Seam-Free Ceramic Brake Pad Body for Corrosion and Thermal Stress
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing friction lining bodies for brakes face challenges in easy manufacturing while meeting mechanical and thermal requirements, and they often suffer from contact corrosion and thermal expansion issues due to material differences between carrier and friction parts.
Innovation Solution
A friction lining body made from integrally formed, seam-free, high-purity ceramic material with the same composition for both carrier and friction parts, produced through isostatic pressing and sintering, eliminating transition surfaces and reducing thermal expansion tensions, with optional reinforcement fibers for enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic carrier plate with separate friction lining is used, then the structural strength is sufficient, but contact corrosion occurs between the carrier plate and brake caliper
Solution Approach 1:
The patent merges the carrier and friction lining into a single integral ceramic component, eliminating the separate metallic carrier plate and its associated corrosion issues. The ceramic material serves both structural and friction functions simultaneously.
Solution Approach 2:
The patent uses homogeneous ceramic material for both the carrier and friction lining portions, eliminating material interfaces that would otherwise be susceptible to corrosion. The entire component is made from the same ceramic composition.
2Reliability
If different materials are used for carrier and friction parts, then functional requirements are met, but thermal expansion differences cause stresses
Solution Approach 1:
The patent employs the same ceramic material throughout the entire component, ensuring uniform thermal expansion characteristics. This eliminates differential thermal stresses that would arise at material interfaces during heating and cooling cycles.
3Ease of manufacture
If traditional manufacturing methods are used for friction lining bodies, then production is possible, but manufacturing complexity and time increase
Solution Approach 1:
The patent combines multiple manufacturing operations into a single isostatic pressing step, forming the entire ceramic friction lining body in one operation without requiring separate steps for carrier fabrication, lining attachment, or interface preparation.
Solution Approach 2:
The patent segments the manufacturing process into distinct operational phases (mixture preparation, molding, sintering) that can be independently optimized and scaled, improving overall production efficiency while maintaining simplicity.
4Reliability
If high-purity ceramic material is used, then mechanical and thermal properties are improved, but material cost increases
Solution Approach 1:
The patent optimizes ceramic particle size distribution, purity levels, and compositional ratios to achieve the required mechanical and thermal properties at minimum cost. By carefully controlling these parameters, high performance is attained without excessive material expense.
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 solution enables easy, efficient production of a friction lining body with improved mechanical and thermal performance, preventing contact corrosion and ensuring uniform heat distribution, while maintaining high purity and precision in geometric shapes without the need for additional coatings or post-processing.
Implementation Method 1
The friction lining body is manufactured by sintering, so that it forms a sintered body
Implementation Method 2
The friction lining consists of a material suitable for friction with a brake disc
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a friction pad body (10) having a backing part (11) and a friction part (14) which integrally consist of the same ceramic material, without a seam or joint. The ceramic material has a purity of at least 80% in relation to the total weight of the friction pad body. The friction pad body is preferably produced in the form of a sintered body by isostatic pressing so that a single-stage production process can be achieved.