Brake Pad Back Plate Retaining Element Distribution
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Solution Overview
Problem
Current manufacturing methods for brake pad back plates result in suboptimal distribution of retaining elements, leading to inadequate adhesion of friction material and increased risk of detachment during braking, particularly near the perimeter of the engaging portion, and are prone to deformation and high production costs.
Innovation Solution
A back plate design featuring transverse rectilinear parallel rows of retaining elements with elongated grooves and protrusions, where the elements are uniformly distributed at a constant distance from the perimeter, reducing the width of the free zone and enhancing heat exchange, and manufactured using equipment that minimizes deformation by orienting grooves parallel to the width of the back plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing methods are used to create retaining elements on back plates, then production can be performed with conventional equipment, but the distribution of retaining elements is suboptimal leading to inadequate adhesion of friction material
Solution Approach 1:
The retaining elements are segmented into discrete protrusions created by individual grooves, allowing each element to be independently positioned and optimized for adhesion performance
Solution Approach 2:
The grooves and protrusions are created during the manufacturing process before the friction material is applied, ensuring optimal distribution and adhesion capability from the outset
2Weight of moving object
If the free peripheral zone width is minimized to reduce weight, then the braking efficiency is improved, but the risk of friction material detachment increases due to insufficient retention near the perimeter
Solution Approach 1:
The density and distribution of retaining elements are optimized locally near the perimeter of the engaging portion, providing enhanced retention exactly where needed without increasing overall weight
Solution Approach 2:
The pattern of retaining elements is systematically distributed across the engaging portion, including near the perimeter, ensuring uniform adhesion quality throughout the friction material interface
3Ease of manufacture
If conventional manufacturing equipment is used to create grooves and protrusions, then existing production lines can be utilized, but deformation of the back plate and high production costs occur
Solution Approach 1:
The manufacturing process applies cutting forces in a controlled manner that is sufficient to create the required grooves and protrusions without excessive force that would cause deformation
Solution Approach 2:
The manufacturing process parameters are optimized to control the depth, spacing, and geometry of grooves and protrusions, ensuring consistent quality and minimizing deformation while maintaining ease of manufacture
Data Source
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AI summary
Back plate (24) for a brake pad (20) of a disc brake assembly, comprising a plate body (26) provided with a pair of opposite surfaces (28) and lateral flanks (29), an engaging portion (23) being defined on a first one of said surfaces and being delimited by a corresponding perimeter (31) and adapted to receive a friction material, said engaging portion being provided with at least a first series (G1) of rectilinear parallel rows of retaining elements (32) for said friction material, for each row of said at least first series (G1) of rows the distance measured along the axis (S) of each row between the mutually adjacent retaining elements (32) closest to the perimeter (31) of said engaging portion (23) and said perimeter (31) is constant.