Brake Back Plate Inserts for Debris Removal and Pad Stress Relief
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Solution Overview
Problem
Current brake systems that condition wheel surfaces during braking often exert excessive stress on brake pads and have limitations in coverage and durability, leading to inefficiencies in debris removal and surface conditioning.
Innovation Solution
The brake system incorporates a back plate with conditioning inserts positioned at the ends, which are more rigid than the brake pads, providing increased coverage and durability, and are designed to contact the wheel surface to remove debris and smooth the surface, with features like tapered shapes and mechanical locking to enhance performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid bodies are used in brake pads to condition wheel surfaces, then surface conditioning capability is improved, but stress on brake pads increases excessively
Solution Approach 1:
The brake assembly is segmented into distinct functional components: a compliant brake pad for friction braking and a rigid conditioning insert for surface conditioning. This segmentation allows each component to perform its specific function without the drawbacks of combining them in a single rigid structure, reducing overall stress on the brake system while maintaining surface conditioning capability.
Solution Approach 2:
The rigid conditioning insert acts as an intermediary element between the brake pad and the wheel surface. It contacts the wheel surface directly to condition it, while the compliant brake pad provides the braking force. This intermediary arrangement protects the brake pad from excessive stress while enabling effective surface conditioning.
2Reliability
If rigid bodies are used in brake pads to condition wheel surfaces, then debris removal capability is improved, but durability of brake pads deteriorates
Solution Approach 1:
The brake assembly is segmented into distinct functional components: a compliant brake pad for friction braking and a rigid conditioning insert for surface conditioning. This segmentation allows each component to perform its specific function without the drawbacks of combining them in a single rigid structure, reducing overall stress on the brake system while maintaining surface conditioning capability.
Solution Approach 2:
The rigid conditioning insert is designed as a replaceable component that can be replaced independently of the brake pad. This allows the durable insert to be reused multiple times, extending the overall system lifespan while the brake pad can be replaced when worn, optimizing the durability of the entire brake assembly.
3Area of stationary object
If conditioning inserts are positioned at the ends of the back plate, then coverage area is improved, but stress distribution becomes more challenging
Solution Approach 1:
The back plate is designed with varying thickness and stiffness characteristics at different locations. The regions near the ends, where conditioning inserts are positioned, have increased thickness or reinforcement to provide additional support and stress distribution capability. This local quality enhancement allows the system to achieve both wide coverage and effective stress management.
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 stress on brake pads, improves debris removal and surface conditioning efficiency, and extends the lifespan of the brake system by distributing pressure effectively and increasing the contact area as the inserts wear down.
Implementation Method 1
conditioning inserts coupled to the back plate and configured to contact a surface of a wheel during a braking event and thereby to condition at least a portion of the surface of the wheel
Data Source
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AI summary
A vehicle brake system (100) includes a back plate (102) configured to support a composite pad (106), and at least one conditioning insert (104) coupled to the back plate (102) and configured to 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 (102) can define a U-shaped coupler (118) that is centrally located and has two ends that are distal from the coupler (118). The back plate (102) 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 (102), and the at least one conditioning insert (104) can be disposed off of the centerline so as to not be centrally disposed.