BRAKE PAD ASSEMBLY

Abstract

Brake pad assembly (10) comprising: a backplate (100) facing a brake disc; a friction lining (200) arranged on a front surface of the back plate (100) to be in contact with a friction surface of the brake disc; and a disc (300) which is arranged on a rear surface of the backplate (100) to reduce brake noise, wherein a fillet weld (340) is performed on a side surface of the disc (300) and the back of the back plate (100) and wherein the back plate (100) comprises a plurality of support elements (110) which support the disc (300) on the rear surface of the back plate (100), wherein the support elements (110) are arranged near four corner points of the disk (300) and the fillet weld (340) between the support elements (110) is carried out on four side surfaces of the disk (300).

Description

BACKGROUND1. AREA

[0001] Embodiments of the present disclosure relate to a brake pad assembly, and more particularly to a brake pad assembly having a disc attached to a backing plate. 2. DESCRIPTION OF THE STATE OF THE ART

[0002] Generally, vehicles necessarily have braking systems for braking. A caliper brake is one such braking system. In a caliper brake, a hydraulic or electronic mechanism and a brake pad are attached to one side surface of a brake disc, which rotates along with the vehicle's wheels. When a pedal is depressed, the brake pad is pressed against the brake disc, so that the frictional force generated is used as braking force to stop a vehicle.

[0003] With such a caliper brake, noise and vibration inevitably arise when the brake disc comes into contact with the brake pad. A squealing noise generated at a frequency between 100 Hz and 16,000 Hz is particularly problematic, and brake engineers are looking for various methods to suppress the squeal.

[0004] Typically, a disc or plate element is added to a backing plate. In particular, a disc made of a metallic material is provided to change the frequency of the sound, or a disc made of an elastic material is provided to absorb or isolate the sound.

[0005] Conventionally, the coupling between the back plate and the disc has been achieved by using an adhesive or by attaching a separate member passing through the disc to the back plate. However, such coupling methods have the problem that the adhesive strength decreases due to an increase in internal temperature during brake application, or the coupling loosens when the elastic material, such as rubber, is compressed. As a result, the disc on the back plate cannot completely suppress the squeal when the brake is applied.

[0006] Therefore, in a brake pad assembly of a caliper brake, a device is needed in which a disc can be fixed to a back plate even when a brake is continuously applied. STATUS OF TECHNICAL PATENT DOCUMENTS

[0007] Korean Disclosure KR 10 2010 0 081 115 A (Disclosed on July 14, 2010)

[0008] The document DE 27 133 77 A1 describes disc brakes for vehicles in which a brake shoe can be applied to one side of a rotatable brake disc by means of a carrier, which, in the case of a directly actuated brake shoe, may comprise a piston or, in the case of an indirectly actuated brake shoe, a component of a brake caliper or a contact member. The document also refers to a brake shoe for a disc brake of the type described above.

[0009] DE 10 2012 106 162 A1 shows a lining carrier plate of a brake shoe which is designed to receive a friction lining, wherein the lining carrier plate has a first part made of a first metal with a first thermal expansion coefficient, and at least one second part which is mechanically connected to the first part and consists of a second metal with a second thermal expansion coefficient, wherein the first thermal expansion coefficient and the second thermal expansion coefficient are different, and the first part is designed as an insert which is mechanically connected to the second part, and wherein the first part penetrates the second part.

[0010] WO 99 / 054636 A1 discloses a disc brake pad assembly comprising a metallic backing plate, a conventional friction lining adhered to one surface of the backing plate, and a laminated vibration damper subassembly adhered to the backing plate by resistance welding to improve the operational reliability of the assembly.

[0011] DE 10 2012 023 012 A1 shows a brake pad for a disc brake, comprising a pad carrier plate and a friction pad arranged thereon, as well as a damping plate arranged on the side of the pad carrier plate facing away from the friction pad, wherein the pad carrier plate has a recess which corresponds to an impression of the damping plate and into which the damping plate can be inserted, and wherein the damping plate is at least partially covered with an elastic material, whereby the recess and the damping plate have a transition fit to one another.

[0012] US 2019 / 0063523 A1 shows a metallic support of a brake pad defined between a first and a second surface and having a peripheral edge substantially perpendicular to the first and second surfaces. The first surface receives a block or layer of friction material, and the second surface receives a damping element. The first surface has at least one projecting portion that is cantilevered and spaced from the peripheral edge so as to be completely embedded in the block or layer of friction material. The at least one projecting portion is defined at the top by a first surface having at least one first recess thereon filled with the block or layer of friction material. The second surface has at least one second recess forged as the at least one projecting portion.At least one first relief is located on the at least one first depression, which is shaped as the at least one first depression.

