Coated Brake Pad Backing Plate for Heat Insulation and Pad Retention
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Solution Overview
Problem
Existing brake pads face challenges in attachment retention and heat management, with raised features on backing plates potentially reducing friction material and generating excessive heat that can lead to brake system failures during extreme braking conditions.
Innovation Solution
A coated backing plate with a reinforcement plate and a multi-layered coating comprising a bond layer and a thermal barrier layer, featuring an open pore network with craters for mechanical interlock and a gradient structure to reduce heat flow, applied using thermal spray processes to enhance adhesion and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If raised features or prominences are added to the backing plate to promote attachment, then attachment retention is improved, but the usable amount of friction material is reduced and contact with the rotor becomes undesirable
Solution Approach 1:
The backing plate incorporates a porous coating layer with controlled porosity (5-50%) that provides mechanical interlocking through pore structures rather than raised features. This allows friction material to bond within the porous network without reducing the overall friction material volume, resolving the contradiction between attachment retention and usable friction material quantity.
Solution Approach 2:
The porous coating is applied locally to specific regions of the backing plate where friction material attachment is needed, rather than using universal raised features across the entire backing plate. This localized approach maintains attachment retention while preserving usable friction material in areas where it is most needed.
2Strength
If the backing plate is designed to provide structural support, then mechanical strength is improved, but heat flow from the friction pad to the caliper assembly increases
Solution Approach 1:
The backing plate uses a composite structure combining a metal reinforcement plate with a porous coating layer. The metal substrate provides mechanical strength while the porous coating layer acts as a thermal barrier, reducing heat flow to the caliper assembly. This composite approach resolves the contradiction between maintaining structural strength and reducing unwanted heat transfer.
Solution Approach 2:
The thermal management function is localized to the porous coating layer applied on the backing plate, while the underlying metal structure maintains its structural support function. This separation of functions allows the backing plate to provide mechanical strength without unnecessarily conducting heat to the caliper assembly.
3Loss of energy
If a thermal barrier coating is applied to reduce heat flow, then thermal insulation is improved, but attachment retention of friction material may be compromised
Solution Approach 1:
The thermal barrier is implemented as a porous coating layer with controlled porosity (5-50%) rather than a dense solid coating. The porous structure provides thermal insulation by trapping air pockets while simultaneously offering mechanical interlocking surfaces for friction material attachment, thus resolving the contradiction between thermal insulation and attachment retention.
Solution Approach 2:
The porous coating layer serves multiple functions simultaneously: it acts as a thermal barrier to reduce heat flow, provides mechanical interlocking for friction material attachment through its pore structure, and maintains a gradient from metal to ceramic composition. This multi-functionality resolves the contradiction by making a single layer that performs both thermal insulation and attachment promotion.
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 improves attachment retention and reduces heat flow through the brake pad, enhancing brake pad life and preventing component failures by promoting mechanical interlock and thermal insulation, thereby ensuring better performance under high braking conditions.
Implementation Method 1
an open pore network at the inboard surface of the bond layer, wherein the open pore network includes a recessed topology having a plurality of craters configured to interlock a friction material of a friction pad
Implementation Method 2
a thermal barrier coating that reduces heat flow through the friction pad to other components of the braking system
Implementation Method 3
applied using thermal spray processes to enhance adhesion and thermal insulation
Data Source
AI summary
A coated backing plate for a brake pad and method of manufacturing a brake pad having a coated backing plate, where the coating for the backing plate includes a bond layer. The bond layer includes an inboard surface, an outboard surface, a closed pore network toward the outboard surface that faces the inboard surface of the reinforcement plate, and an open pore network at the inboard surface of the bond layer. The open pore network includes a recessed topology having a plurality of craters configured to interlock a friction material of a friction pad or one or more intermediate layers, such as a transition layer and/or a thermal barrier layer.