Brake Pad Spring Assembly for Disk Brake Squeal Suppression
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Solution Overview
Problem
Existing brake pad assemblies for disk brake systems often fail to reliably suppress squeal noises across various braking conditions due to uncontrolled relative motion between components, which is exacerbated by temperature and frequency variations.
Innovation Solution
A brake pad assembly with a pad spring attached to the guiding protrusion of the back plate, preventing direct contact between the back plate and the carrier, and allowing only relative motion in the axial direction, thereby reducing unwanted radial and tangential motion and enhancing noise dampening by ensuring a well-defined contact area and dynamic behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a steel shim is glued to the back plate to suppress squeal noises, then noise suppression is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the steel shim component entirely and instead modifies the carrier structure by integrating a damping layer directly onto the carrier surface. This extraction of the separate shim component simplifies the overall device structure while maintaining noise suppression functionality through the damping layer's viscoelastic properties.
Solution Approach 2:
The damping layer is merged with the carrier structure, creating an integrated noise suppression system. Instead of using a separate steel shim glued to the back plate, the damping material is applied directly to the carrier, combining the carrier's structural function with the damping layer's noise suppression function in a single integrated component.
2Object-affected harmful factors
If multiple components are used to improve NVH characteristics, then noise suppression is improved, but mass and manufacturing cost increase
Solution Approach 1:
The patent eliminates the steel shim component from the brake pad assembly, reducing the overall mass. By removing this additional component and relying solely on the damping layer integrated with the carrier, the solution achieves noise suppression with lower total mass compared to assemblies using both shims and separate damping elements.
Solution Approach 2:
The damping layer is implemented as a relatively simple, lightweight material applied to the carrier, replacing more massive traditional noise suppression components like steel shims. This approach uses lighter materials that provide adequate noise suppression without the mass penalty of traditional metal-based solutions.
3Object-affected harmful factors
If traditional noise suppression solutions are used, then squeal noise is reduced under specific conditions, but reliability across various braking conditions deteriorates
Solution Approach 1:
The patent utilizes the viscoelastic properties of the damping layer, which change with temperature and frequency. By selecting a damping material whose viscoelastic characteristics vary appropriately across different temperature ranges and vibration frequencies, the system maintains effective noise suppression under diverse braking conditions including cold and warm temperatures, as well as low and high frequency squeal.
Solution Approach 2:
The damping layer is made from viscoelastic material that combines the properties of viscosity and elasticity, allowing it to dissipate vibrational energy effectively across a wide range of frequencies and temperatures. This composite material behavior enables the damping layer to adapt its mechanical properties to match the varying operating conditions of the brake system.
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 reduces squeal noise generation by minimizing uncontrolled relative motion between components, achieving a compact, robust, and low-mass brake pad assembly with improved noise dampening characteristics across different braking conditions.
Implementation Method 1
a pad spring configured to be arranged between the guiding protrusion of the back plate and the guiding recess of the carrier
Implementation Method 2
The pad spring may be configured to prevent direct contact between the back plate and the carrier... the noise dampening behavior of the brake system may be improved
Data Source
AI summary
The application relates to a brake pad assembly (10) for a disk brake system and to a disk brake system. The proposed brake pad assembly (10) comprises a back plate (5) having a front side (4) for facing a brake disk (1) of the disk brake system and a friction layer (3) arranged on the front side (4) of the back plate (5) for contacting a friction surface of the brake disk (1). The back plate (5) comprises a guiding protrusion (9) configured to be slidably received within a guiding recess (19) of a carrier (20) of the disk brake system. The brake pad assembly (10) further comprises a pad spring (16) configured to be arranged between the guiding protrusion (9) of the back plate (5) and the guiding recess (19) of the carrier (20). The pad spring (16) is attached to the guiding protrusion (9) of the back plate (5).