[0013] DE 10 2021 212 499 A1 relates to a brake pad assembly for a disc brake system and a disc brake system. The disc brake system has a brake piston and a brake caliper finger movably coupled to the brake piston. The brake pad assembly includes a back plate having a front side facing a brake disc of the disc brake system and a rear side, a friction layer arranged on the front side of the back plate to make contact with a friction surface of the brake disc, and a disc arranged on the rear side of the back plate.

[0014] US 0 622 646 S shows a decorative design for a brake pad unit with replaceable friction elements. DEMOLITION

[0015] Therefore, it is an aspect of the present disclosure to provide a brake pad assembly that reduces the squeal noise of a caliper brake.

[0016] Another aspect of the present disclosure is to provide a brake pad assembly in which the position of a disc on a backing plate is maintained even when the internal temperature increases during continuous application of a caliper brake.

[0017] Another aspect of the present disclosure is to provide a brake pad assembly in which the position of a disc on a backing plate is maintained even when the disc is compressed during continuous application of a caliper brake.

[0018] It is another aspect of the present disclosure to provide a brake pad assembly in which the manufacturing cost of a brake is reduced by fixing the position of a disc on a back plate using a simple structure.

[0019] To achieve the stated object, a brake pad arrangement according to claim 1 is proposed. Particular embodiments are disclosed in the dependent claims.

[0020] According to one aspect of the present disclosure, a brake pad assembly includes a back plate facing a brake disc, a friction pad disposed on a front surface of the back plate to contact a friction surface of the brake disc, and a disc disposed on a rear surface of the back plate to reduce braking noise, wherein a fillet weld is performed on a side surface of the disc and the rear surface of the back plate.

[0021] The back plate includes a plurality of support elements that support the disc on the rear surface of the back plate.

[0022] The support elements are arranged near four corner points of the disc, and the fillet weld is made between the support elements on four side surfaces of the disc.

[0023] The fillet weld can be made symmetrically to the disc.

[0024] According to another aspect of the present disclosure, a brake pad assembly includes a back plate facing a brake rotor, a friction pad disposed on a front surface of the back plate to contact a friction surface of the brake rotor, and a disc disposed on a rear surface of the back plate to reduce braking noise, the back plate including a plurality of support members supporting the disc on the rear surface of the back plate.

[0025] The support elements can be arranged symmetrically to the disc.

[0026] Each of the support elements can be attached to the back plate and one side of each of the support elements can be in contact with and support the disc.

[0027] The disc may have an adhesive layer on a surface of the disc that is in contact with the backing plate.

[0028] The disc may contain a copper-containing metal layer.

[0029] The disc may contain an elastic layer made of an elastic material. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Aspects of the disclosure will become clear and better understood from the following description taken in conjunction with the accompanying drawings, in which: Fig. 1 is a side view showing a brake pad assembly in which a fillet weld is performed on a side surface of a disc and a rear surface of a back plate according to a first embodiment of the present disclosure, as viewed from the side; Fig. 2 is a front view showing a state in which fillet welding is performed on the entire side surface of the disk and the rear surface of the back plate according to the first embodiment of the present disclosure, as viewed from the front; Fig. 3 is a front view illustrating a state in which fillet welding is performed on a part of a side surface of a disk and a rear surface of a back plate according to a second embodiment of the present disclosure, as viewed from the front; Fig. 4 is a front view illustrating a state in which a support member is provided on a rear surface of a back plate and a disk is in contact with and supported by the support member according to a third embodiment of the present disclosure, as viewed from the front; and Fig. 5 is a front view illustrating a state in which fillet welding is performed on a part of a side surface of a disk and a rear surface of a back plate, and a support member is provided on the rear surface of the back plate to contact and support the rear surface, according to a fourth embodiment of the present disclosure, as viewed from the front. DETAILED DESCRIPTION

[0031] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. The following embodiments are provided to fully convey the spirit of the present disclosure to those skilled in the art. The present disclosure is not limited to the embodiments disclosed herein and may be implemented in various forms. In the drawings, parts unrelated to the description may be omitted to make the present disclosure clearer, and components may be exaggerated to facilitate understanding of the present disclosure.

[0032] Fig. 1 is a side view illustrating a brake pad assembly 10 in which the fillet weld 340 is formed on a side surface of a disc 300 and a rear surface of a back plate 100 according to a first embodiment of the present disclosure, as viewed from the side, and Fig. 2 is a front view illustrating a state in which the fillet weld 340 is performed on the entire side surface of the disk 300 and the rear surface of the back plate 100 according to the first embodiment of the present disclosure, as viewed from the front.

