Brake Pad Back Plate Thickness Gradient for Bonding Strength
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Solution Overview
Problem
Conventional brake pads have low bonding strength between the friction material and the back plate, resulting in inadequate durability and bending rigidity, particularly due to the use of heavy and costly metal or ceramic back plates, and the limitations of carbon fiber reinforced plastic alternatives.
Innovation Solution
A brake pad design featuring a back plate with a central region thicker than the end regions, formed from a resin and fiber composition, including glass fibers and specific resins like phenol or epoxy, to enhance bonding strength and durability, and integrated into a caliper device for improved braking performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal or ceramic back plates are used, then heat resistance and mechanical strength are improved, but weight and cost increase
Solution Approach 1:
The invention changes the material parameters by transitioning from metal/ceramic back plates to synthetic resin mixed with fibers (such as carbon fiber reinforced plastic). This material substitution maintains adequate mechanical strength while significantly reducing weight and cost, as explicitly stated in the background section where conventional metal/ceramic plates are replaced with lighter synthetic resin composites.
Solution Approach 2:
The invention uses composite materials by mixing synthetic resin with reinforcing fibers (carbon fibers, glass fibers, etc.) to create a back plate that combines the light weight and cost benefits of polymers with the strength and heat resistance properties of fiber reinforcements, thereby resolving the contradiction between weight reduction and maintaining mechanical strength.
2Strength
If conventional brake pad design is used, then manufacturing simplicity is maintained, but bonding strength between lining and back plate is insufficient
Solution Approach 1:
The invention applies local quality by creating a thickness gradient in the back plate where the central region is thicker than the end regions. This localized thickness variation specifically enhances bonding strength between the friction material and back plate at the central region where it is most needed, while maintaining thinner ends to reduce overall weight and complexity.
Solution Approach 2:
The invention addresses the bonding strength issue by transitioning from a uniform two-dimensional back plate design to a three-dimensional design with varying thickness. By adding the thickness dimension variation (making the central region thicker), the invention enhances bonding strength without significantly increasing overall structural complexity.
3Strength
If uniform thickness back plate is used, then manufacturing simplicity is maintained, but bending rigidity is insufficient
Solution Approach 1:
The invention applies local quality by creating a thickness gradient in the back plate where the central region is thicker than the end regions. This localized thickness variation specifically enhances bonding strength between the friction material and back plate at the central region where it is most needed, while maintaining thinner ends to reduce overall weight and complexity.
Solution Approach 2:
The invention addresses the bonding strength issue by transitioning from a uniform two-dimensional back plate design to a three-dimensional design with varying thickness. By adding the thickness dimension variation (making the central region thicker), the invention enhances bonding strength without significantly increasing overall structural complexity.
Data Source
AI summary
A brake pad 10 can brake a rotation of a disc 200. The brake pad 10 includes a friction material 12 provided on the side of the disc 200 and a back plate 11 bonded to the friction material 12 on the opposite side of the disc 200. A thickness of a central region of the back plate 11 in a rotational direction of the disc 200 is larger than thicknesses of both end regions of the back plate 11 in the rotational direction of the disc. In the case where a minimum value of the thicknesses of the end regions of the back plate 11 is defined as “h1 [mm]” and a maximum value of the thickness of the central region of the back plate 11 is defined as “h2 [mm]”, h1 and h2 preferably satisfy a relationship of “h2−h1<3”.