Brake pad and manufacturing method thereof

Abstract

The invention relates to a novel brake pad and a manufacturing method thereof, which are suitable for various types of vehicles, including bicycles, motorcycles and automobiles. The brake pad has a metal backing plate with an integrally formed flange formed on one major surface, these features being covered by a friction material. The flanges are designed to provide an audible wear indication when the friction material is worn to its level, providing a clear and definite warning for brake pad replacement. According to the innovative wear indication method, the safety of the vehicle is enhanced by ensuring that the brake system is maintained in time. In addition, the design optimizes the performance of the brake pad by improving heat dissipation and maintaining consistent brake power. The manufacturing process of the brake pad includes embossing a flange on a metal backing plate, applying a friction material, and curing the friction material to ensure durable adhesion and optimal functionality.

Description

TECHNICAL FIELD

[0001] The present invention relates to a brake system for a vehicle, and more particularly to a brake pad. BACKGROUND

[0002] Brake pads are critical safety components in vehicle design, responsible for generating the necessary friction with a brake disc (rotor) to slow or stop the vehicle.

[0003] Traditionally, brake pads are composed of a friction material bonded to a metal backing plate. The friction material wears over time due to the friction encountered during braking. As the friction material thins, the brake pad's effectiveness decreases, necessitating replacement to maintain optimal braking performance and vehicle safety.

[0004] The life of a brake pad is typically indicated by wear indicators, which are usually mechanical components that emit a noise when the friction material has worn to a certain degree. Alternatively, wear indicators can provide a visual indication, requiring the vehicle owner to check to determine the remaining thickness of the brake pad. However, these methods can be inadequate or inconvenient for various reasons. Audible wear indicators can not be loud enough to be heard in all operating environments, and visual indicators require a manual check, which the vehicle owner can neglect.

[0005] Additionally, the metal backing plate is typically provided with a plurality of mounting holes that pass through the metal backing plate, the purpose of which is to secure the friction material to the metal backing plate more firmly. However, these mounting holes can be a point of penetration for water and dirt, leading to rust and contamination of the metal backing plate. Furthermore, the presence of the mounting holes can cause the density of the friction material to be different at the locations corresponding to the mounting holes than elsewhere on the metal backing plate after the friction material has cured to the metal backing plate. Additionally, the method of creating the mounting holes by stamping them into the metal backing plate presents several challenges. One challenge is that this method creates waste (or "swarf"), which, if not properly managed, can cause the tooling used to manufacture the brake pad or the interior of the tooling to become clogged. These clogs can interrupt the manufacturing process, requiring frequent cleaning and maintenance, which reduces overall production efficiency. Additionally, some mounting holes are not through-holes in the metal backing plate, but rather are formed as recesses in the metal backing plate, which create protrusions on the other side of the metal backing plate. This requires the tooling used to stamp the metal backing plate to have recesses, which over time can accumulate dirt and require additional cleaning.

[0006] Therefore, there is a need for a brake pad with an improved wear indicator that provides a clear and unambiguous alert to the vehicle operator when the friction material has worn to a critical level, and is easily discernible. There is also a need for a method of manufacturing such a brake pad to ensure the integrity of the wear indicator throughout the operational life of the brake pad. Furthermore, how to avoid creating a through hole in the metal backplate and yet secure the friction material more firmly to the metal backplate is also worth thinking about by those having ordinary knowledge in the art. SUMMARY

[0007] The present invention aims to provide a brake pad and a method of manufacturing the same to solve the above problems.

[0008] The present invention introduces a brake pad with novel features: flanges formed on the metal backplate configured to provide an audible wear indication. This design allows a clear audible signal to inform the vehicle operator that the brake pad needs to be replaced when the friction material has worn to a critical level, without the need for visual inspection or reliance on additional mechanical wear indicators.

[0009] A key aspect of the brake pad includes a metal backplate having a first major surface and an opposing second major surface, a plurality of flanges integrally formed and protruding from the first major surface, and a friction material covering the first major surface including the flanges. The flanges are carefully designed to maintain a uniform thickness of the metal backplate in areas not occupied by the flanges, ensuring structural integrity and uniform support of the friction material.

[0010] The flanges serve a dual purpose. First, the flanges embed into the friction material, which can enhance the degree of bonding between the friction material and the metal backplate, making it less likely for the friction material to detach from the metal backplate. Additionally, these features are designed to emit a unique sound after the friction material has worn, serving as an audible indication for brake pad replacement. This sound is designed to be distinguishable from the normal operating sound of the brake system, providing a clear alert to the vehicle operator.

