Pad Spring Surface Roughening for Coating Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pad springs for disc brakes experience noise and disrupted sliding due to metal-to-metal contact, and existing coating methods are inefficient with poor coverage and many defects, leading to a need for improved surface roughening and adhesive force enhancement.
Innovation Solution
A manufacturing method involving pressing, heat treatment, surface sanding using a basket-based sanding device, and coating with Teflon or elastic materials to enhance the adhesive force and reduce friction, including specific steps for sanding and coating processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a coating material is coated on a smooth pad spring surface, then the coating process is simple, but the adhesive force is insufficient leading to poor coating quality and many defects
Solution Approach 1:
The pad spring surface is roughened through sanding before coating to create a surface structure that enhances coating adhesion. This preliminary surface preparation action prevents coating defects and improves coating quality, resolving the contradiction between coating simplicity and adhesion effectiveness.
2Ease of operation
If metal-to-metal contact is used between pad plates and pad springs, then the structure is simple, but noise is generated and sliding is disrupted due to friction
Solution Approach 1:
A coating material is introduced as an intermediary layer between the metal pad plates and metal pad springs. This coating layer acts as a mediator that reduces direct metal-to-metal contact, thereby reducing friction, eliminating noise, and ensuring smooth sliding operation of the pad plates.
3Productivity
If conventional coating methods are used on pad springs, then the process is straightforward, but coating time is long and coverage is poor with many defects
Solution Approach 1:
The pad spring surface is pre-treated by roughening through sanding before coating application. This preliminary surface preparation creates optimal surface conditions that enable faster, more uniform coating application with better coverage and fewer defects, thereby improving both coating efficiency and coating quality simultaneously.
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 method results in improved smooth sliding, reduced noise, and extended durability by increasing the adhesive force of the coating on the pad springs, maintaining friction reduction and shock absorption functions over time.
Implementation Method 1
a pad spring sanding step of roughly sanding a surface of the pad spring heat treated at the pad spring heat treatment step
Implementation Method 2
increasing adhesive force of a coating material coated on the pad spring
Data Source
AI summary
Disclosed are a pad spring for disc brakes wherein the surface of the pad spring is roughened through the use of a sanding device using a basket, thereby increasing adhesive force of a coating material coated on the pad spring, and a manufacturing method thereof.