coefficient decreased by up to 0.1, which can be critical for braking performance.
- Environmental and Health Concerns: Some rubber accelerators, including MBTS and DM, may have environmental and health implications. They can release certain chemicals during the production process and also when the brake pads are in use. For example, during high – temperature braking, small amounts of sulfur – containing compounds may be released into the air. Prolonged exposure to these compounds can be harmful to human health, especially for workers in the manufacturing plants and vehicle users in poorly ventilated areas.
- Compatibility Issues: Rubber Accelerator (MBTS/DM) may have compatibility issues with some other components in the brake pads mixture. For instance, it may react with certain types of fillers or additives under high – temperature or high – humidity conditions. This can lead to the formation of unwanted by – products that may affect the overall performance of the brake pads. In some brake pads mixes, compatibility problems were observed when using certain types of new – generation fillers, resulting in a 10 – 15% decrease in the overall braking efficiency.