[0033] As in the Fig. 1 and Fig. 2, the brake pad assembly 10 in a brake caliper comprises the backing plate 100, a friction pad 200 and the disc or shim or pad or intermediate layer 300.

[0034] The back plate 100 is arranged to face a brake disc, and the friction pad 200 may be arranged on a front surface of the back plate 100 and come into contact with a friction surface of the brake disc.

[0035] Because the caliper brake uses frictional force as braking force, noise and vibration are generated when the brakes are operated. A squeal, in particular, is a noise with a frequency between 1,000 Hz and 16,000 Hz, which is unpleasant for a passenger.

[0036] Disc 300 is a component used to reduce braking noise. Disc 300 is in the shape of a plate and is arranged on the rear surface of back plate 100. Disc 300 may include a metal layer 320 or an elastic layer 330 for noise reduction, and disc 300 may include an adhesive layer 310 that is in contact with back plate 100.

[0037] The metal layer 320 may contain copper. Due to its internal structure, the copper-containing metal layer 320 achieves higher damping at high temperatures compared to other materials, such as steel. Furthermore, the copper-containing metal layer 320 separates the vibrations generated by the brake in the normal, radial, and tangential directions to improve noise performance.

[0038] The elastic layer 330 may be formed from an elastic material such as rubber. The elastic layer 330 formed from an elastic material can absorb or dampen noise in a dynamic sense.

[0039] The adhesive layer 310 may be disposed on one side in contact with the backing plate 100 to secure the disc 300 to the backing plate 100.

[0040] Typically, an adhesive layer 310 in the form of an adhesive or a separate member penetrating through the disc 300 is used to firmly bond the disc 300 to the backplate 100. However, during brake operation, a problem arises in which the bond between the backplate 100 and the disc 300 loosens because the adhesive force of the adhesive layer 310 decreases due to a high temperature condition in the brake or the volume of the disc 300 decreases due to a high pressure condition in the brake. That is, there is a problem in that the disc 300 moves on the backplate 100, and thus the squeal cannot be reduced. Accordingly, the embodiments of the present disclosure use the fillet weld 340 or provide a separate support member 110 to secure the disc 300 to the backplate 100 during brake operation.

[0041] The fillet weld 340 is a welding method for joining two materials by welding a base material and another material in a triangular shape along an intersection line. In the first embodiment of the present disclosure, the fillet weld 340 is formed between the entire side surface of the washer or spacer 300 and the back surface of the back plate 100, as shown in FIGS. Fig. 1 and Fig. 2. In the disk or intermediate layer 300 in which the adhesive layer 310, the metal layer 320, and the elastic layer 330 are stacked one after the other, the fillet weld 340 can be performed only on one side surface of the adhesive layer 310 and one side surface of the metal layer 320, so that a volume change of the elastic layer 330 is not affected.

[0042] Fig. 3 is a front view illustrating a state in which a fillet weld 340 is performed on a part of a side surface of a washer 300 and a back surface of a back plate 100 according to a second embodiment of the present disclosure, as viewed from the front. Unlike the first embodiment in which the fillet weld is performed on the entire side surface of the washer 300, in the second embodiment of the present disclosure, a partial side surface of the washer 300 is welded.

[0043] When the partial fillet weld 340 is performed on the side surface of the disk 300, the fillet weld 340 may be performed symmetrically to the disk 300. However, in the present disclosure, a shape or arrangement by the partial fillet weld 340 is not limited to the embodiment of the present disclosure, and the present disclosure includes any shape or arrangement capable of firmly connecting the disk 300 to the back plate 100.

[0044] Fig. 4 is a front view illustrating a state in which a support member 110 is provided on a rear surface of a back plate 100 and a disk 300 is in contact with and supported by the support member 110 according to a third embodiment of the present disclosure, as viewed from the front.

[0045] Referring to Fig. 4, in contrast to the first and second embodiments, in the third embodiment the support element 110 is provided instead of the fillet weld 340.

[0046] The support member 110 is provided so as to protrude from the rear surface of the back plate 100. That is, the support member 110 may be fixed to the back plate 100, and one side thereof may be in contact with and support the disk 300. In this case, the support member 110 may be attached by driving a rivet or a nail into the rear surface of the back plate 100. The support member 110 fixes the disk 300 to the back plate 100 without deforming the shape of the disk 300, for example, by penetrating through the disk 300. Accordingly, the disk 300 can be stably attached to the back plate 100 even when the adhesive force of an adhesive layer 310 decreases at high temperature or when the volume of the disk changes due to compression of the disk 300 under high pressure.

