Multilayer Disc Brake Pad Structure for Vibration Damping
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Solution Overview
Problem
Existing disc brake pads fail to adequately dampen vibrations and securely anchor friction material to the support plate while being compatible with pre-existing disc brake callipers, leading to noise issues like rattling and drumming.
Innovation Solution
A multiple layer pad design featuring a support plate with a first plate and a second plate connected by separate junction points, allowing independent vibration and enhanced anchoring, along with a second friction surface and stiffening ribs to modify vibration frequency and improve friction material grip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single rigid support plate is used, then the friction material can be firmly anchored, but vibrations and noise (rattling and drumming) cannot be adequately dampened
Solution Approach 1:
The support plate is divided into multiple separate layers (first support plate and second support plate) that are positioned one over the other but not rigidly connected across their entire surfaces. This segmentation allows each layer to vibrate independently, dampening vibrations and reducing noise while still providing firm anchoring for the friction material through the combined structure.
2Object-affected harmful factors
If multiple layers are connected by welding points to allow independent vibration, then vibrations are dampened, but the anchoring of friction material may be compromised
Solution Approach 1:
The support plate structure has different properties in different regions: the edges and specific zones of the plates are designed to allow relative movement and independent vibration for damping purposes, while the central regions and interface zones provide stable anchoring for the friction material. This local differentiation of properties allows both vibration dampening and firm anchoring to coexist.
3Strength
If a meshed or netted metallic layer is added to reinforce the structure, then the friction material coupling is improved, but the device complexity increases
Solution Approach 1:
The invention uses a composite structure consisting of multiple support plate layers with different characteristics (solid plates rather than meshed layers). This composite approach provides both structural reinforcement and friction material coupling through the layered configuration and edge connections, avoiding the need for complex meshed or netted metallic layers while achieving the same functional benefits.
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 dampens vibrations, securely anchors the friction material, and is compatible with existing disc brake callipers, reducing noise and extending the lifespan of obsolete pads by modifying vibration frequencies and improving friction during braking.
Implementation Method 1
a multiple layer pad for a disc brake, with anti-rattling and anti-drumming effect... allows the relative sliding of the layers forming the plate, which may therefore vibrate in independent manner from one another, thus dampening the vibrations
Implementation Method 2
said first plate comprises a flat piston support surface suitable for facing at least one thrust means, and a first friction surface opposite to the piston support surface and at least partially suitable for facing the friction material... said at least one second plate... connected to the first plate in a plurality of junction points
Implementation Method 3
friction elements, typically pads for a disc brake, against a braking surface of the disc of a disc brake... vibrations may arise, under conditions of contact between the pad and disc of a disc brake, for example from the transition between dynamic and static friction phenomena
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A pad (1) for a disc brake comprising a support plate (10) and a friction material (5), in which said pad (10) mainly extends in a plane defined, when the plate (10) is in use, by a radial direction (R- R) and a tangential direction (T-T), which define a lying plane that can face a disc of a disc brake, and in which said support plate (10) comprises at least one first plate (11) and at least one second plate (12), in which said first plate (11) is in single-piece and extends over a region of said lying plane which defines the overall dimensions of the pad (1) in said lying plane, and in which said first plate (11) comprises a flat piston support surface (14) suitable for facing at least one thrust means, and a first friction surface (16) opposite the piston support surface (14) and at least partially suitable for facing the friction material (5), and in which said at least one second plate (12) is suitable for being interposed between said at least one first plate (11) and the friction material (5), and in which said at least one second plate (12) is connected to the first plate (11) in a plurality of junction points (18) which are separate from one another, in which said at least one second plate (12) extends over at least one portion of the friction surface (16) of said at least one first plate (11) delimited by a single closed perimeter, at least one portion of the friction surface (16) of said at least one first plate (11) is external to said closed perimeter of said at least one second plate (12) and faces said friction material (5), and in which said at least one second plate (12) defines a second friction surface (20) facing said friction material (5), which is continuous.