Additive Brake Pad Lattice with Matched Compressibility
Solution Overview
Problem
Existing brake pads face challenges in maintaining consistent coefficient of friction and wear resistance across their tribological surfaces, leading to reduced lifespan and increased noise during vehicle operation.
Innovation Solution
A brake pad assembly featuring a base plate with a tribological lining and an enhancement framework, where the enhancement framework is designed to have a compressibility factor equal to the tribological lining, providing reinforcement and manufactured using additive techniques such as interlaced lattice structures or spring-like coils, ensuring consistent performance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a reinforcement structure is added to the friction lining, then wear resistance and noise reduction are improved, but the coefficient of friction consistency deteriorates
Solution Approach 1:
The reinforcement structure's compressibility factor is specifically engineered to match the friction lining material, creating a harmonized mechanical response that prevents disruption to friction consistency while maintaining wear resistance benefits
Solution Approach 2:
The brake pad assembly combines the friction lining material with a reinforcement structure having matched compressibility characteristics, creating a composite system where both materials work together without compromising the tribological performance
2Object-generated harmful factors
If a reinforcement structure is added to the friction lining, then noise reduction is improved, but the compressibility factor consistency deteriorates
Solution Approach 1:
The reinforcement structure is designed with a compressibility factor substantially equal to the friction lining material, ensuring that the addition of reinforcement does not create compressibility mismatches that would lead to noise and inconsistent performance
3Ease of manufacture
If traditional manufacturing methods are used for brake pads, then manufacturing simplicity is maintained, but wear resistance and lifespan deteriorate
Solution Approach 1:
The reinforcement structure is strategically disposed within the friction lining at specific locations where additional support is needed, rather than uniformly throughout, allowing targeted improvement of wear resistance while maintaining manufacturing efficiency
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 enhances the wear resistance and noise reduction of brake pads by maintaining consistent coefficient of friction and compressibility across the tribological surface, extending the brake pad's lifespan and improving operational efficiency.
Implementation Method 1
the enhancement framework is designed such that its compressibility is substantially factor equal to that of the tribological lining, such that both the tribological lining and enhancement structure at the tribological surface of the brake pad act in coordination
Implementation Method 2
the interlaced lattice structures may be manufactured using an additive manufacturing technique
Data Source
AI summary
A brake pad assembly having a consolidated lining comprised of an enhancement framework disposed within a tribological lining, the enhancement framework and tribological lining having substantially the same compressibility factor. The enhancement framework or tribological lining may advantageously be manufactured using an additive manufacturing technique.