Disc Brake Pad Scorch Pattern for Fade Resistance and Braking Grip
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Solution Overview
Problem
Existing disc brake pads experience a reduction in braking effectiveness known as the fading phenomenon due to the thermal decomposition of organic substances at high temperatures, which conventional scorch treatments fail to adequately address, particularly in the central area of the friction surface.
Innovation Solution
The disc brake pad features a friction surface with mixed areas of different heat histories from scorch treatment, including areas with large and relatively small heat histories, ensuring partial removal of organic substances like cashew dust to prevent fading while maintaining adhesive friction and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If scorch treatment is performed on the friction surface to remove organic substances, then fading phenomenon is prevented, but braking effectiveness is reduced due to loss of adhesive friction
Solution Approach 1:
The friction surface is divided into two distinct regions with different organic substance compositions: a first region containing cashew dust that provides adhesive friction for braking effectiveness, and a second region free from cashew dust that prevents fading phenomenon. This local differentiation allows each region to fulfill its specific function without compromising the other.
Solution Approach 2:
The friction surface is segmented into functionally distinct zones: a central region (first region) with organic friction modifiers for adhesive friction, and an outer region (second region) without organic friction modifiers for fade resistance. This segmentation resolves the contradiction by assigning different properties to different parts of the same surface.
2Reliability
If uniform scorch treatment is applied to the entire friction surface, then fading is prevented, but the cashew dust film cannot form on the rotor reducing braking effectiveness
Solution Approach 1:
The friction surface is designed with non-uniform organic substance distribution: the first region contains cashew dust for forming adhesive films during braking, while the second region is free from cashew dust to prevent fading. This local quality differentiation ensures both braking effectiveness and fade resistance coexist.
Solution Approach 2:
Instead of completely removing organic substances from the entire friction surface (excessive action), the invention applies selective removal only from the second region while preserving cashew dust in the first region (partial action). This partial approach maintains the necessary adhesive friction while preventing fading in the outer region.
3Reliability
If organic substances are completely removed from the friction surface, then fading phenomenon is eliminated, but adhesive friction and stable braking effectiveness are lost
Solution Approach 1:
The friction surface exhibits local quality variation with the first region containing organic friction modifiers (cashew dust) for stable adhesive friction, and the second region free from organic substances for fade resistance. This spatial differentiation preserves braking stability where needed while eliminating fading where organic substances would be harmful.
Solution Approach 2:
The friction surface is segmented into functional zones: a central region preserving organic substances for braking stability and an outer region without organic substances for fading resistance. This segmentation allows the system to simultaneously achieve both stability and fade resistance through regional specialization.
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 effectively prevents fading and maintains sufficient braking effectiveness by allowing the formation of a cashew dust film on the rotor, enhancing adhesive friction and providing stable braking performance.
Implementation Method 1
a gas or liquid decomposition product is generated when organic substances such as the binder and the organic friction modifier contained in the friction material of the disc brake pad are exposed to a high temperature and high load condition and are thermally decomposed
Implementation Method 2
it is known to use a scorch treatment that uses such as a heating plate, flame throw and laser irradiation to perform a high temperature heat treatment on the friction surface of the friction material and burns to remove the organic substances
Implementation Method 3
The cashew dust forms a film on the friction surface of the disc rotor and functions to provide an excellent and stable braking effectiveness as generating an adhesive friction between the disc brake pad and the friction surface
Data Source
AI summary
[Object]To provide the disc brake pad including the friction material having the friction surface with the scorch treatment that can provide sufficient braking effectiveness while preventing the fading phenomenon at the initial stage of the disc brake pad usage.[Means to Resolve]In the disc brake pad including the friction material having the friction surface with the heat history due to the scorch treatment, the friction surface has the mixed areas including the area with the large heat history of the scorch treatment and the area with relatively small heat history of the scorch treatment. The following formula needs to be satisfied where the reduction rate of the mass of the inside of the friction material without the heat history due to the scorch treatment when performing the thermogravimetric analysis of the friction material at 500 centigrade is A, the reduction rate of the mass of the friction surface area with the largest heat history due to the scorch treatment when performing the thermogravimetric analysis at 500 centigrade is B1, and the reduction rate of the mass of the friction surface area with the relatively small heat history due to the scorch treatment relative to the friction surface area with the largest heat history when performing the thermogravimetric analysis at 500 centigrade is B2. 30≤B1/A×100≤90 50≤B2/A×100 B2/A×100−B1/A×100≤60 Formula: