Composite Brake Backing Plate Weight Reduction
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Solution Overview
Problem
Traditional solid steel backing plates for disc brake pads are heavy, affecting ride quality, handling, and fuel efficiency, and attempts to reduce weight by thinning or embossing have not been sufficient.
Innovation Solution
A composite brake backing plate is created by sandwiching a non-compressible core material between two sheet metal stampings with textured faces and integrally formed piercing members, which are embedded in the core to lock the structure, providing strength and rigidity while reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single piece solid steel backing plate is used, then strength and rigidity are sufficient, but weight becomes very heavy
Solution Approach 1:
The patent applies composite materials by combining a lightweight core material (such as foam, honeycomb structure, or other non-metallic materials) with metal face sheets. This composite construction provides the necessary strength and rigidity while significantly reducing the weight compared to solid steel backing plates. The core material acts as a structural support that maintains dimensional stability, while the metal face sheets provide surface strength and attachment points for friction material.
2Weight of moving object
If the backing plate is made thinner to reduce weight, then weight decreases, but local areas require thickening by embossing which maintains heaviness
Solution Approach 1:
The patent applies local quality by providing a generally thin backing plate structure with reduced weight, while incorporating localized embossed or raised features at specific positions where additional strength is required. These local thickenings are strategically placed to provide structural support without significantly increasing the overall weight of the backing plate, thus resolving the contradiction between weight reduction and maintaining necessary strength.
3Weight of moving object
If a composite structure with core material and stampings is used, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies merging by integrating the core material and metal face sheets into a single composite backing plate assembly that functions as one unified structural component. The core material is bonded or mechanically attached to the face sheets to form a integrated structure, simplifying the overall manufacturing process compared to assembling multiple separate components. This merging approach reduces the number of discrete parts while maintaining the weight reduction benefits of the composite construction.
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 backing plate achieves equivalent strength and rigidity to solid steel while significantly reducing weight, improving vehicle performance and material efficiency.
Implementation Method 1
By rolling or pressing, the textured faces of each of the stampings engage the core material and their piercing members are fully embedded in the core material. Thus, the piercing members act to lock together the first sheet metal stamping, the second sheet metal stamping and the core material.
Data Source
AI summary
A brake backing plate is provided in which a non-compressible core material is sandwiched between two sheet metal stampings to make a lightweight, composite brake backing plate. Each of the stampings has a textured face with a plurality of integrally formed piercing members. By rolling or pressing, the piercing members of the textured faces are fully embedded in the core material, and thus lock the stampings and the core material together.