Brake Pad Manufacturing with Quality Stabilization Pressing

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Solution Overview

Problem

The manufacturing process of brake pads is hindered by the need for manual clamping with a pressing jig, leading to inconsistent pressure, quality defects, and prolonged heat treatment times, which reduce productivity and increase labor costs.

Innovation Solution

A method and apparatus that omit the clamping process by using a quality stabilization process involving heating and pressing the friction material after forming, followed by heat treatment, allowing for automated processing and reduced manufacturing time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual clamping with a pressing jig is used, then the brake pad can be held during heat treatment, but the pressing pressure cannot be accurately controlled and quality defects occur

Engineering Contradiction:

Improvequality stabilityVSAvoidmanual operation difficulty

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces the manual mechanical clamping system with an automated pressing device that applies pressure through a pressing plate. The automated system uses controlled pressing force to hold the brake pad during heat treatment, eliminating the need for manual operation with pressing jigs and ensuring consistent, accurate pressure application throughout the process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the control parameter from manual operator skill to automated pressing force control. By precisely controlling the pressing force parameter through automation, the system achieves accurate and consistent pressure application, eliminating quality variations caused by differences in operator skill and manual operation inconsistencies.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If manual alignment of brake pads with pressing jig is performed, then clamping can be achieved, but a large amount of working time is required

Engineering Contradiction:

Improveclamping capabilityVSAvoidmanufacturing speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces the manual alignment and clamping process with an automated pressing device. The automated system automatically positions and clamps the brake pads without requiring manual alignment operations, significantly reducing the working time required for the clamping process while maintaining effective clamping capability during heat treatment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If heat treatment is performed with brake pad clamped in pressing jig, then the brake pad can be maintained, but the heat treatment time becomes prolonged (5 to 12 hours)

Engineering Contradiction:

Improvebrake pad maintenanceVSAvoidheat treatment time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the traditional pressing jig clamping system with an automated pressing device that provides more efficient heat treatment. The automated pressing device maintains the brake pad during heat treatment through controlled pressing force, enabling shorter heat treatment times while still achieving the necessary maintenance and quality standards.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical 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

This approach reduces manufacturing time and labor, stabilizes brake pad quality, and decreases heat treatment time, resulting in more efficient production with fewer quality deviations.

Implementation Method 1

a quality stabilization process of heating and pressing the friction material after the forming process is completed

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a heat treatment process of heating the brake pad at a predetermined temperature after the quality stabilization process is completed

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Data Source

PatentUS11111976B2Method and apparatus for manufacturing brake pad for quality stabilization

Publication Date: 2021.09.07 AUTOSYS

AI summary

The present invention relates to a method and an apparatus for manufacturing a brake pad, which are configured to stabilize quality of the brake pad. The present invention provides a method of manufacturing a brake pad including a friction material and a backing plate which are coupled to each other, the method including: a preliminary process of preparing friction material powder and the backing plate; a forming process of forming the friction material powder in the form of the friction material and attaching the friction material to one surface of the backing plate; a quality stabilization process of heating and pressing the friction material after the forming process is completed; a heat treatment process of heating the brake pad at a predetermined temperature after the quality stabilization process is completed; and a grinding process of grinding the friction material.