[0011] Furthermore, the invention also includes a method of manufacturing such a brake pad, comprising the following steps:

[0012] 1. providing a metal backplate having a first major surface and a second major surface opposite to the first major surface;

[0013] 2. stamping the second major surface of the metal backplate to form a plurality of bumps on the first major surface;

[0014] 3. stamping the bumps of the first major surface to form a plurality of flanges on the first major surface, each flange surrounding an embedded hole, and the metal backplate maintaining a uniform thickness in areas not occupied by the flanges;

[0015] 4. applying a friction material to the first major surface such that the friction material covers the flange;

[0016] 5. curing the friction material on the metal back plate to adhere the friction material to the first major surface including the flange.

[0017] In summary, the present invention introduces a brake pad with a flange that provides an audible wear indication without the need for additional mechanical components to address these needs. The flanges are designed to produce a clear sound that alerts the user that the brake pads need to be replaced, improving the limitations of traditional wear indicators. This innovation aims to improve the safety and maintenance of the vehicle by ensuring that the wear condition of the brake pads is clearly communicated to the vehicle operator. Additionally, the metal back plate of the present invention does not form a through-hole in the metal back plate, so it is less likely to cause water and dirt to penetrate from the outside. Moreover, the metal back plate has a uniform thickness, so the uniformity of the overall density of the friction material after curing on the metal back plate will be better.

[0018] In order to make the above features and advantages of the present invention more obvious and easy to understand, the following preferred embodiments are described in detail below, together with the accompanying drawings, as follows. BRIEF DESCRIPTION OF DRAWINGS

[0019] The differences between the present invention and the prior art, various embodiments, will be described below according to the accompanying drawings, which are used to illustrate but not to limit the scope in any way, wherein like reference numerals represent like components, and wherein:

[0020] Figure 1 A perspective view of one embodiment of a brake pad for a bicycle according to the present invention is shown.

[0021] Figure 2 A cross-sectional view of a brake pad according to the present invention is shown. Figure 1

[0022] Figure 3 A cross-sectional view of a brake pad that has been worn to a certain extent is shown.

[0023] Figure 4 A flowchart of one embodiment of the manufacturing process of a brake pad is shown.

[0024] Figure 5 A semi-finished product diagram of a brake pad during the manufacturing process is shown.

[0025] Figure 6 A perspective view of a brake pad for a motorcycle is shown.

[0026] Figure 7 ​A perspective view of a brake pad for a bicycle is shown.

[0027] Figure 8 A schematic view of the flanges formed at an angle outwardly relative to the first major surface of the metal backing plate is shown.

[0028] Figure 9 A schematic view of the flanges formed integrally with the metal backing plate is shown. DETAILED DESCRIPTION

[0029] The present invention relates to an advanced brake pad and its manufacturing process, specifically designed to enhance the wear indication function and reliability of the brake pad on various types of vehicles, including bicycles, motorcycles and automobiles.

[0030] Reference is made to Figure 1 and Figure 2 , Figure 1 A perspective view of a brake pad for a bicycle is shown, Figure 2 A cross-sectional view of the brake pad is shown, wherein Figure 1 The brake pad of the present embodiment incorporates a metal backing plate 110, which serves as the base component of the brake pad, supporting the friction material 120, which is essential during braking. The metal backing plate 110 of the brake pad 100 provides structural support and a base for the attachment of the friction material 120. The metal backing plate 110 has a first major surface 112, on which a plurality of flanges 116 (2 in the present embodiment) are formed, which protrude from the first major surface 112 and are embedded in the friction material 120, and a second major surface 114, opposite the first major surface 112.

[0031] In the present embodiment, the metal backing plate 110 is typically made of steel or an alloy with high strength, and the material of the metal backing plate 110 also has durability and effective heat dissipation capacity. Durability ensures that the metal backing plate 110 can withstand mechanical stress and environmental conditions encountered during the service life, while effective heat dissipation capacity is of some importance to maintain the performance and reliability of the brake pad 100. The metal backing plate 110 helps to prevent overheating by carrying heat away from the friction surface of the friction material 120, thereby preventing brake fade and reducing the life of the friction material 120.

