Compressed Base-Rim Friction Pad for Delamination and Drag Torque
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Solution Overview
Problem
Existing friction pads tend to experience delamination and increased drag torque due to fibrous cutting edges when in contact with steel plates, particularly in wet-running applications, as they are prone to tearing during punching or cutting processes.
Innovation Solution
The friction pad features a compressed base rim with an embossed, rounded edge instead of a sharp cutting edge, which enhances stability and reduces delamination risk by creating a stronger attachment to the carrier element and minimizing contact with steel plates, thereby reducing wear and drag torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the friction pad is cut or punched from friction lining material using conventional tools, then the friction pad can be manufactured, but the cutting edge becomes fibrous and prone to tearing, causing delamination during operation
Solution Approach 1:
The patent applies preliminary action by compressing the base rim area of the friction pad before the cutting or punching process. This pre-compression densifies the friction lining material at the base rim, creating a stronger foundation that prevents fiber tearing and delamination during subsequent cutting operations and during operation. The pre-compression is achieved through a forming process that applies pressure to the base rim area before the friction pad is separated from the friction lining material.
2Ease of manufacture
If the friction pad has a sharp cutting edge from punching, then manufacturing is simple, but the sharp edge increases drag torque when contacting steel plates
Solution Approach 1:
The patent applies spheroidality by forming a rounded edge at the base rim of the friction pad instead of leaving a sharp cutting edge. This rounding is achieved through the compression process that creates a curved, non-sharp edge profile. The rounded edge reduces contact stress and friction when the friction pad contacts steel plates during operation, thereby reducing drag torque and energy loss while maintaining manufacturing simplicity.
3Strength
If the base rim is more compressed than the friction pad interior, then delamination is prevented and strength is increased, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies local quality by selectively compressing only the base rim area of the friction pad while leaving the interior regions with different compression characteristics. This localized compression is achieved through a forming process that applies pressure specifically to the base rim area, creating a density gradient where the base rim is denser and stronger than the interior. This approach increases strength where needed without requiring complex compression of the entire friction pad, thus limiting the increase in manufacturing process complexity.
Data Source
AI summary
A friction pad includes a fastening surface, a friction surface facing away from the fastening surface, a shape delimited by a peripheral cutting edge, and a base rim extending along the peripheral cutting edge. The base rim is more compressed than a remainder of the friction pad. The reminder of the friction pad has a pad height and the base rim may have a base height that is at least one quarter of the pad height. The base rim may have a base width that is at least as large as the pad height.