Brake Lining Backing Plate Structure for Lower Weight and Space
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Solution Overview
Problem
Existing disc brake lining carrier plates are heavy and occupy significant space due to protruding contact areas, which can be reduced in weight and installation space while maintaining strength and rigidity by adopting a flat design with a closed peripheral edge and strategically positioned support areas and depressions.
Innovation Solution
The carrier plate features a flat, multi-cornered design with a closed peripheral edge on one side and support areas at a lower level, surrounded by depressions and rib-like connecting areas that transition into the support areas, potentially incorporating a honeycomb structure for enhanced strength and vibration damping, using materials like GJS with vermicular graphite for optimal rigidity and reduced material thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If protruding pressure pieces are used for support areas, then the contact area for the infeed device is increased, but the weight and installation space are significantly increased
Solution Approach 1:
The support areas are transitioned from protruding three-dimensional pressure pieces to recessed two-dimensional areas on the flat side surface of the carrier plate. This dimensional change allows the support function to be maintained while eliminating the additional weight and axial space required by protruding structures.
Solution Approach 2:
The carrier plate features locally differentiated surface structures: the friction lining carrier side remains flat, while the opposite side incorporates recessed support areas with specific geometries (circular, oval, or polygonal) at strategically positioned locations. This local modification provides targeted contact areas for the infeed device without compromising overall plate integrity.
2Weight of moving object
If the carrier plate is designed flat without protruding pressure pieces, then weight and installation space are reduced, but the strength and rigidity may be compromised
Solution Approach 1:
The recessed support areas are designed with optimized parameters including depth (0.5-5mm), diameter (10-50mm), and positioning relative to the plate edges and center. These parameter variations allow the flat plate design to achieve the required strength and rigidity while maintaining reduced weight compared to protruding structures.
Solution Approach 2:
The carrier plate is manufactured from composite materials such as GJS (gray cast iron with spherical graphite) or GGL (gray cast iron with lamellar graphite), which provide enhanced strength-to-weight ratios. The material composition includes specific elements (C: 3.0-4.0%, Si: 2.0-4.0%, Mg: 0.03-0.06%) to optimize both mechanical properties and vibration damping characteristics.
3Ease of manufacture
If conventional cast iron materials are used, then production is simplified, but vibration and noise behavior is not optimized
Solution Approach 1:
The patent employs specialized cast iron compositions (GJS with spherical graphite or GGL with lamellar graphite) that inherently provide superior vibration damping and noise reduction properties compared to conventional cast iron. The graphite structure acts as a natural vibration absorber while maintaining ease of casting production.
Solution Approach 2:
The material parameters are precisely controlled within specific ranges (carbon content 3.0-4.0%, silicon content 2.0-4.0%, magnesium content 0.03-0.06%) to optimize the graphite morphology and distribution. This parameter optimization enhances vibration and noise behavior while keeping the manufacturing process relatively simple through conventional casting methods.
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 design reduces weight and production costs while maintaining or enhancing strength, rigidity, vibration behavior, and noise performance, allowing for the use of the carrier plates in passenger vehicles with minimal material thickness and reduced machining costs.
Implementation Method 1
the vibration and noise behavior to enhance
Data Source
Figure 1a~1e
Figure 2a~2d
Figure 3a~3c
AI summary
The invention relates to a backing plate for a brake lining of a disc brake.