[0032] The friction material 120 attached to the first major surface 112 of the metal backing plate 110 can be selected from the group consisting of organic materials, metallic compounds or ceramic-based compounds, each having unique advantages in terms of braking performance, durability and noise characteristics. The manufacturer can select the appropriate friction material based on the specific requirements of the vehicle and the expected operating conditions.

[0033] Also, please refer to Figure 6 With Figure 7 , Figure 6 illustrated as a perspective view of a brake pad 300 for a motorcycle, Figure 7 illustrated as a perspective view of a brake pad 400 for an automobile. While the dimensions and specific design details vary, the core concepts of the brake pads 300, 400 - including the metal back plate 310, 410, the friction material, and the flanges 316, 416 for wear indication - remain consistent across all vehicle types. This versatility highlights the broad applicability of the present invention and the potential for improving brake pad functionality and safety in a wide variety of brake systems, from the smallest bicycles to the largest automobiles.

[0034] Please continue to refer to Figure 1 With Figure 2 , the flanges 116 on the metal back plate 110 are, in this embodiment, integrally formed with the metal back plate 110 through a stamping process (to be described later), such that flanges 116 with specific shapes and heights can be created without compromising the structural integrity of the metal back plate 110 and without affecting the uniform thickness of the metal back plate 110. In this embodiment, the flanges 116 are disposed around the plurality of embedded holes 115.

[0035] The flanges 116 serve multiple functions. First, the flanges 116 play a crucial role in the wear indication mechanism of the brake pad 100. As the friction material 120 wears due to use, it will eventually reach the level of these flanges 116 (as shown in Figure 3 At this point, the friction between the flanges 116 and the brake disc produces a unique sound signal, alerting the vehicle user that the brake pad 100 has reached a certain level of wear. Since the sound emitted when the flanges 116 are rubbed is different from the sound emitted when the friction material 120 is rubbed, that is, this sound is different from the normal operating sound of the brake pad 100, it provides a clear and explicit indication that the brake pad 100 needs to be replaced. In addition, it can be found that when the friction material 120 reaches the level of these flanges 116 due to wear, the remaining friction material 120 can still play a certain braking role to provide the user with more generous time to replace the brake pad 100.

[0036] Secondly, compared with the known metal back plate, the metal back plate 110 of the present embodiment does not form through holes in the metal back plate 110, so it is less likely to cause water and dirt to penetrate from the outside. In addition, the flanges 116 are embedded in the friction material 120, which can enhance the bonding between the friction material 120 and the metal back plate 110, so that the friction material 120 is not easy to separate from the metal back plate 110.

[0037] In summary, the arrangement of flanges 116 is crucial for audible wear indication, ensuring effective heat dissipation, and enhancing integration with the metal backplate 110. By directly integrating these flanges 116 into the metal backplate 110, this embodiment provides a simple and efficient solution to address the challenges of wear monitoring in brake pads 100, improving the safety and convenience of brake system maintenance.

[0038] The friction material 120 has been briefly described above; a more detailed description follows. The material of the friction material 120 is selected based on a variety of factors, including the intended use of the brake pad 100, braking performance requirements, and a balance between durability, noise reduction, and heat resistance. In this embodiment, three main types of friction materials can be used: organic materials, metal compounds, and ceramic matrix composites, each with unique advantages and properties. Organic materials are blends of various fibers, fillers, and binding resins. These materials are characterized by quiet operation and low stress on the brake disc. Organic friction materials are generally suitable for lightweight applications, such as in some bicycle brake pads, where performance requirements are balanced with the need for noise reduction and brake disc protection.

[0039] Metallic compounds combine metal fibers with other materials to enhance heat dissipation and improve braking performance. These friction materials are more durable than organic compounds and have better heat resistance, making them suitable for high-performance applications, including motorcycles and automobiles. Ceramic matrix composites consist of ceramic fibers, non-ferrous fillers, and binders. These materials offer excellent heat resistance, low dust generation, and reduced wear on brake pads and rotors. Moreover, ceramic brake pads provide consistent braking performance across a wide range of temperatures and conditions, making them ideal for a variety of applications, from everyday driving to more demanding automotive use.

[0040] In another embodiment, such as Figure 8 As shown in the schematic diagram, the flange 216 is formed by tilting outward at a specific angle relative to the first main surface 212 of the metal backing plate 210. Unlike the vertical flange 216 described in the previous embodiment, this outward tilting design allows for a more effective bond with the friction material 120 after application and curing. In particular, because the flange 216 is tilted, the friction material 120 is more likely to flow into and cover the flange during the coating process, thereby producing a stronger mechanical interlocking effect and improving the overall bonding strength between the friction material 120 and the metal backing plate 210.

