Brake Pad Counterweight Locking to Prevent Rotation Under Vibration
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Solution Overview
Problem
Existing methods for attaching counterweights to brake pad support plates are inadequate due to rotation issues under stress and vibration, requiring high precision and increasing production time and cost.
Innovation Solution
A brake pad design with counterweights rigidly fixed to support plates via protrusions inserted into holes, where the protrusions are partially housed in grooves on the support plate, preventing rotation and forming a rigid body with the plate, using machining or stamping to create grooves that offer significant resistance to tangential stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protrusions are inserted into holes to fix counterweights to support plates, then the counterweights can be attached to modify vibration, but the counterweights rotate in the holes under stress and vibration over time
Solution Approach 1:
The invention introduces grooves with asymmetric cross-sections (trapezoidal or rectangular) that do not match the circular cross-section of the holes. This asymmetry prevents the protrusions from rotating within the holes, as the non-circular groove geometry provides mechanical interference in the rotational direction while allowing insertion. The asymmetric shape creates inherent resistance to rotation, solving the reliability issue without requiring high precision alignment.
Solution Approach 2:
The groove acts as an intermediary element between the hole and the protrusion. While the hole provides the insertion path, the groove provides the locking mechanism that prevents rotation. This intermediary structure mediates between the simple circular hole and the need for rotation prevention, allowing the protrusion to be securely fixed without requiring complex features directly in the hole or protrusion.
2Reliability
If high precision is used to arrange protrusions in holes, then counterweights can be fixed effectively, but production time increases and manufacturing cost increases
Solution Approach 1:
The asymmetric groove geometry provides inherent alignment guidance during assembly. The trapezoidal or rectangular cross-section naturally guides the protrusion into the correct position during insertion, eliminating the need for high-precision pre-alignment. This reduces assembly time and complexity while maintaining secure fixation, as the groove shape itself provides the positioning function that previously required precise hole placement.
Solution Approach 2:
Instead of trying to achieve secure fixation through precise alignment of circular features (holes and protrusions), the invention inverts the approach by using a non-circular groove that inherently prevents rotation. This inversion of the geometric approach simplifies the assembly process, as the groove's asymmetric shape provides self-aligning and self-locking characteristics that do not require high precision manufacturing.
3Object-generated harmful factors
If counterweights are fixed to support plates, then vibration and noise are reduced, but the fixing mechanism must withstand large stresses and repeated vibrations
Solution Approach 1:
The asymmetric groove cross-section creates mechanical interference that resists rotational forces generated during braking. The trapezoidal or rectangular shape provides lateral walls that contact the protrusion, creating friction and geometric interference that prevent rotation under stress. This asymmetric geometry distributes the stress more effectively compared to a simple circular hole, enhancing the fixing strength while maintaining vibration reduction.
Solution Approach 2:
The invention uses non-circular (non-spheroidal) groove cross-sections with specific angular characteristics (trapezoidal or rectangular shapes). These curved or angled geometries provide better stress distribution and mechanical interlocking compared to circular features. The specific shape characteristics create optimal contact surfaces that withstand repeated vibrations and large stresses while preventing counterweight rotation.
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 effectively prevents counterweight rotation and enhances braking efficiency by forming a rigid body with the support plate, reducing noise and increasing braking effectiveness while simplifying the manufacturing process and reducing production costs.
Implementation Method 1
these techniques are based on the friction between external shapes of the protrusions housed in the holes and the internal walls of the holes themselves to fix the relative position of the counterweights with respect to the support plates
Implementation Method 2
the brake pad is provided with at least one of the counterweights fixed on the support plate exerting compression on said support plate together through the first face and the protrusion
Implementation Method 3
offer resistance to rotation due to friction on a bottom of the grooves, which is the most depressed part of the grooves with respect to the second surface, offer a large degree of resistance due to the frontal contact with several sides of the grooves
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5D
AI summary
The invention relates to a brake pad for brake disc, and for a method for producing said brake pad, which comprises a support plate (1) with a first surface (1.1), a second surface (1.2) and at least one hole (3) that extends from the first surface (1.1) to the second surface (1.2); at least one counterweight (5) rigidly connected to the support plate (1) to modify a vibration of the support plate (1), with the counterweight (5) having a first face (5') facing the first surface (1.1) and a protrusion (6) that projects from the first face (5') and has a free end (6'), with the protrusion (6) being inserted into the hole (3); and at least one groove (4) in the second surface (1.2) in a region near the hole (3), wherein the protrusion (6) is partially embedded in the groove (4).