阅读说明：本技术 带有具有预定设计的表面涂层的制动垫块 (Brake pad with surface coating having predetermined design ) 是由 M·菲普斯 M·盖蒂 R·巴克德 于 2020-08-25 设计创作，主要内容包括：本发明涉及带有具有预定设计的表面涂层的制动垫块。一种制动垫块,具有：背板、摩擦衬片和被附连到所述摩擦衬片的表面涂层。所述表面涂层可以被配制为比单独的摩擦衬片更快地在制动盘上生成传递层。所述表面涂层可以按照预定设计被粘附到所述摩擦衬片。(The invention relates to a brake pad with a surface coating having a predetermined design. A brake pad, comprising: a backing plate, a friction lining, and a surface coating attached to the friction lining. The surface coating may be formulated to produce a transfer layer on the brake disc more quickly than the friction lining alone. The surface coating may be adhered to the friction lining according to a predetermined design.)

1. A brake pad, comprising:

a back plate having a mounting surface;

a friction lining having a tribological surface and coupled to the mounting surface such that the tribological surface is parallel to the mounting surface within a certain tolerance; and

a surface coating affixed to the tribological surface, the surface coating configured to establish tribological contact of the brake pad with a brake disc, wherein,

the surface coating is affixed to the tribological surface using an adhesive, the surface coating having a predetermined design, and wherein the surface coating is configured to create a transfer layer of material on the brake disc during tribological contact of the brake pad with the brake disc.

2. The brake pad of claim 1, wherein the predetermined design of the surface coating is created via a stamping operation using a plate characterized by the predetermined design.

3. The brake pad of claim 1, wherein the predetermined design of the surface coating comprises a geometric pattern.

4. The brake pad of claim 3, wherein the geometric pattern comprises a repeating pattern of polygonal shapes.

5. The brake pad of claim 4, wherein the geometric pattern comprises a repeating pattern of hexagonal shapes.

6. The brake pad of claim 3, wherein the geometric pattern comprises a repeating pattern of elliptical shapes.

7. The brake pad of claim 3, wherein the geometric pattern comprises a repeating pattern having at least two different repeating shapes within the pattern.

8. The brake pad of claim 1, wherein the predetermined design comprises an asymmetric distribution of surface coating relative to a surface area of the tribological surface.

9. The brake pad of claim 8, wherein the friction lining includes a width dimension and a length dimension orthogonal to the width dimension and defining the friction pad between a proximal end and a distal end, and wherein the asymmetric distribution of surface coating includes a greater coverage of the width near the proximal end and a lesser coverage of the width near the distal end, wherein surface coating coverage transitions gradually along the length from the proximal end to the distal end.

10. The brake pad of claim 1, wherein the adhesive has a specific cure time of no greater than 180 seconds.

11. A brake pad, comprising:

a back plate having a mounting surface;

a friction lining having a tribological surface and coupled to the mounting surface such that the tribological surface is parallel to the mounting surface within a certain tolerance; and

a surface coating affixed to the tribological surface, the surface coating configured to establish tribological contact of the brake pad with a brake disc, wherein,

the surface coating is affixed to the tribological surface using an adhesive, the surface coating being visually distinct from the friction lining, and wherein the surface coating is configured to create a transfer layer of material on the brake disc during tribological contact of the brake pad with the brake disc.

12. The brake pad of claim 11, wherein the surface coating comprises a predetermined design having an asymmetric distribution of surface coating relative to a surface area of the tribological surface.

13. The brake pad of claim 12, wherein the friction lining includes a width dimension and a length dimension orthogonal to the width dimension and defining the friction lining between a proximal end and a distal end, and wherein the asymmetric distribution of surface coating includes a greater coverage of the width near the proximal end and a lesser coverage of the width near the distal end, wherein surface coating coverage transitions gradually along the length from the proximal end to the distal end.

14. The brake pad of claim 11, wherein the adhesive has a specific cure time of no greater than 180 seconds.

15. A brake pad, comprising:

a back plate having a mounting surface;

a friction lining having a tribological surface and coupled to the mounting surface such that the tribological surface is parallel to the mounting surface within a certain tolerance; and

a surface coating affixed to the tribological surface, the surface coating configured to establish tribological contact of the brake pad with a brake disc, wherein,

the surface coating is affixed to the tribological surface using an adhesive, the surface coating being visually distinct from the friction lining and having a predetermined design, and wherein the surface coating is configured to create a transfer layer of material on the brake disc during tribological contact of the brake pad with the brake disc.

16. The brake pad of claim 15, wherein the predetermined design of the surface coating is created via a stamping operation using a plate characterized by the predetermined design.

17. The brake pad of claim 15, wherein the predetermined design of the surface coating comprises a geometric pattern having a repeating pattern of polygonal shapes.

18. The brake pad of claim 17, wherein the geometric pattern comprises a repeating pattern including at least two different repeating shapes within the pattern.

19. The brake pad of claim 15, wherein the predetermined design comprises an asymmetric distribution of surface coating relative to a surface area of the tribological surface.

20. The brake pad of claim 19, wherein the friction lining includes a width dimension and a length dimension orthogonal to the width dimension and defining the friction lining between a proximal end and a distal end, and wherein the asymmetric distribution of the surface coating includes a greater coverage of the width near the proximal end and a lesser coverage of the width near the distal end, wherein surface coating coverage transitions gradually along the length from the proximal end to the distal end.

Technical Field

The present disclosure relates to brake pads (brake pads) and brake pad assemblies.