[0047] The support element 110 may be provided as a plurality of support elements 110 and arranged on the rear surface of the back plate, and referring to the Fig. 4, in this case, the support elements 110 in the third embodiment of the present disclosure may be arranged near the vertices of the disk 300 and symmetrically with respect to the disk 300.

[0048] The support elements 110 have the advantage of being able to attach the disk 300 to the backing plate 100 more securely than the fillet weld 340. On the other hand, the fillet weld 340 has the advantage of being simple to implement compared to the support element 110 and can be easily used even when the support elements 110 are difficult to install depending on the type of backing plate 100.

[0049] Fig. 5 is a front view illustrating a state in which a fillet weld 340 is performed on a part of a side surface of a disk 300 and a rear surface of a back plate 100, and support members 110 are provided on the rear surface of the back plate 100 to be in contact with and support the disk 300, according to a fourth embodiment of the present disclosure, as viewed from the front.

[0050] Referring to Fig. 5, in a method for attaching the disk 300 to the backing plate 100 according to the fourth embodiment of the present disclosure, both the partial fillet weld 340 of the second embodiment and the support member 110 of the third embodiment are provided.

[0051] Specifically, according to the fourth embodiment of the disclosure, the support members 110 are arranged near four vertices of the disk 300, and the fillet weld 340 is formed between the support members 110 on four surfaces of the disk 300. In this case, the support members 110 may be arranged symmetrically, and the fillet weld 340 may be formed symmetrically with respect to the disk 300. Accordingly, both the advantage of the fillet weld 340 and the advantage of the support members 110 can be utilized when attaching the disk 300 to the back plate 100.

[0052] In the brake pad assembly 10 according to the present embodiment having such a structure, in order to fix the disc 300, which includes an adhesive layer 310, a metal layer 320, and an elastic layer 330 and is capable of reducing squeal noise, to the back plate 100, the support members 110 are provided on the back plate 100, or a fillet weld 340 is performed between the side surface of the disc 300 and the rear surface of the back plate 100. Accordingly, the disc 300 can be prevented from moving on the back plate 100 even if the adhesive force of the adhesive layer 310 decreases when the internal temperature of the brake increases or the volume of the disc 300 changes due to compression of the disc 300 under high pressure according to the operation of a brake.That is, the disc 300 can stably reduce a squeal noise by maintaining the disc 300 in a state where the disc 300 is fixed to the back plate 100. Since the fillet weld 340 is formed with a simple structure or the support members 110 have a simple structure, the manufacturing cost of the brake can be reduced, thereby improving the marketability of a vehicle.

[0053] As can be seen from the above description, a brake pad assembly is provided in which the squeal of a caliper brake is reduced.

[0054] A brake pad assembly in which the position of a disc on a backing plate is maintained even when the internal temperature increases during continuous application of a caliper brake is provided.

[0055] A brake pad assembly in which the position of a disc on a backing plate is maintained even when the disc is compressed when a caliper brake is continuously applied is provided.

[0056] A brake pad assembly in which the manufacturing cost of a brake is reduced by fixing the position of a disc on a back plate using a simple structure is provided.

Claims

[1] Brake pad assembly (10) comprising: a back plate (100) facing a brake disc; a friction lining (200) disposed on a front surface of the back plate (100) to be in contact with a friction surface of the brake disc; and a disc (300) arranged on a rear surface of the back plate (100) to reduce braking noise, wherein a fillet weld (340) is made on a side surface of the disc (300) and the back of the back plate (100) and wherein the back plate (100) comprises a plurality of support elements (110) supporting the disc (300) on the rear surface of the back plate (100), wherein the support elements (110) are arranged near four corner points of the disc (300) and the fillet weld (340) is carried out between the support elements (110) on four side surfaces of the disc (300). [2] Brake pad assembly (10) according to claim 1, wherein the fillet weld (340) is symmetrical with respect to the disc (300). [3] Brake pad arrangement (10) according to one of the preceding claims, wherein the support elements (110) are arranged symmetrically with respect to the disc (300). [4] Brake pad assembly (10) according to one of the preceding claims, wherein: each of the support elements (110) is attached to the back plate (100); and one side of each of the support elements (110) is in contact with and supports the disc (300). [5] Brake pad assembly (10) according to any one of the preceding claims, wherein the disc (300) has an adhesive layer (310) on a surface of the disc (300) that is in contact with the backing plate (100). [6] Brake pad assembly (10) according to one of the preceding claims, wherein the disc (300) has a copper-containing metal layer (320). [7] Brake pad assembly (10) according to one of the preceding claims, wherein the disc (300) has an elastic layer (330) made of an elastic material.

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