Sintered Friction Lining Cut-Out Design for Tear Prevention
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Solution Overview
Problem
Conventional sintered friction linings often tear between rivet holes during the sintering process, leading to reduced effective friction surface, loose parts, and potential damage to brake or clutch components, posing safety risks due to unevenness and material detachment.
Innovation Solution
A method of producing a friction lining with strategically designed cut-outs that surround regions for connecting elements, either before or after the sintering process, to prevent tears and ensure secure attachment, thereby maintaining friction performance and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate cut-outs are provided for each connecting element in the friction lining, then each connecting element can be accommodated, but tears occur between the cut-outs during sintering and cold-forging
Solution Approach 1:
The patent merges multiple separate cut-outs into a single common cut-out that accommodates multiple connecting elements (rivets). This unified cut-out design eliminates the vulnerable regions between separate cut-outs where tears would occur during sintering and cold-forging operations, while still providing adequate accommodation for all connecting elements.
2Ease of operation
If the friction lining is cold-forged to improve seating on the clutch disc, then better contact is achieved, but high surface tensions cause tearing between rivet holes
Solution Approach 1:
By combining multiple cut-outs into one common cut-out, the patent eliminates the vulnerable material regions that would exist between separate cut-outs. This allows the friction lining to be cold-forged for better seating without creating high surface tensions that would cause tearing between rivet holes, as there is no vulnerable material between separate cut-out regions.
3Strength
If rivet holes are disposed in the region of the friction surface, then secure attachment is achieved, but the friction lining must contain corresponding bores which leave slim free regions
Solution Approach 1:
The patent combines multiple individual bores into a single common cut-out that accommodates multiple rivet holes. This approach maintains secure attachment by providing adequate space for all connecting elements while minimizing the total area removed from the friction lining, thereby preserving more effective friction surface area compared to multiple separate cut-outs.
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 effectively prevents tears and detachment, maintaining the friction surface and ensuring the safety and functionality of brake and clutch components by optimizing the design of cut-outs in the friction lining.
Implementation Method 1
different materials are mixed with one another in varying proportions and then 'baked' to the desired shape of a component by means of a known sintering process
Data Source
AI summary
The invention relates to a method of producing a friction element comprising a friction lining (1) made from sintered material, which is applied to a support (2), and at least two recesses (4) are provided in the support (2), each for accommodating a connecting element for fitting the support (2) with the friction lining (1) on a supporting element (3). A cut-out (A, A1, A2) is provided in the friction lining (1) which surrounds at least two regions (B1 . . . B4) spaced apart from one another in which the at least two recesses (4) of the support (2) for accommodating the connecting elements are disposed. The invention further relates to the friction lining (1) itself.