Brake Pad Insulating Layer Segmentation for Drag Reduction
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Solution Overview
Problem
Conventional brake pad apparatuses experience increased drag torque and brake fluid consumption due to the pressing member engaging the insulating layer, which affects brake assembly performance and fuel economy.
Innovation Solution
The brake pad apparatus features a backing plate with a liner for frictional contact and an insulating layer for noise and heat insulation, along with projections extending through the insulating layer to be directly engaged by the pressing member, avoiding contact with the insulating layer and maintaining its damping properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the insulating layer covers the area directly aligned with the contact face of the piston, then noise and heat insulation is improved, but drag torque and brake fluid consumption increase
Solution Approach 1:
The insulating layer is segmented by creating openings that expose the backing plate in specific areas. This segmentation allows the pressing member to contact the backing plate directly through the openings while the insulating layer remains intact in other areas to provide noise and heat insulation. The insulating layer is divided into functional zones: insulated areas for noise/heat reduction and open areas for low-drag contact.
Solution Approach 2:
Different regions of the brake pad apparatus are given different properties. The insulating layer is applied locally to areas where noise and heat insulation are needed, while specific local areas (openings) are left exposed to provide low-drag contact surfaces. The pressing member contact areas have different properties (direct metal-to-metal contact) compared to the insulated areas.
2Object-affected harmful factors
If the insulating layer covers the area directly aligned with the contact face of the piston, then noise and heat insulation is improved, but brake fluid consumption increases
Solution Approach 1:
The insulating layer is segmented by creating openings that expose the backing plate in specific areas. This segmentation allows the pressing member to contact the backing plate directly through the openings while the insulating layer remains intact in other areas to provide noise and heat insulation. The insulating layer is divided into functional zones: insulated areas for noise/heat reduction and open areas for low-drag contact.
Solution Approach 2:
Different regions of the brake pad apparatus are given different properties. The insulating layer is applied locally to areas where noise and heat insulation are needed, while specific local areas (openings) are left exposed to provide low-drag contact surfaces. The pressing member contact areas have different properties (direct metal-to-metal contact) compared to the insulated areas.
3Stability of the object's composition
If the pressing member engages the insulating layer, then the insulating layer provides damping properties, but drag torque and brake fluid consumption increase
Solution Approach 1:
The insulating layer is segmented by creating openings that expose the backing plate in specific areas. This segmentation allows the pressing member to contact the backing plate directly through the openings while the insulating layer remains intact in other areas to provide noise and heat insulation. The insulating layer is divided into functional zones: insulated areas for noise/heat reduction and open areas for low-drag contact.
Solution Approach 2:
The openings in the insulating layer act as intermediaries that allow direct contact between the pressing member and backing plate. The insulating layer itself serves as a mediator that provides damping and insulation properties in areas where it remains intact, while allowing mechanical contact through the openings. This intermediary structure resolves the conflict between damping and low drag.
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 design reduces brake drag and fluid consumption, enhancing brake assembly performance and contributing to improved fuel economy and brake pedal feel.
Implementation Method 1
A liner is connected to the inside surface of the backing plate for contacting the rotor for creating a frictional force against the rotor to reduce the speed of the vehicle
Implementation Method 2
An insulating layer is connected to the outside surface of the backing plate for providing heat and noise insulation to the backing plate during contact of the liner against the rotor
Implementation Method 3
An insulating layer is connected to the outside surface of the backing plate for providing heat and noise insulation to the backing plate during contact of the liner against the rotor
Data Source
AI summary
The invention provides for a brake pad apparatus for connecting to a brake assembly of a motor vehicle. The brake pad apparatus includes a backing plate that extends along a first plane and has an inside surface and an outside surface. A liner is connected to the inside surface of the backing plate for contacting the rotor for creating a frictional force against the rotor to slow the motor vehicle. An insulating layer is connected to the outside surface of the backing plate for providing heat and noise insulation during contact of the liner against the rotor. At least one projection extends from the outside surface of the backing plate through the insulating layer, and past the insulating layer for being engaged by a pressing member of the brake assembly for compressing the liner against the rotor of the brake assembly.