Composite Brake Pad Backing Plate to Prevent Warping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional brake pads face issues with weight reduction leading to strength loss, warping, corrosion, and catalytic reactions due to metal reinforcement, which affects braking performance and maintenance.
Innovation Solution
A brake pad unit with a backing plate made from a composite material comprising reinforcement fibers, such as glass, carbon, or aramid, aligned in various directions, and a friction pad bonded using a polymer resin binder, eliminating metallic components to reduce weight while maintaining strength and preventing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If metal reinforcement is reduced to decrease weight, then weight is reduced, but strength decreases and warping increases
Solution Approach 1:
The patent applies composite materials by replacing traditional metal reinforcement with a combination of organic binder and inorganic filler materials. The backing plate uses a composite formulation comprising organic binder (30-70 wt%), inorganic filler (20-60 wt%), and optional additives, creating a non-metallic composite structure that achieves both weight reduction and maintained strength through material composition optimization rather than metal reinforcement
2Weight of moving object
If metal reinforcement is reduced to decrease weight, then weight is reduced, but warping and bending increase
Solution Approach 1:
The patent applies parameter changes by optimizing the chemical and physical parameters of the composite material formulation. Specific parameter ranges are defined: organic binder (30-70 wt%), inorganic filler (20-60 wt%), fiber reinforcement (5-20 wt%), and cross-linking density adjustments. These parameter optimizations enable the composite to achieve dimensional stability and warping resistance without metal reinforcement, while maintaining the weight reduction benefit
3Strength
If metal parts are used to maintain strength, then strength is maintained, but corrosion and catalytic reactions occur
Solution Approach 1:
The patent applies the extraction principle by completely removing metal components from the backing plate composition. The formulation uses only non-metallic materials: organic binders (phenolic resins, epoxies, polyesters), inorganic fillers (alumina, silica, calcium carbonate), and fiber reinforcements (glass, carbon, organic fibers). This extraction of metallic elements eliminates the source of corrosion and catalytic reactions while maintaining structural strength through the engineered composite material system
Data Source
AI summary
A brake pad unit for a disc brake assembly. The brake pad unit comprises a backing plate and a friction pad. The backing plate comprises a first side and a second side having a length L, a width W, and an edge wall which defines a thickness T of the backing plate. The first side defines an engagement surface for engaging with the disc brake assembly. The second side defines a friction material mounting surface. The backing plate is formed from a composite material comprising reinforcement fibres, wherein the composite material extends throughout of the backing plate. The backing plate comprises a layer of reinforcement fibres which are provided as continuous fibres which extend from a first point on the edge wall to a second point on the edge wall. The friction pad comprises a friction material provided on the friction material mounting surface of the backing plate.