Undulated Disc Brake Pad Edge for Heat and Wear Control
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Solution Overview
Problem
Current brake pads face performance issues such as brake noise, stopping power, stopping distance, wear resistance, manufacturability, and thermal management, which are not adequately addressed for various vehicle platforms.
Innovation Solution
The development of a brake pad with a friction surface defined by a peripheral edge featuring a complex edge profile with undulations, curved grooves, and chamfered surfaces, which increases the contact area and edge length, improving thermal management and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional friction pads with simple edge profiles are used, then manufacturing is easier and device complexity is lower, but brake noise increases and stopping power decreases
Solution Approach 1:
The peripheral edge of the friction pad is segmented into multiple discrete undulations rather than being a continuous smooth edge. This segmentation creates multiple small contact zones that distribute stress and reduce vibration-induced noise while maintaining the overall edge structure.
Solution Approach 2:
The edge profile incorporates curved undulations with specific radii of curvature instead of sharp angular features. These curved surfaces distribute contact pressure more evenly and reduce stress concentration points that would otherwise generate noise and wear.
2Power
If conventional friction pads with simple edge profiles are used, then device complexity is lower, but stopping power and stopping distance performance worsen
Solution Approach 1:
The edge is divided into multiple undulating segments that increase the total contact length with the rotor. This segmentation allows for greater frictional force generation across the contact interface, improving stopping power without requiring a larger overall pad size.
Solution Approach 2:
The edge profile transitions from a two-dimensional planar edge to a three-dimensional undulating structure. This adds vertical dimensionality to the contact surface, increasing the effective contact area and frictional engagement with the rotor for improved braking performance.
3Temperature
If conventional friction pads are used, then thermal management is insufficient, but increasing friction surface area increases device complexity
Solution Approach 1:
The friction surface is segmented into multiple undulating zones rather than a single continuous surface. This segmentation increases the total surface area available for heat dissipation while distributing thermal loads across multiple zones, preventing hot spot formation.
Solution Approach 2:
The curved undulations create increased surface area through geometric curvature. These curved surfaces provide greater contact area with the rotor for heat generation and dissipation, improving thermal management through enhanced heat transfer pathways.
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 complex edge profile design enhances brake performance by reducing brake noise, improving stopping power, and extending the life of the brake pad, particularly in heavy-loaded conditions, while maintaining consistent pedal response and reducing rotor wear.
Implementation Method 1
increases the contact area and edge length, improving thermal management
Implementation Method 2
friction pad attached to the backing plate... friction surface at least partially defined by a peripheral edge
Data Source
Figure 1~3
Figure 4A~4C
Figure 5~6
AI summary
A vehicle disc brake pad having a backing plate and a friction pad that includes a complex edge profile formed from a plurality of undulations on at least one side edge of the periphery. Each undulation includes a wave crest and a wave trough that extend toward and away from the periphery of the backing plate, respectively. The brake pad may provide improved thermal management and wear resistance, thereby improving the life span of the brake pad, particularly when used with heavier vehicles such as trucks, crossover vehicles, and sports utility vehicles.