Composite Brake Friction Assembly for Lower Weight and Reliability
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Solution Overview
Problem
Traditional friction assemblies for brake callipers are heavy due to the use of metal materials, which is inefficient in terms of fossil fuel usage and weight reduction, while maintaining reliability.
Innovation Solution
A friction assembly made from co-moulded heat-resistant resin, such as phenolic resin, with reinforcing fibers and optional friction modifying components, integrated with a support plate and brake pad, designed to be lighter while maintaining reliability through the use of phenolic resin and reinforcing fibers, and incorporating features like anchor components and accessory connection seats for improved functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal materials (iron or steel) are used for the intermediate body to ensure high performance and reliability, then the reliability is improved, but the overall weight of the friction element-intermediate body assembly increases considerably
Solution Approach 1:
The patent applies composite materials by combining phenolic resin (polymer matrix) with reinforcing fibers (glass, carbon, or organic fibers) to create an intermediate body that achieves both lightweight properties and high mechanical strength. This composite structure replaces traditional metal materials while maintaining the necessary reliability and performance characteristics for brake calliper applications.
Solution Approach 2:
The patent changes the material parameters by transitioning from metal-based materials to polymer-composite materials with specific tensile strength, elastic modulus, and thermal stability parameters. The phenolic resin composite is designed to meet minimum performance thresholds while significantly reducing density and weight compared to metal alternatives.
2Strength
If traditional metal materials are used for the friction assembly, then the mechanical strength and durability are maintained, but the fossil fuel efficiency deteriorates due to increased vehicle weight
Solution Approach 1:
The phenolic resin composite material provides sufficient mechanical strength for brake calliper applications while reducing the weight of moving components. This weight reduction directly improves vehicle fuel efficiency by decreasing the energy required for acceleration and operation, thereby resolving the contradiction between maintaining strength and improving fossil fuel efficiency.
3Adaptability or versatility
If the friction element and intermediate body are manufactured from different materials and connected subsequently, then the manufacturing flexibility is improved, but the manufacturing complexity and assembly steps increase
Solution Approach 1:
The patent merges the friction element and intermediate body into a single monoblock component manufactured from phenolic resin composite material. This integration eliminates the need for separate manufacturing processes and subsequent assembly operations, thereby reducing manufacturing complexity while maintaining the ability to achieve different functional properties through material composition and structural design.
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 achieves a significant weight reduction in brake calliper components while maintaining reliability and performance, with the phenolic resin and fibers providing mechanical strength and durability, and the design ensuring effective braking and reduced noise and thermal conductivity.
Implementation Method 1
heat-resistant resin, such as phenolic resin
Implementation Method 2
co-moulded heat-resistant resin, such as phenolic resin, with reinforcing fibers
Implementation Method 3
optional friction modifying components
Data Source
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AI summary
Friction assembly (1) comprising a support plate (2) and at least one brake pad (4), made by co-moulding of at least one heat-resistant resin, the heat-resistant resin of the support plate (2) being partially loaded with non- metallic reinforcement fibres. The support plate (2) identifies one or more accessory- connection seat, made by co-moulding. This invention further relates to a method for the manufacture of a friction assembly and a brake calliper.