Composite Brake Backing Plate With Piercing Lock
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional disc brake backing plates made of solid steel are heavy, which is a concern for large and fast vehicles, and attempts to reduce weight by making thinner plates with local thickening have not been effective in achieving significant weight reduction while maintaining strength and rigidity.
Innovation Solution
A composite brake backing plate is created using first and second sheet metal stampings with textured faces and a soft metal core, where the piercing members from the stampings penetrate the core to lock the layers together without adhesives, providing a lightweight yet strong structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-piece solid steel backing plate is used, then strength and rigidity are maintained, but weight increases significantly
Solution Approach 1:
The backing plate uses a composite structure combining steel stampings with an aluminum core, creating a multi-material construction that leverages the high strength of steel and the lightweight properties of aluminum to achieve both strength and weight reduction
Solution Approach 2:
The single-piece steel plate is divided into multiple discrete layers (steel stampings and aluminum core) that are assembled together, allowing each component to contribute its optimal properties while reducing overall weight
2Weight of moving object
If the backing plate is made thinner with local thickening by embossing, then weight is reduced slightly, but strength and rigidity are compromised
Solution Approach 1:
The composite construction with aluminum core and steel stampings provides superior strength-to-weight ratio compared to thinned steel plates, achieving weight reduction without compromising structural integrity
Solution Approach 2:
The steel stampings are strategically positioned and textured to provide localized reinforcement where needed, while the aluminum core provides lightweight bulk material in areas requiring less structural support
3Weight of moving object
If a composite structure with multiple layers is used, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The steel stampings are pre-textured with piercing members before assembly, and the aluminum core is prepared in advance, allowing for efficient assembly through a single pressing operation that simultaneously locks all layers together
Solution Approach 2:
The piercing members on the steel stampings automatically penetrate and lock into the aluminum core during the pressing operation, creating self-securing connections without requiring additional fasteners or bonding materials
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 composite plate is significantly lighter than standard steel plates, maintaining strength and rigidity, with the piercing members creating a strong locking mechanism that resists deformation, resulting in a stiff and rigid laminate.
Implementation Method 1
The textured face of the first stamping is rolled or pressed into the first face of the metal core so that the piercing members penetrate into the metal core. The textured face of the second stamping is rolled or pressed into the second face of the metal core so that the piercing members penetrate into the metal core. This locks the first sheet metal stamping, the second sheet metal stamping and the metal core together.
Implementation Method 2
Each piercing member on each sheet metal stamping preferably extends substantially perpendicularly from the face of the sheet metal stamping and is tapered so the piercing member has a thickness that decreases from the face of the metal stamping to the distal end of the piercing member. As a result, the relatively soft metal core is bound to the first and second sheet metal stampings by a locking taper fit of the piercing members and the metal core.
Data Source
AI summary
A layered brake backing plate is provided made of stampings in which a softer, lighter metal core, such as aluminum, is sandwiched between skins of harder metal stampings, such as steel, to make a lightweight composite brake backing plate. The harder stampings are textured with integrally raised piercing barbs. By rolling or pressing, the barbs are made to embed in the core, locking the layers together.