Brake Pad Backing Plate with Integral Piercing Barbs
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Solution Overview
Problem
Existing brake pad manufacturing methods face challenges in securely attaching friction pads to backing plates due to differences in physical properties between materials, requiring techniques that are not readily usable or increasing the weight and energy required for production.
Innovation Solution
A multilayer metal composite is created by using a thin metal substrate layer with protrusions that can be easily secured to a thicker backing plate, allowing for the attachment of friction pads without significantly increasing the brake pad's weight or energy needed for manufacturing, and enhancing the bond between the friction pad and backing plate through piercing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing methods are used to attach friction pads to backing plates, then secure attachment is achieved, but manufacturing complexity and energy requirements increase
Solution Approach 1:
The backing plate is segmented with multiple piercing members distributed across its surface, dividing the attachment function into discrete localized points rather than requiring a continuous complex bonding process. Each piercing member independently secures the friction pad, simplifying the overall manufacturing process while maintaining secure attachment.
Solution Approach 2:
The piercing members are self-forming structures that create their own attachment mechanism through the piercing action. The barbs formed on the friction pad material during piercing automatically provide retention without requiring additional fastening steps, adhesives, or complex assembly operations, thereby reducing manufacturing complexity and energy requirements.
2Reliability
If piercing members are used to attach friction pads to backing plates, then attachment security is improved, but weight may increase
Solution Approach 1:
The piercing members are formed as thin, flexible barbs that penetrate the friction pad material. These thin-film structures provide effective mechanical interlocking and retention while minimizing additional mass. The barbs are designed to be sufficiently thin to avoid significant weight increase but sufficiently robust to maintain attachment security under braking loads.
3Strength
If metal substrate layer with protrusions is used, then structural support is enhanced, but manufacturing energy requirements may increase
Solution Approach 1:
The backing plate and piercing members are combined into a single integrated component, eliminating the need for separate manufacturing and assembly steps for attaching the piercing members. This merging reduces manufacturing energy by consolidating production into one process while maintaining the structural support function of the backing plate and the attachment function of the piercing members.
Solution Approach 2:
The piercing members are self-forming structures that create their own attachment mechanism through the piercing action. The barbs formed on the friction pad material during piercing automatically provide retention without requiring additional fastening steps, adhesives, or complex assembly operations, thereby reducing manufacturing complexity and energy requirements.
Data Source
AI summary
A multilayer metal composite includes a metal base layer having a base layer surface textured with a plurality of integral base layer barbs, and a metal substrate layer having a substrate layer surface textured with a plurality of integral substrate layer barbs. The substrate layer is impaled on the base layer barbs to secure the substrate layer to the base layer.