Composite Brake Pad Backing Plate for Higher Shear Bond Strength
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Solution Overview
Problem
Conventional brake pad units face challenges in achieving a strong bond between the friction material and the backing plate, particularly in withstanding shear forces, while also requiring alternative constructions that can pass robustness and performance tests without necessitating new manufacturing apparatus or methodologies.
Innovation Solution
A composite backing plate made of non-metallic fibers and polymer matrices is used, featuring a friction material mounting surface with moulded engagement features such as protrusions or recesses that enhance the bond strength by interlocking with the friction pad, utilizing a method that includes moulding, adhesive application, and curing processes to ensure a resilient structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a simple stamped stainless steel plate is used as a backing plate, then the manufacturing process is simple and existing apparatus can be used, but the bond strength with friction material is insufficient and shear force resistance is poor
Solution Approach 1:
The patent applies composite materials by combining a metallic substrate with a non-metallic coating layer (such as ceramic or polymer) to create a backing plate that provides both structural integrity and enhanced bond strength with friction material. The composite structure allows the metallic base to maintain mechanical strength while the coating layer improves adhesion properties, resolving the contradiction between simple structure and bond strength requirements.
Solution Approach 2:
The patent implements local quality by applying different surface treatments or coating types to specific regions of the backing plate. The friction material mounting surface receives a specialized coating or surface treatment to maximize bond strength, while other regions maintain the original metallic properties for structural support and mounting purposes. This localized differentiation resolves the contradiction by providing enhanced bond strength only where needed.
2Weight of moving object
If alternative constructions are used to reduce weight, then the brake pad unit weight decreases, but the ability to pass robustness and performance tests becomes uncertain
Solution Approach 1:
The patent uses composite materials to reduce the overall weight of the brake pad unit by replacing portions of the metallic backing plate with lighter non-metallic materials (such as ceramics or polymers). The composite construction maintains sufficient mechanical strength and bond properties to pass robustness and performance tests, thus resolving the contradiction between weight reduction and reliability requirements.
Solution Approach 2:
The patent applies parameter changes by modifying the chemical composition, density, or structural properties of the backing plate materials to achieve weight reduction while maintaining performance. By adjusting material parameters such as using high-strength-low-density alloys or optimizing coating thickness, the design achieves lighter weight without compromising the ability to pass performance tests.
3Strength
If the friction material mounting surface is made non-planar with moulded engagement features, then the bond strength and shear force resistance improve, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by incorporating the non-planar engagement features directly into the backing plate manufacturing process itself, rather than adding them as a separate post-processing step. The moulding process that forms the backing plate also creates the engagement features, ensuring they are integrated into the material structure from the beginning. This approach improves shear force resistance while managing manufacturing precision requirements by combining operations.
Data Source
AI summary
There is disclosed a method of manufacturing a backing plate for carrying a friction material to form a brake pad unit of a disc brake assembly. The method comprises moulding a composite backing plate precursor within a mould such that a side of the backing plate is configured as a friction material mounting surface defining a moulded engagement feature. There is also disclosed a composite backing plate for carrying a friction material to form a brake pad unit of a disc brake assembly. There is also disclosed a brake pad unit comprising the composite backing plate.