Sensorized Brake Pad with Protective Element

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing sensorized brake pads for vehicles face challenges with high temperatures and pressures during production and operation, which can compromise the structural integrity and performance of piezoceramic sensors, leading to unreliable stress detection and potential damage.

Innovation Solution

A protective element made of electrically insulating material with specific mechanical properties is used to limit and redirect external compression forces away from piezoceramic sensors, combined with a thermal shield for temperature protection, allowing the sensors to operate effectively under high temperatures and pressures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If high compression load is applied to join friction material to metallic support element, then permanent joining is achieved, but piezoceramic sensors may be damaged due to crushing

Engineering Contradiction:

Improvejoining strengthVSAvoidsensor integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The support element is divided into a first portion (metallic) and a second portion (protective element) that are mechanically separated but functionally integrated. This segmentation allows the first portion to handle high compression loads for joining friction material while the second portion protects the piezoceramic sensor from crushing, resolving the contradiction between achieving strong joining and maintaining sensor integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The protective element acts as an intermediary between the high compression load from friction material joining and the piezoceramic sensor. It mediates the force transmission by providing mechanical protection and distributing loads away from the sensor, enabling both strong joining and sensor protection simultaneously.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If piezoceramic sensors are used to detect braking forces, then stress detection capability is improved, but sensors are vulnerable to damage from high temperatures and pressures

Engineering Contradiction:

Improvestress detectionVSAvoidthermal and mechanical stress

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The protective element is pre-installed around the piezoceramic sensor before the sensor is exposed to high temperatures and pressures during braking operations. This beforehand cushioning provides mechanical protection against crushing forces and thermal shielding against high temperatures, allowing the sensor to maintain measurement precision without vulnerability to damage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The support element combines a metallic first portion with a protective second portion made of different material properties. This composite structure integrates the load-bearing capability of metal with the protective and thermal-resistant properties of the second material, enabling the sensor to detect stresses accurately while being protected from harmful thermal and mechanical factors.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If the braking device is designed for heavy vehicles with operating temperatures exceeding 600°C, then versatility is improved, but sensor reliability under such extreme conditions deteriorates

Engineering Contradiction:

Improveapplication rangeVSAvoidsensor performance at high temperature

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The protective element serves multiple functions simultaneously: mechanical protection against crushing, thermal shielding from high temperatures, and structural support. This multi-functionality enables the braking device to be adapted to heavy vehicle applications with temperatures exceeding 600°C while maintaining sensor reliability, thus expanding versatility without sacrificing performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 ensures the reliability and longevity of sensorized brake pads by protecting piezoceramic sensors from mechanical and thermal stress, maintaining optimal performance across various vehicle types, including heavy vehicles, and extending the operational lifespan.

Implementation Method 1

one or more piezoceramic sensors supported by the metallic support element... the piezoceramic sensors detect the forces that are exchanged

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

said protective element exhibits mechanical properties such as to limit the force transmitted to the piezoceramic sensor when an external compression force is applied

Methodology Applied

Scientific EffectMechanical stress distribution:

Implementation Method 3

said protective element has a thermal shield for said at least one piezoceramic sensor

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP3289238B1Brake pad for vehicles

Publication Date: 2020.10.21 ITT ITAL SRL

Figure 1
Figure 2
Figure 3

AI summary

A braking device for vehicles, comprising a support element (2), a block of friction material (3) supported by the support element (2), at least one piezoceramic sensor (4) supported by the support element (2) and interposed between the block of friction material (3) and the support element (2), and a protective element (16) located at the piezoceramic sensor (4) and embedding the latter.