Brake Pad Retention Plate Structure for Higher Shear Resistance
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Solution Overview
Problem
Conventional brake pad retention plates fail to effectively distribute shear forces, leading to peeling or shearing of brake pads, which results in uneven friction distribution and potential cracking without adequate support.
Innovation Solution
A method of forming a retention plate with a metal plate featuring a gutter and vertical tooth structure, where the tooth is deformed to create a mezzanine that extends over the gutter, providing enhanced shear resistance by forming alternating rows with retention protrusions on both sides, and using a mechanical press to solidify friction material around these features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal barbs are formed by gouging the surface in singular directions or rows, then the manufacturing process is simple, but the shear force distribution is inadequate causing brake pad peeling
Solution Approach 1:
The retention plate surface is segmented into multiple rows of gutters with alternating tooth directions, creating discrete retention features that distribute shear forces across different orientations rather than relying on single-direction barbs
Solution Approach 2:
Different regions of the retention plate have locally optimized tooth orientations - alternating rows of gutters create local variations in tooth direction to match the multi-directional stress patterns experienced by the brake pad during operation
2Reliability
If metal barbs are formed in singular directions or alternative rows, then the manufacturing process is straightforward, but friction distribution becomes uneven causing cracks
Solution Approach 1:
The retention plate employs asymmetric tooth orientations in alternating rows, where odd rows have teeth inclined one way and even rows have teeth inclined the opposite way, creating a pattern that promotes uniform friction distribution across the brake pad surface
Solution Approach 2:
The solution transitions from single-direction or simple alternating row barbs to a multi-dimensional arrangement where gutters are organized in multiple rows with alternating tooth directions, adding dimensional complexity to the retention feature pattern to improve friction distribution
3Strength
If the tooth forms an acute angle with the gutter base and extends over the gutter, then shear resistance is enhanced, but the manufacturing precision requirements increase
Solution Approach 1:
The gutter features are pre-formed with specific geometric parameters (width, length, acute angles) before the pressing operation, so that when pressure is applied to deform the teeth, they naturally form the desired mezzanine structure extending over the gutter with consistent geometry
Solution Approach 2:
The pressing operation changes the physical state and geometry of the metal tooth by applying controlled force, transforming it from a simple protrusion into a mezzanine structure with specific dimensional parameters that optimize shear resistance
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 significantly increases shear resistance in the X-Y-Z directions, preventing brake pad peeling and ensuring consistent friction distribution, thereby enhancing the durability and performance of brake pads during braking.
Implementation Method 1
A mechanical press is used to deform the tooth to form a mezzanine extending over a portion of the gutter
Data Source
AI summary
A method of making a brake pad retention plate and a brake pad retention plate is provided. The method includes upsetting a brake pad facing surface on the retention plate to form a first set of rows having a gutter, or a negative feature such as a depression in the primary plane, in the surface of the retention plate and a tooth feature on a first side of the gutter. The surface of the retention plate is upset to form a second set of rows having a gutter and a tooth feature on the second side of the gutter. The second set of rows being a single row. The second set of rows is placed adjacent to or between first set of rows. A mechanical press is used to deform the tooth to form a base portion and a mezzanine portion extending over a portion of the gutter.