Brake Pad Back Plate With Copper-Rubber Damping for Squeal Control
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Solution Overview
Problem
Existing brake pad assemblies for disk brake systems struggle to reliably suppress squeal noises across a wide range of braking conditions, with existing solutions often being effective only under specific conditions such as low or high frequency, cold or warm temperatures.
Innovation Solution
A brake pad assembly with a back plate featuring a recess containing a layered structure of copper and rubber layers, which improves noise damping by decoupling vibrational modes and providing a compact, robust design, allowing direct contact with the brake piston or caliper finger for enhanced noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing noise suppression solutions (steel shim, chamfers, slots) are used, then squeal noise is reduced under specific conditions, but the solution is not reliable across a wide range of braking conditions
Solution Approach 1:
The patent uses a composite layered structure consisting of a copper layer and a rubber layer. The copper layer provides damping through material properties, while the rubber layer adds viscoelastic damping characteristics. This composite structure enables reliable noise suppression across a wide range of braking conditions including different temperatures and frequencies, overcoming the limitation of single-material solutions.
Solution Approach 2:
The patent changes the physical and material parameters of the back plate by introducing a layered structure with different material properties (copper and rubber layers). This allows the system to adapt to different braking conditions (temperature, frequency) by utilizing the combined damping characteristics of the layered materials, achieving reliable noise suppression across varying parameters.
2Object-generated harmful factors
If additional shims are added to suppress noise, then noise reduction is achieved, but the device complexity and width increase
Solution Approach 1:
The patent merges the noise suppression function directly into the back plate by integrating a layered structure (copper layer and rubber layer) within the back plate body. This eliminates the need for separate additional shims, reducing device complexity while achieving effective noise reduction through the combined damping properties of the layered materials.
Solution Approach 2:
The patent nests the layered structure (copper layer and rubber layer) within the back plate body, placing one material layer inside another and within the back plate structure. This nested arrangement achieves noise suppression without increasing overall device width or complexity, as the damping layers are integrated within the existing back plate geometry.
3Object-generated harmful factors
If additional shims are added to suppress noise, then noise reduction is achieved, but the width of the caliper bridge increases
Solution Approach 1:
The patent combines the noise suppression function with the back plate structure by integrating the layered copper and rubber layers directly into the back plate. This eliminates the need for separate shims that would increase caliper bridge width, achieving noise reduction while maintaining a compact width suitable for space-constrained brake systems.
Solution Approach 2:
The layered structure is nested within the back plate body, with the copper layer and rubber layer positioned inside the back plate geometry. This nested configuration achieves noise suppression without protruding beyond the back plate boundaries, thereby avoiding an increase in caliper bridge width and enabling compact brake system design.
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 layered structure effectively reduces squeal noises across various braking conditions by improving dynamic behavior and damping characteristics, enabling a compact arrangement and homogeneous force distribution for efficient noise suppression.
Implementation Method 1
The layered structure in the recess of the back plate body improves the dynamic behavior of the disk brake system to reduce the squeal noises, e.g., at hot temperatures. The layered structure in the recess may improve a global damping characteristic and reduce a sound pressure level among a wide frequency range by decoupling the vibrational modes in the normal, radial, and tangential directions, while using beneficial material damping properties of copper.
Implementation Method 2
The layered structure in the recess may improve a global damping characteristic and reduce a sound pressure level among a wide frequency range by decoupling the vibrational modes in the normal, radial, and tangential directions, while using beneficial material damping properties of copper.
Data Source
AI summary
The application relates to a brake pad assembly for a disk brake system and to a disk brake system. The proposed brake pad assembly for a disk brake system comprises a back plate having a front side for facing a brake disk of the disk brake system and a back side. The brake pad assembly further comprises a friction layer arranged at the front side of the back plate for contacting a friction surface the brake disk. The back plate comprises a back plate body having a recess on its back side. The back plate further comprises a layered structure that is received within the recess of the back plate body. The layered structure comprises a copper layer and a rubber layer. The rubber layer covers the copper layer.