Brake Pad Metallic Support Cavity Design for Adhesion and Noise
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Solution Overview
Problem
Existing brake pad metallic supports are costly and inefficient in improving adhesion between friction material and the support, often introducing asymmetries and noise due to additional plastic deformation operations and non-uniform adhesion enhancements.
Innovation Solution
A metallic support for brake pads manufactured through a single fine shearing operation, featuring projecting parts and cavities on one face and corresponding cavities and reliefs on the other, allowing for enhanced adhesion and reduced thickness without additional deformation steps, enabling effective mounting of damping elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional plastic deformation operations are introduced to improve adhesion, then adhesion between friction material and metallic support is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple functions (adhesion enhancement, damping element mounting, and mass reduction) into a single integrated cavity structure on the metallic support. This eliminates the need for separate plastic deformation operations that would otherwise be required to create adhesion-improving features, thereby resolving the contradiction between improved adhesion and manufacturing complexity
Solution Approach 2:
The cavity structure serves multiple purposes simultaneously: it enhances adhesion between the friction material and metallic support, provides a mounting location for the damping element (shim), and reduces the overall mass of the metallic support. This multi-functionality eliminates the need for additional operations, resolving the contradiction between adhesion improvement and manufacturing complexity
2Strength
If additional plastic deformation operations are introduced to improve adhesion, then adhesion between friction material and metallic support is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple functions (adhesion enhancement, damping element mounting, and mass reduction) into a single integrated cavity structure on the metallic support. This eliminates the need for separate plastic deformation operations that would otherwise be required to create adhesion-improving features, thereby resolving the contradiction between improved adhesion and manufacturing complexity
Solution Approach 2:
The cavity structure serves multiple purposes simultaneously: it enhances adhesion between the friction material and metallic support, provides a mounting location for the damping element (shim), and reduces the overall mass of the metallic support. This multi-functionality eliminates the need for additional operations, resolving the contradiction between adhesion improvement and manufacturing complexity
3Strength
If projecting parts are added to improve adhesion, then adhesion is improved, but asymmetries are introduced that modify natural frequencies and generate noise
Solution Approach 1:
The patent strategically places cavities at specific locations on the metallic support where they enhance adhesion without creating harmful asymmetries. The cavity configuration is designed to maintain symmetric mass distribution and preserve natural frequencies, thereby avoiding noise generation while still improving adhesion between the friction material and metallic support
4Length of moving object
If the metallic support thickness is reduced, then brake pad dimensions are reduced, but adhesion and mounting capability may be compromised
Solution Approach 1:
The patent transitions from relying on the thickness of the metallic support for adhesion to utilizing surface cavity structures. By creating cavities on the surface of the metallic support, the invention enhances adhesion through increased surface area and mechanical interlocking, while simultaneously reducing the overall thickness of the brake pad assembly
Data Source
AI summary
A metallic support of a brake pad delimited between a first and a second face, and having a perimeter edge substantially perpendicular to the first and second faces. The first face receives a block or layer of friction material, and the second face receives a dampening element. The first face has at least one projecting part extending cantilevered spaced apart from the perimeter edge so as to be completely embedded within the block or layer of friction material. The at least one projecting part is delimited at the top by a first surface upon which there is at least one first cavity filled with the block or layer of friction material. The second face has at least one second cavity forged as the at least one projecting part. At the at least one first cavity, there is at least one first relief shaped as the at least one first cavity.