[0041] Furthermore, when the friction material 120 eventually wears down to the level of the inclined flange 216, the audible wear indication produced by the flange 216 contacting the brake disc remains equally reliable, while simultaneously providing the enhanced positioning effect of the inclined flange. This configuration is particularly advantageous when higher friction material holding force is required or when enhanced friction layer stability is needed to cope with varying braking conditions.

[0042] Although Figure 8 The flange 216 shown is only a representative tilt angle, but those skilled in the art will understand that the tilt angle may cover a wide range (e.g., 5° to 45°) in order to achieve the best balance between process feasibility, friction material flow characteristics and wear indication performance for a particular vehicle type or braking system design.

[0043] Please refer to Figure 4 ,like Figure 4 The diagram illustrates the manufacturing process of brake pads. In this embodiment, the manufacturing process of brake pads can be summarized into the following key stages.

[0044] First, as shown in step S110, a metal backing plate 110 is provided. The manufacturing process of the brake pad begins with the selection and preparation of the metal backing plate 110. As mentioned above, the metal backing plate 110 is typically made of steel or a durable alloy, chosen for its mechanical strength and thermal conductivity. The metal backing plate 110 serves as the foundation for constructing the brake pad 100, providing structural support for the friction material 120.

[0045] Next, as shown in step S120, the second main surface 114 of the metal back plate 110 is stamped to form a protrusion 116' on the first main surface 112 (e.g., Figure 5 (As shown) Flange 116. Next, as shown in step S125, another stamping process is performed, but this stamping process mainly stamps the bump 116', so that only the outermost edge of the original bump 116' (i.e., the flange 116) still protrudes from the first main surface 112. The insertion hole 115 is also formed at the same time as the flange 116. Moreover, since step S125 involves pushing most of the volume of the bump 116' back, the metal back plate 110 can maintain a consistent uniform thickness overall.

[0046] Next, as shown in step S130, friction material 120 is applied. After forming flange 116, friction material 120 is applied to the first primary surface 112 of metal backing plate 110. This involves uniformly applying a premixed compound of friction material 120 to the surface of metal backing plate 110, ensuring complete coverage of flange 116. The premixed compound of friction material 120 must be uniformly applied to prevent any voids or weaknesses that could affect braking performance or brake pad durability.

[0047] Next, as shown in step S140, the friction material 120 is cured. After the friction material 120 is applied, the brake pad 100 enters the curing stage. This involves heating the assembled brake pad 100 to a specific temperature and holding it for a certain time. The curing process strengthens the bond between the friction material 120 and the metal backing plate 110, ensuring it can withstand the stress of repeated braking cycles. Furthermore, curing also enhances the performance of the friction material, optimizing its performance for effective braking. It is also worth noting that the metal backing plate 110 maintains a consistent uniform thickness overall. This is because the friction material 120 is partially flowable before curing, and its density may decrease or become unevenly distributed as it flows deeper. This is why it is known that the friction material density is lower at the mounting holes. However, since the metal backing plate 110 in this case maintains a consistent uniform thickness overall, this situation is less likely to occur.

[0048] Compared to prior art, the manufacturing method of the brake pad 100 of the present invention eliminates the need to form mounting holes in the metal backing plate 110. Instead, the brake pad 100 of the present invention includes a plurality of flanges 116 integrally formed with the metal backing plate 110, which enhance the adhesion between the backing plate and the friction material without incurring the disadvantages associated with stamped mounting holes. This innovative method not only simplifies the manufacturing process by reducing the number of steps involved and avoiding clogging problems, but also enhances the structural integrity of the brake pad 100 and the uniformity of the overall density of the friction material 120.

[0049] By omitting the process of stamping mounting holes, the brake pad 100 of the present invention also increases production speed and reduces maintenance downtime associated with clearing stamping debris blockages during manufacturing. Furthermore, reducing stamping debris contributes to energy conservation and supports efforts to reduce carbon emissions, aligning with environmental sustainability goals. These advancements demonstrate significant improvements in the efficiency and sustainability of brake pad manufacturing, providing substantial benefits far exceeding those of prior art.

