Induction-Heated Brake Pad Underlayer for Cold Squeal Reduction
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Solution Overview
Problem
Brake pads in vehicles, especially in electric and hybrid vehicles, tend to squeal during braking at low temperatures due to vibrations, which can be exacerbated by regenerative braking systems and the absence of engine noise.
Innovation Solution
A braking system that includes a brake pad with an underlayer warmed by a thermal power source utilizing magnetic induction, generated by an electromagnetic field produced by electric coils. This ensures the underlayer operates at optimal damping conditions, reducing the likelihood of squealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the underlayer temperature is low during cold braking, then the damping properties of the underlayer drop drastically, but increasing the temperature through conventional means (friction during braking) is not sufficient or reliable
Solution Approach 1:
The heating element is activated before braking occurs to pre-heat the underlayer to its optimal damping temperature range. This preliminary action ensures that when braking happens in cold conditions, the underlayer is already at the correct temperature to provide effective damping and prevent squeal, rather than relying on friction heat that comes too late.
Solution Approach 2:
The patent replaces the conventional mechanical/thermal approach (relying on friction heat from braking) with an electrical heating system. The heating element converts electrical energy directly into thermal energy to heat the underlayer, providing reliable temperature control independent of braking force or duration.
2Reliability
If the underlayer temperature is maintained at optimal levels through additional heating systems, then damping behavior is improved, but the device complexity and cost increase
Solution Approach 1:
The heating element is integrated directly into the brake pad structure, allowing the brake pad to self-regulate its underlayer temperature without requiring external heating systems from the vehicle. The brake pad's own structure incorporates the heating capability, making the system self-sufficient and eliminating complex external temperature control mechanisms.
Solution Approach 2:
The heating element is merged with the brake pad assembly, combining the friction material, underlayer, and heating components into a single integrated unit. This consolidation reduces the number of separate systems and components needed, simplifying the overall device while maintaining the temperature control function.
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 maintains the underlayer at a temperature that ensures maximum damping behavior, significantly reducing or eliminating the squealing phenomenon during cold braking, thereby ensuring smooth and silent operation.
Implementation Method 1
a thermal power source exploiting the principle of magnetic induction generated by an electromagnetic field
Data Source
AI summary
Braking system (1) and method aimed to produce a forced increase in a damping layer (7) temperature of a brake pad (3), arranged between a metal support (5) and a friction material block (6) thereof, wherein the damping layer (7) is heated such as to stay at a temperature above a glass transition temperature of rubber components thereof, so assuring a maximum damping behavior; the heating is caused by magnetic induction generated by one or more electrically conducting coils (15) fed in AC by a power source (10) carried by the vehicle and arranged either integrated in the brake pad (3), e.g. carried by the support (5), or in the vicinity thereof.