Multi-Layer Brake Pad Assembly for Rust-Resistant Bonding
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Solution Overview
Problem
Conventional brake pad manufacturing processes face challenges with friction pad delamination due to rust on bare steel backing plates, requiring additional coatings and complex texturing to prevent delamination, which complicates the assembly process and increases energy consumption.
Innovation Solution
A method for assembling brake pads using pre-formed multi-layer friction pads with a soft first layer and standard friction material, where the first layer is pierced by texturized backing plate members, and a shim is secured concurrently, allowing for a single-step assembly at room temperature without heating, reducing energy consumption and greenhouse gas emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bare steel backing plates are used, then manufacturing cost is reduced, but rust-related delamination occurs
Solution Approach 1:
The friction pad is segmented into multiple layers with different properties. The first layer (softer, more compliant) is positioned adjacent to the backing plate to prevent delamination, while the second layer (standard friction material) provides braking function. This segmentation allows each layer to perform its specific function optimally.
Solution Approach 2:
The friction pad uses composite material construction with at least two layers of different materials. The first layer has different mechanical properties (softer, more compliant) compared to the second layer (standard friction material), creating a composite structure that combines delamination prevention with effective friction performance.
2Reliability
If texturized surfaces and coatings are applied to backing plates, then delamination resistance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
Instead of complicating the backing plate surface, the solution segments the friction pad into layers, placing the softer first layer adjacent to the backing plate. This simple interface requires no surface treatment of the backing plate while still preventing delamination.
Solution Approach 2:
The delamination prevention function is extracted from the backing plate surface treatment and transferred to the friction pad material selection and layering. The backing plate remains simple bare steel, while the friction pad's first layer provides the delamination resistance.
3Manufacturing precision
If batch heat treatment processes are used, then friction pad curing is achieved, but energy consumption and production time increase
Solution Approach 1:
The friction pad material composition is designed to cure at lower temperatures or through alternative mechanisms that do not require high-temperature batch heat treatment. The material itself provides the curing pathway, reducing external energy input requirements.
Solution Approach 2:
The curing process parameters are changed from high-temperature batch treatment to lower temperature or alternative curing methods. This may involve adjusting the material composition to enable curing at reduced temperatures or through different chemical pathways.
4Strength
If multi-layer friction pads with soft first layer are used, then mechanical bond strength is enhanced, but manufacturing complexity increases
Solution Approach 1:
The friction pad is divided into functional segments (layers) where each layer has a specific purpose. The first layer provides bond strength, the second layer provides friction performance. This functional segmentation achieves high bond strength while keeping the manufacturing process relatively simple through standardized layering.
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 approach enhances the mechanical bond between the friction pad and backing plate, reduces rust-related delamination, and streamlines the manufacturing process by enabling efficient, continuous assembly of brake pads with reduced energy use and lower carbon footprint.
Implementation Method 1
A friction pad is secured to the rotor facing surface. The friction pad includes a first layer of a first material impaled on the piercing members, and a second layer of a friction material adjacent the first layer.
Data Source
AI summary
A method of assembling a brake pad includes impaling a first layer of a preformed multi-layer friction pad on piercing members of a rotor facing surface of a brake pad backing plate. A shim is concurrently assembled to a caliper facing surface of the backing plate.