Brake Back Plate Inserts for Wheel Surface Conditioning
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Solution Overview
Problem
Existing brake systems face challenges with rigid bodies exerting excessive stress on brake pads and other shortcomings, such as inadequate coverage and durability of conditioning inserts.
Innovation Solution
The proposed brake system incorporates a back plate with projecting inserts that are mechanically coupled or integrally formed with the back plate, providing increased coverage and durability. These inserts are designed to contact the wheel surface during braking, conditioning it by removing debris and protrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid bodies are used in brake pads to condition wheel surfaces, then wheel surface conditioning is improved, but stress on brake pads increases excessively
Solution Approach 1:
The brake pad is segmented into a composite pad material and separate rigid conditioning inserts. The conditioning inserts are discrete elements embedded within or attached to the composite pad, allowing the braking function and conditioning function to be separated. This segmentation enables the rigid inserts to condition the wheel while the composite pad absorbs and distributes stress, preventing excessive stress concentration on the brake pad as a whole.
Solution Approach 2:
The brake system uses a composite pad made of multiple materials with different properties. The composite pad combines softer braking material with harder conditioning inserts, creating a multi-material structure that simultaneously provides effective braking with reduced stress and effective wheel surface conditioning. The composite structure allows each material to perform its optimal function without compromising the other.
2Reliability
If conditioning inserts are added to brake pads, then wheel surface conditioning is improved, but device complexity increases
Solution Approach 1:
The conditioning inserts are merged with the composite pad structure through embedding or attachment methods. Rather than being separate components requiring separate installation, the inserts are integrated into the pad assembly as a single unit. This merging reduces assembly complexity and ensures proper positioning of the inserts relative to the braking surface.
Solution Approach 2:
The composite pad structure serves multiple functions: it provides the braking surface, supports the conditioning inserts, distributes stress, and conditions the wheel. By making the pad multi-functional, the design avoids adding separate components for each function, thereby reducing overall device complexity while achieving wheel surface conditioning.
3Area of stationary object
If multiple conditioning inserts are positioned at different locations on the back plate, then coverage is improved, but manufacturing complexity increases
Solution Approach 1:
The conditioning inserts are pre-positioned at their final locations on the back plate during the manufacturing process. The back plate is designed with predetermined insert locations that correspond to optimal wheel surface coverage areas. This preliminary positioning during manufacturing ensures proper coverage without requiring complex post-assembly adjustments or multiple assembly steps.
Solution Approach 2:
The back plate is designed with different properties at different locations to optimize both coverage and manufacturability. Specific areas of the back plate are designed to accommodate inserts, with local features such as recesses, mounting holes, or reinforcement zones only where needed. This localized differentiation provides the necessary coverage while keeping the overall manufacturing process simple and efficient.
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 system effectively conditions the wheel surface while reducing stress on the brake pads, offering improved durability and coverage due to the strategically positioned and constructed inserts.
Implementation Method 1
Rigid bodies in the brake pads can concurrently condition the wheel surfaces by removing protrusions, debris, etc. from surfaces of the wheels
Data Source
AI summary
A vehicle brake system includes a back plate that may support a composite pad, and at least one conditioning insert coupled to the back plate and that may contact a surface of a wheel during a braking event and thereby to condition at least a portion of the surface of the wheel. Optionally, the back plate can define a U-shaped coupler that is centrally located and has two ends that are distal from the coupler. The back plate can have a centerline extending from a first end of the ends to a second end of the ends while passing through a center of the back plate, and the at least one conditioning insert can be disposed off of the centerline so as to not be centrally disposed.