Multi-Layer Brake Pad Assembly Without Heat Curing
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Solution Overview
Problem
Conventional brake pad manufacturing processes face challenges with friction pad delamination due to rust on bare steel backing plates, leading to inefficiencies and environmental impacts from heat treatment.
Innovation Solution
A method for assembling brake pads with pre-formed multi-layer friction pads and shims, where the backing plate is texturized with piercing members to secure the friction pad without heating, allowing for a single-step assembly process that reduces energy consumption and greenhouse gas emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bare steel backing plates are used to reduce cost, then manufacturing cost is reduced, but rust occurs leading to friction pad delamination
Solution Approach 1:
The patent applies composite materials by combining bare steel backing plate with a multi-layer friction pad structure. The friction pad consists of multiple layers including a corrosion-resistant layer that protects the steel substrate from rust while maintaining the cost benefits of bare steel construction. This composite approach resolves the contradiction by providing both economic advantage and reliability through the protective friction pad layers.
2Strength
If texturized surface with raised features is formed on backing plate, then mechanical bond strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by providing the texturized surface only on the rotor-facing surface of the backing plate where the friction pad contacts, rather than the entire plate surface. This localized texturing provides the necessary mechanical interlocking strength at the critical bonding interface while minimizing manufacturing complexity and cost for the overall backing plate production.
3Reliability
If heat treatment is applied to cure friction material, then friction pad bonding is achieved, but energy consumption and greenhouse gas emissions increase
Solution Approach 1:
The patent applies parameter changes by modifying the curing process to use lower temperatures and reduced heat treatment time. The multi-layer friction pad composition is formulated to cure effectively at reduced thermal parameters, thereby achieving reliable bonding while significantly reducing energy consumption and greenhouse gas emissions associated with conventional high-temperature curing processes.
4Use of energy by stationary object
If multi-layer friction pad with softer first layer is used, then piercing members can secure the pad without heating, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-forming the multi-layer friction pad structure with precisely controlled layer thicknesses and material properties before assembly. The softer first layer is pre-configured with optimal characteristics that enable mechanical securing by piercing members without requiring thermal processing. This pre-engineering of the friction pad structure reduces energy consumption while the precision is achieved through controlled manufacturing of the layered composition.
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
This approach enhances the mechanical bond between the friction pad and backing plate, reduces delamination, and streamlines the manufacturing process while saving time, money, and energy, thereby lowering the carbon footprint of the brake industry.
Implementation Method 1
The friction pad may be secured to the rotor facing surface by mechanically impaling the piercing members through the friction pad
Implementation Method 2
Some friction pads are made from a resin adhesive, which may be a phenolic resin adhesive powder, mixed with fibres of copper, brass, bronze, glass, steel, and aramide
Implementation Method 3
Such texturing can mechanically reinforce the bond between the friction pad and the backing plate, and may improve shear strength and resistance against delamination of the friction pad
Data Source
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AI summary
A method of assembling a brake pad includes impaling a first layer of a preformed multi-layer friction pad on piercing members of a rotor facing surface of a brake pad backing plate. A shim is concurrently assembled to a caliper facing surface of the backing plate.