Curved Chamfer Brake Pad for Noise Reduction and Uniform Wear
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Solution Overview
Problem
Existing brake pad arrangements for disc brakes face challenges in reducing noise emissions and ensuring uniform wear while being cost-effective, as they require complex and time-consuming production processes, especially for diamond chamfer configurations.
Innovation Solution
A brake pad arrangement with a chamfer edge having a curved course, allowing for simpler production by eliminating the need for multiple grinding steps, where the chamfer edge can be formed in a single material-removing step using a continuous machining path, such as a circular arc shape, to reduce noise and ensure uniform wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If diamond chamfer configuration with multiple inclined chamfer surfaces is used, then noise emissions are reduced, but production time and cost increase due to multiple grinding steps
Solution Approach 1:
The patent applies curvature by replacing the traditional diamond-shaped chamfer with a curved chamfer edge that follows a circular arc. This curved geometry maintains the noise reduction effectiveness while allowing the entire chamfer to be produced in a single continuous grinding motion, eliminating the need for multiple grinding steps and tool repositioning required by the angular diamond configuration.
2Object-affected harmful factors
If diamond chamfer configuration with multiple inclined chamfer surfaces is used, then noise emissions are reduced, but production complexity increases due to multiple working steps
Solution Approach 1:
The patent merges multiple grinding operations into a single continuous process. The curved chamfer edge geometry allows one grinding tool to create the entire chamfer in one pass, combining what would traditionally require multiple separate grinding steps with different tool orientations into a unified, simpler production process.
3Ease of manufacture
If simple chamfer edges free from kinks are used, then production is simplified, but bearing surface area and adaptation to circumferential speeds are reduced
Solution Approach 1:
The curved chamfer edge following a circular arc provides a continuously varying angle of contact with the brake disc, adapting to different circumferential speeds across the friction surface. This curved geometry increases the effective bearing surface area compared to straight chamfer edges, while maintaining production simplicity through single-step manufacturing.
Data Source
AI summary
A brake lining arrangement for a disk brake, and a method for producing such a brake lining arrangement, comprises a brake lining carrier and a friction pad mounted thereon, a friction surface of which can be attached to a disk brake for generating a friction effect. In at least one border area, the friction pad is provided with a bevel, which at one bevel edge transitions into the friction surface. In order to simplify production, the bevel edge is configured to extend in a curved line.