[0050] In another embodiment, such as Figure 9 As shown in the schematic diagram, the flange 516 is integrally formed with the metal backing plate 510 and protrudes from its first main surface 512, defining an insertion hole 517 below each flange 516. This embodiment provides a similar structure and function as described above, including: when the thickness of the friction material wears down to the level of the flange 516, the flange 516 can produce an audible wear indication. However, the manufacturing process of the formed flange 516 used in this embodiment may differ from... Figure 4 The two-stage stamping methods differ. For example, the flange 516 can be stamped or bent directly from the first main surface 512, or the flange can be partially cut around its perimeter and then bent upwards into a convex shape.

[0051] Regardless of the actual forming technique employed, the resulting structural features are largely identical: (1) each flange 516 surrounds its corresponding embedded hole 515, ensuring mechanical embedding with the friction material 120; (2) the areas of the metal backing plate 510 not occupied by the flanges 516 maintain a uniform plate thickness; (3) the flanges 516 are designed with the goal of producing a distinct audible sound during the gradual wear of the friction material. In other words, even with slight variations in the manufacturing method, the resulting brake pad structure provides similar performance in terms of enhanced bonding, consistent thickness distribution, and reliable audible wear indication.

[0052] In summary, the brake pad of the above embodiments has the following advantages:

[0053] 1. Enhanced safety: The distinct audible wear indication ensures that users are promptly informed of the need to replace the brake pad, significantly reducing the risk of brake failure and potential accidents.

[0054] 2. Improved maintainability: The clear and explicit wear indication eliminates the guesswork and frequent manual checks associated with traditional wear indicators. This convenience ensures that the brake pad is replaced in a timely manner, maintaining the optimal performance of the braking system.

[0055] 3. Manufacturing efficiency: The use of stamping alone to form the flanges is highly beneficial in maintaining cost competitiveness. Additionally, since the metal backing plate maintains a consistent uniform thickness overall, the density distribution of the friction material after curing is also more uniform. Furthermore, since no stamping chips are generated, the process is simplified, production speed is increased, and energy and carbon savings are achieved.

[0056] 4. Versatility and applicability: The design of the invention is suitable for various types of vehicles, from bicycles to heavy-duty vehicles, demonstrating its universal applicability.

[0057] The invention will have a significant impact on the field of braking systems, setting new standards for wear indication and brake pad performance. It addresses important safety and maintenance issues that existing technologies cannot meet. As the bicycle industry continues to evolve, with increasing emphasis on safety, efficiency, and environmental sustainability, the invention provides a timely and effective solution that meets and exceeds current and future needs.

[0058] In summary, this innovative brake pad and its manufacturing method represent a significant advancement in bicycle road safety and maintenance. By providing an innovative wear indication method and optimizing the overall performance and efficiency of the brake pad, the invention promises to improve the safety, reliability, and maintenance convenience of vehicles worldwide, having a profound and lasting impact on the field of braking systems.

[0059] While the present application has been disclosed in its preferred embodiments with reference to the drawings, it is not intended to limit the application and it will be understood by those skilled in the art that changes in form and details of the application can be made without departing from the spirit and scope of the application. Therefore, the scope of the present application should be governed by the appended claims rather than the embodiments described above.

Claims

1. A brake pad, characterized in that, include: A metal backplate having a first main surface and a second main surface opposite to the first main surface; Multiple flanges are integrally formed and protrude from the first main surface, and each flange surrounds an insert hole. as well as A friction material is disposed on the first main surface, and the flange is embedded in the friction material; The flange is configured to provide an audible wear indication when the thickness of the friction material wears down to the level of the flange during use; and The metal back plate maintains a consistent thickness in the area not occupied by the flange.

2. The brake pad as described in claim 1, characterized in that, The friction material is an organic material, a metal compound, or a ceramic-based compound selected according to the required braking characteristics.

3. A method for manufacturing brake pads, characterized in that, include: A metal backplate is provided, having a first main surface and a second main surface opposite to the first main surface; The second main surface of the metal back plate is stamped to form a plurality of protrusions on the first main surface; The protrusions on the first main surface are stamped to form a plurality of flanges on the first main surface, each flange surrounding an insert hole, and the metal back plate having a consistent thickness in the area not occupied by the flanges. Apply a friction material to the first primary surface such that the friction material covers the flange; and The friction material on the metal backing plate is cured so that the friction material adheres to the first main surface, including the flange.

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