Bicycle Disk Brake Pad Integral Sintering
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Solution Overview
Problem
Conventional disk brake pads for bicycles require complex manufacturing processes and high temperatures for diffusion bonding, leading to increased hardness and potential braking noise due to the need for a copper plating layer and pressure application during heat treatment.
Innovation Solution
A disk brake pad design where the backplate and friction parts are made of a copper-based sintering alloy with specific weight percentages, allowing for integral sintering at a lower temperature without the need for a copper plating layer or pressure application, simplifying manufacturing and reducing hardness and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If diffusion bonding is used to join the friction member to the backplate, then strong bonding is achieved, but the manufacturing process becomes complicated and requires high temperature
Solution Approach 1:
The invention merges the friction member and backplate into a single integrally sintered component. By forming both parts from a copper-based sintering alloy in one sintering process, the separate joining step (diffusion bonding) is eliminated, simplifying the manufacturing process while maintaining structural integrity through integral formation.
Solution Approach 2:
The invention changes the material parameter by using a copper-based sintering alloy for both the friction member and backplate, enabling integral sintering at lower temperatures (below 900°C) compared to conventional diffusion bonding. This parameter change allows the friction member and backplate to be formed as one piece without requiring the high temperatures and complex pretreatment steps of diffusion bonding.
2Strength
If high temperature sintering is used to join the friction member, then bonding is achieved, but the hardness of the friction member increases causing braking noise
Solution Approach 1:
The invention changes the sintering temperature parameter to below 900°C, which is lower than the conventional diffusion bonding temperature. This temperature parameter change prevents excessive hardening of the friction member while still achieving sufficient bonding strength through integral sintering, thereby reducing braking noise caused by hard friction surfaces.
Solution Approach 2:
By combining the friction member and backplate into a single integrally sintered component, the invention eliminates the need for post-sintering heat treatment and joining operations that would require high temperatures. The integral structure allows the entire component to be sintered at a controlled lower temperature, preventing friction member hardening and associated noise.
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
The solution enables quieter braking and simplified manufacturing by eliminating the need for pre-treatment steps and reducing the sintering temperature, while maintaining strength and heat resistance through the use of tin in the alloy composition.
Implementation Method 1
The backplate part and the friction part are integrally sintered together as a one piece body
Data Source
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AI summary
A bicycle disk brake pad basically comprises a backplate part 77 and a friction part 79. The backplate part 77 is made of a copper-based sintering alloy. The friction part 79 is made of a copper-based sintering alloy that is integrally sintered with the backplate part 77.