Brake Module Friction Layer for Stable Braking Force
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Solution Overview
Problem
Existing brake modules for drive systems, particularly in vehicle doors, face issues with non-constant braking force over their service life and temperature dependence, which affects operational reliability and longevity.
Innovation Solution
The implementation of a brake module with friction surfaces formed from fiber-reinforced or carbon-reinforced materials, including a zigzag spring for uniform pressure, and a carrier made of cost-effective plastic, reduces temperature dependence and enhances the predictability and consistency of braking force, thereby extending the service life and improving operational reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional friction materials (sintered steel and nitrided chrome steel) are used for brake disc and thrust washer, then the brake module can be manufactured with standard materials and processes, but the braking force becomes non-constant over service life and temperature-dependent
Solution Approach 1:
The patent applies composite materials by combining a thermoplastic carrier material with friction particles (such as sintered metal particles, ceramic particles, or carbon particles) to form a friction layer. This composite structure provides both mechanical stability from the thermoplastic matrix and consistent friction characteristics from the embedded particles, resulting in temperature-independent braking force and constant performance over service life.
Solution Approach 2:
The patent changes the material parameters by selecting a thermoplastic carrier with specific flow characteristics and melting behavior that compensates for thermal expansion and maintains constant contact pressure between friction surfaces. The friction layer composition is optimized to maintain stable friction coefficients across temperature ranges, transforming the temperature-sensitive behavior into temperature-stable performance.
2Reliability
If fiber-reinforced or carbon-reinforced friction layers are used, then temperature dependence is reduced and braking force consistency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes the porous structure of sintered metal particles or ceramic particles within the thermoplastic matrix to create a friction layer that maintains porosity for lubricant retention while providing consistent friction. The porous structure is formed during sintering or particle bonding, creating a self-contained friction material that requires minimal additional processing steps.
Solution Approach 2:
The composite of thermoplastic carrier with embedded friction particles creates a material that can be processed using conventional injection molding or extrusion techniques followed by a simple sintering or heat treatment step. This two-stage process maintains manufacturing ease while achieving the performance benefits of fiber or carbon reinforcement.
3Manufacturing precision
If a zigzag spring is used to press thrust washers against the brake disc, then uniform pressure distribution is achieved, but device complexity increases
Solution Approach 1:
The zigzag spring utilizes a curved or serpentine geometry instead of a straight linear spring. This curved configuration naturally distributes the applied force uniformly across the contact surface between the thrust washer and brake disc. The zigzag pattern acts as a mechanical compliance element that equalizes pressure distribution through its geometric configuration rather than requiring complex multi-component assemblies.
4Ease of manufacture
If the carrier is made of thermoplastic material, then cost is reduced and ease of manufacture is improved, but high-temperature resistance may be compromised
Solution Approach 1:
The thermoplastic carrier is combined with high-temperature-resistant friction particles such as sintered metal particles, ceramic particles, or carbon particles. This composite structure allows the thermoplastic matrix to provide cost-effective manufacturing and structural integrity, while the embedded particles contribute high-temperature stability and friction resistance, compensating for the thermoplastic's lower inherent thermal resistance.
Solution Approach 2:
The patent selects thermoplastic materials with specifically elevated melting points and thermal stability parameters, such as polyetheretherketone (PEEK) or other high-performance thermoplastics. These materials maintain structural integrity at elevated temperatures while retaining the manufacturing advantages of thermoplastic processing. The friction layer composition is also optimized to maintain stable friction coefficients across the operating temperature range.
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 solution provides a more consistent and predictable braking force, reduces temperature dependence, and extends the service life of the brake module, making it more reliable and efficient across varying operating conditions.
Implementation Method 1
at least one thrust washer and at least one brake disc, wherein the at least one thrust washer and the at least one brake disc each have at least one friction surface rubbing against each other during braking operation
Implementation Method 2
a zigzag spring for uniform pressure
Data Source
AI summary
A brake module for a drive system, in particular for doors, including at least one thrust washer and at least one brake disc, wherein the at least one thrust washer and the at least one brake disc each have at least one friction surface rubbing against each other during braking operation is provided. The embodiments also relate to a drive system, in particular for doors, including such a brake module. The embodiments further relate to a production method for a brake module of the abovementioned type. Known brake modules have a high variation in the braking force on the one hand in the course of their service life and on the other hand as a function of the temperature.