Gas Nitriding Backing Plate for Disc Brake Pad Adhesion
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Solution Overview
Problem
Existing methods for forming a compound layer on steel back plates for automotive disc brake pads, such as nitriding, fail to achieve sufficient adhesive strength due to limitations in forming a thick porous layer, and often require additional burr removal steps that are inefficient, while also posing environmental concerns with certain methods.
Innovation Solution
A surface treatment process involving fluorine-based gas activation followed by gas nitriding or soft nitriding with ammonia gas, optimizing the treatment temperature and time to form a compound layer with a depth of 5-20 μm and a porous layer thickness of 40-80% of the compound layer depth, which enhances adhesive strength without forming excessive oxide layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional brake pad designs are used, then manufacturing is simpler, but brake pad wear and tear is excessive leading to frequent replacements
Solution Approach 1:
The backing plate is divided into a body portion and a flange portion with distinct functions. The body portion contains the brake pad material while the flange portion extends to provide structural support and mounting features. This segmentation allows each part to be optimized independently for its specific function, extending overall brake pad life.
Solution Approach 2:
The flange portion extends the backing plate structure beyond the simple flat plate configuration into a three-dimensional form with elevated edges. This dimensional change provides additional structural support and creates mounting surfaces without significantly increasing overall complexity.
2Loss of time
If brake pads are designed for durability, then replacement frequency decreases, but vehicle maintenance costs increase due to complex components
Solution Approach 1:
The mounting features, wear indicators, and structural support elements are merged into a single integrated flange portion of the backing plate. This consolidation reduces the number of separate components that need to be manufactured and assembled, simplifying production while providing durable brake pad functionality.
Solution Approach 2:
The flange portion serves multiple functions simultaneously: it provides structural support, contains mounting features for attachment to the brake assembly, and incorporates wear indicators. This multi-functionality reduces the need for separate components, easing manufacturing while extending service life.
3Reliability
If brake pads are replaced frequently, then performance is maintained, but resource waste increases from discarded components
Solution Approach 1:
The reinforced flange portion is designed to withstand stress and deformation that would normally cause premature failure. By providing this structural cushioning in advance, the brake pad can maintain reliable performance for longer periods, reducing the frequency of replacements and associated material waste.
4Manufacturing precision
If simple backing plate designs are used, then manufacturing is easier, but brake pad alignment and positioning are poor
Solution Approach 1:
The flange portion is pre-formed with specific geometric features including elevated edges and mounting surfaces during the backing plate manufacturing process. This preliminary structuring ensures proper alignment and positioning of the brake pad within the assembly before installation, improving manufacturing precision without requiring complex post-processing or assembly steps.
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 process significantly improves the adhesive strength between the friction material and the back plate, preventing reformation of oxide films and ensuring effective adhesion, thus enhancing the performance of disc brake pads under high shear forces.
Implementation Method 1
after activating the metal surface by substituting the oxide film existing on the metal surface to the fluorinated film by the fluorine based gas
Implementation Method 2
the compound layer is formed on the metal surface by ammonia gas
Data Source
AI summary
[Summary] This invention is to provide a steel back plate and a disc brake pad for a brake pad of such as an automotive car, where the back plate improves the adhesive strength between the friction material and the back plate and the disc brake pad has sufficient adhesive strength. [Means to Resolve] The steel back plate for the disc brake pad has the compound layer with the depth of 5 µ m to 20 µ m that is formed by a gas nitriding method or a gas soft nitriding method on the back plate surface on which the friction material is adhered. The compound layer has a porous layer with a thickness of 40% or more than a depth of a compound layer at the front surface layer side of the compound layer and the thickness of the oxide layer formed on the surface layer is 1 µ m or less.