Brake Pad Backing Plate Non-Uniform Recesses
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Solution Overview
Problem
Existing methods for preventing detachment of friction material from brake pad backing plates are not effective across varying parameters such as steel type, friction material composition, and brake disc size, leading to inconsistent adhesion and potential loss of braking effect.
Innovation Solution
A method involving coining to create a smooth surface with non-uniformly distributed engagement recesses on the backing plate, optimized based on specific parameters, which enhances adhesion without protrusions or asperities, allowing for precise distribution and orientation of recesses to counteract applied forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protrusions are made on the front surface of the backing plate to receive friction material, then adhesion of friction material is improved, but manufacturing complexity and cost increase due to material deposition or welding processes
Solution Approach 1:
Instead of adding protrusions to the backing plate surface, the invention inverts the approach by creating engagement recesses (depressions) in the backing plate. The friction material fills these recesses during application, creating mechanical interlocking without requiring complex protrusion formation processes like welding or material deposition. This simplifies manufacturing while maintaining adhesion reliability.
Solution Approach 2:
The invention extracts the engagement features from the friction material side rather than the backing plate side. By creating recesses in the backing plate and allowing the friction material to fill them naturally during application, the solution eliminates the need for complex protrusion formation processes, reducing manufacturing complexity while achieving reliable adhesion.
2Reliability
If engagement recesses are made by material removal using movable blades, then adhesion is improved through created asperities, but manufacturing precision decreases due to random distribution of protrusions
Solution Approach 1:
Instead of creating protrusions through material removal with movable blades (which results in random distribution), the invention inverts the approach by precisely forming engagement recesses using a stamping die. This allows controlled, uniform distribution of recesses across the backing plate surface, improving manufacturing precision while maintaining adhesion reliability.
Solution Approach 2:
The engagement recesses are preliminarily formed in the backing plate before friction material application using a stamping die. This preliminary action ensures precise, uniform distribution of engagement features, eliminating the random distribution problem associated with movable blade methods while maintaining reliable adhesion.
3Reliability
If the free peripheral zone width is increased to prevent friction material detachment, then reliability is improved, but weight increases due to greater total area of the backing plate
Solution Approach 1:
Instead of uniformly increasing the free peripheral zone width across the entire backing plate, the invention applies engagement recesses locally at specific positions where friction material detachment is most likely to occur. This localized approach provides enhanced adhesion where needed without unnecessarily increasing the overall backing plate area and weight.
Solution Approach 2:
The invention uses a stamping die to copy the engagement recess pattern onto the backing plate. This copying process allows precise replication of the optimal recess distribution pattern, providing reliable detachment prevention without requiring increased backing plate dimensions, thus avoiding unnecessary weight increase.
4Manufacturing precision
If a regular matrix of engagement recesses is used, then manufacturing precision is improved through uniform distribution, but adaptability decreases for different braking conditions and force distributions
Solution Approach 1:
The invention transitions from a uniform regular matrix to a non-uniform distribution of engagement recesses, with varying density and positioning tailored to local requirements. Areas subject to higher shear forces or vibration have denser or strategically positioned recesses, while other areas have fewer recesses. This local quality approach maintains manufacturing precision through controlled formation while significantly improving adaptability to different braking conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach improves the uniformity and effectiveness of friction material adhesion, reducing detachment risks and production costs while maintaining flexibility in manufacturing processes.
Implementation Method 1
at least one coining step and one blanking step are carried out with a mold
Data Source
Figure 1~6B
Figure 2
Figure 3A~3C
AI summary
Method of obtaining a backing plate (11) for a brake pad (13), comprising the steps of: providing a band (113) of a material suitable for the making of the backing plate (11); carrying out, on said band (113), the blanking of the backing plate (11) so as to define, on said backing plate (11), a front surface (11a) and a back surface (lib) essentially parallel to each other, the flat front surface (11a) being adapted to receive a layer of friction material; carrying out, on said band (113), the coining of a plurality of engagement recesses (19) on the front surface (11a); characterized in that the engagement recesses (19) are distributed over the front surface (19a) in a non-uniform way and in accordance with a predetermined pattern.