Disk Brake Pad Backplate Structure for Lightweight Force Resistance
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Solution Overview
Problem
Existing brake pads for disk brakes face challenges in reducing weight while maintaining strength and stability, which is essential for fuel efficiency and extended service life, as they are prone to lateral and gravitational forces due to thin web dimensions and inadequate anchoring of the frictional mass.
Innovation Solution
A brake pad design featuring a pad backplate with a structural arrangement of recesses and elevations of varying shapes and sizes, arranged in specific patterns to enhance stability and distribute forces effectively, including hexagonal honeycomb structures and spoke wheel arrangements, which also reduces material usage and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the web dimensions are reduced to save weight, then the weight of the brake pad is reduced, but the resistance to lateral and gravitational forces deteriorates
Solution Approach 1:
The pad backplate is segmented into a modular structural arrangement comprising multiple recesses and elevations of varying shapes and sizes. This segmentation creates a lightweight lattice structure that maintains strength through geometric distribution of material, allowing weight reduction while preserving resistance to lateral and gravitational forces.
Solution Approach 2:
The structural arrangement features local variations in material distribution with recesses and elevations of different shapes and sizes positioned at specific locations. This local quality optimization ensures that material is concentrated where needed for strength while minimizing weight in less critical areas, resolving the contradiction between weight reduction and force resistance.
2Weight of moving object
If thin web dimensions are used to reduce weight, then the weight of the brake pad is reduced, but the anchoring of the frictional mass becomes inadequate
Solution Approach 1:
The anchoring structure is segmented into multiple recesses and elevations that collectively provide sufficient anchoring surface area and mechanical interlocking. This segmentation allows the frictional mass to be securely anchored through distributed engagement points rather than relying on thick continuous webs.
Solution Approach 2:
The structural arrangement combines the pad backplate material with the frictional mass through a composite anchoring interface created by the recesses and elevations. This composite structure enhances the bonding and mechanical interlocking between components, ensuring reliable anchoring despite reduced web dimensions.
3Ease of manufacture
If uniform structural elements are used, then the manufacturing process is simplified, but the stability and strength of the connection are insufficient
Solution Approach 1:
The structural arrangement employs varying shapes and sizes of recesses and elevations at different locations to optimize connection stability. This local variation in geometry enhances mechanical interlocking and distribution of stresses while maintaining a relatively simple manufacturing process through standardized production methods.
Solution Approach 2:
The parameters of the structural elements (shape, size, distribution) are optimized to achieve the required connection stability. By carefully selecting and varying these parameters, the design achieves enhanced stability and strength without significantly complicating the manufacturing process.
Data Source
AI summary
A brake pad for a disk brake for a utility vehicle, includes a pad backplate, which has a pad side with a frictional mass and an application side opposite the pad side. The pad side is provided with a structural arrangement having a plurality of recesses with elevations arranged therein. The structural arrangement of the pad side comprises structural elements which differ in shape and size.