Multi-Layer Brake Pad with Abrasive Rotor Cleaning
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Solution Overview
Problem
Brake pads experience uneven wear, leading to non-planar surface portions on brake pads and rotors, which can result in reduced braking efficiency and rotor refurbishing challenges.
Innovation Solution
A brake pad design featuring multiple layers with different materials, where a friction-generating material is combined with an abrasive material to provide both braking friction and rotor cleaning/refurbishing properties, ensuring consistent contact and surface maintenance during use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-material brake pad is used, then the structure is simple and manufacturing is easy, but the brake pad cannot simultaneously provide both braking friction and rotor cleaning/refurbishing properties
Solution Approach 1:
The brake pad employs a composite structure with a first material providing friction properties and a second material providing abrasive properties. This composite material approach enables the single brake pad component to simultaneously deliver both braking friction and rotor cleaning/refurbishing functions, directly resolving the technical contradiction between functional versatility and structure complexity.
Solution Approach 2:
The brake pad is divided into distinct functional layers: a first material layer for friction and a second material layer for abrasion. This segmentation allows each material to be optimized for its specific function while working together as an integrated system, enabling dual functionality without excessive structural complexity.
2Manufacturing precision
If brake pad and rotor surfaces are initially machined to be planar, then initial braking contact is uniform, but uneven wear develops over time creating non-planar surface portions
Solution Approach 1:
The brake pad incorporates an abrasive second material that proactively cleans and refurbishes the rotor surface during normal braking operations. This preliminary action prevents the accumulation of wear debris and maintains surface planarity throughout the service life, counteracting the natural tendency toward uneven wear and non-planar surface development.
Solution Approach 2:
The brake pad's second material provides self-service rotor cleaning during each braking event. The abrasive properties automatically refurbish the rotor surface as the brake pad engages, creating a self-maintaining system that preserves surface planarity without requiring external intervention or additional components.
3Productivity
If repeated contact between brake pad and rotor occurs, then braking function is achieved, but uneven wear forms non-planar surface portions on both surfaces
Solution Approach 1:
The abrasive second material continuously refurbishes the rotor surface during each braking operation. This continuous useful action maintains surface consistency and planarity throughout repeated braking cycles, preventing the degradation of surface quality that would otherwise occur with repeated contact and wear.
Solution Approach 2:
The natural wear that occurs during repeated braking contact is converted into a beneficial cleaning action. The second material's abrasive properties transform the harmful effect of wear into a useful rotor refurbishing process, maintaining surface consistency while achieving the braking 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 multi-layered brake pad design maintains effective braking performance while continuously refurbishing the rotor surfaces, reducing wear and improving braking efficiency over time.
Implementation Method 1
a second material with abrasive properties that cleanse and/or refurbish braking surfaces of the brake rotor during braking operations
Implementation Method 2
a first material that produces friction when in contact with a brake rotor
Data Source
AI summary
A brake pad includes a backing plate that defines a first plane. A brake lining is attached to the backing plate, and has a first layer, a second layer and a third layer. The first layer includes a first material, a first side fixed to the brake lining attachment surface and a second side opposite the first side. The second side defines a second plane non-parallel to the first plane. The second layer includes a second material, a first side and a second side. The first side of the second layer extends along the second side of the first layer and along the second plane. The second material is different from the first material. The third layer includes the first material, overlays and attaches to the second side of the second layer, and has a friction surface that is parallel to the first plane.