Background

Brake pads used in motor vehicles undergo a "break-in" process that involves the gradual deposition of friction material onto the surface of the brake disc. After the break-in process, the brake pads exhibit a more efficient and smoother delivery of braking power.

However, the break-in process is time consuming and may require slow and careful operation to make the newly installed brake most effective. Current braking systems can suffer from rapid heat build-up if the brakes are applied before or during the break-in process, which can lead to brake disc damage due to warping. If the brake pad is exposed to excessive heat buildup, it may itself suffer "burnishing" of the surface material, thereby reducing the efficiency of the brake and shortening the service life of the brake pad.

Disclosure of Invention

One aspect of the present disclosure relates to a brake pad, comprising: a back plate having a mounting surface; a friction lining coupled to the mounting surface; and a surface coating adhered to a tribological (tribological) surface of the friction lining. The tribological surfaces of the friction linings are operable to apply a frictional force to the drum rotor to generate braking power. The surface coating may be applied to the tribological surface using an adhesive. In some embodiments, the surface coating may be applied using a stamping operation. In some embodiments, the surface coating may include a predetermined design, such as a geometric pattern or an asymmetric distribution about the tribological surface.

Another aspect of the present disclosure is directed to a brake pad including a backing plate, a friction lining, and a surface coating, wherein the surface coating is visually distinct from the friction lining. In some embodiments, the visual difference between the friction lining and the surface coating may allow the surface coating to be applied using a predetermined design to create different visual effects.

The above and other aspects of the present disclosure will be explained in more detail below with reference to the accompanying drawings.

Drawings

FIG. 1 is an illustration of a brake pad having a surface coating.

FIG. 2 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 3 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 4 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 5 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 6 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 7 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 8 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 9 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 10 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 11 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 12 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 13 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 14 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 15 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 16 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 17 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 18 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 19 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 20 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

FIG. 21 is an illustration of a brake pad having a surface coating applied according to a predetermined design.

Detailed Description

The illustrated embodiments are disclosed with reference to the accompanying drawings. However, it is to be understood that the disclosed embodiments are intended only as examples that may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. Specific structural and functional details disclosed are not to be interpreted as limiting, but as a representative basis for teaching one skilled in the art how to practice the disclosed concepts.

Fig. 1 illustrates a brake pad 100 according to embodiments of the teachings herein. Brake pad 100 includes a backing plate 101 having a mounting surface 103. Mounting surface 103 may be adapted to provide a coupling surface between back plate 101 and friction lining 105. The friction linings 105 may be operable to apply a frictional force to the brake disc to generate a braking power of the vehicle. The friction of the friction lining 105 is transmitted via a tribological surface 107, which tribological surface 107 is substantially parallel to the mounting surface 103 within certain tolerances. The friction lining 105 formulation may be adapted for a particular vehicle type, actuator design, brake disc type, or any combination thereof without departing from the teachings disclosed herein.

During normal braking operation, the friction linings 105 wear and during the break-in period of operation, residual material may be left on the surface of the drum rotor. Such residual material is referred to as a "transfer layer," and a properly formed transfer layer can improve the efficiency of braking, the smoothness of the application of braking force, and the service life of the brake pads. Until break-in is complete, the brake can operate at sub-optimal performance.

The transfer layer also reduces heat build-up during braking, which may prevent damage to the brake disc or heat from adversely affecting the friction lining. However, because friction lining 105 is formulated to resist wear, the time taken to run-in may be longer than desired. To this end, the brake pad 100 includes a surface coating 109 applied to the tribological surface 107 of the friction lining 105.

Surface coating 109 may be advantageously formulated to readily produce a transfer layer having properties similar to those of friction lining 105, except that it forms faster under normal use. The transmission layer generated by surface coating 109 may exhibit friction characteristics similar to the transmission layer generated by friction lining 105 within certain tolerances, except that the transmission layer may be generated at a substantially lower heating level and substantially fewer braking cycles than friction lining 105 alone. Thus, the brake disc may be protected from heat-related warping, and the friction lining 105 may be protected from adverse conditions caused by heat build-up during running-in. In some previous designs, break-in may require 300 miles to 400 miles of operation, but the addition of the surface coating 109 may advantageously reduce the necessary operations to complete the break-in. The formulation of the surface coating 109 may be adapted for a particular vehicle type, brake design, brake disc type, friction lining formulation, or any combination thereof without departing from the teachings disclosed herein.

The surface coating 109 may be applied to the friction lining 105 using an adhesive. The adhesive may be formulated for a cure time that is reasonably long for complete application, but short enough that the addition of a surface coating to the brake pad 100 has minimal impact on manufacturing and production time. In some embodiments, the cure time may be 180 seconds or less. In some embodiments, the cure time may be 60 seconds. In the depicted embodiment, the curing time may be accelerated by forced drying using heat, but other embodiments may utilize ambient temperature drying without departing from the teachings disclosed herein. In some embodiments, commercial adhesives may be utilized, such as "quick dry" formulations. In some embodiments, the adhesive may include an aliphatic resin or polyvinyl acetate. Other embodiments may include other formulations without departing from the teachings disclosed herein.

FIG. 1 provides an illustration of a brake pad 100 having a surface coating 109 that is uniformly applied to the entire area of the tribological surface 107 of the friction lining 105. Other embodiments may include different applications that may be advantageously used to accommodate different vehicle specifications. The application of the surface coating 109 may be applied using a stamping operation operable to accommodate a wide variety of application designs. The stamping operation may advantageously allow any arbitrary design desired to be utilized during manufacturing.

In the depicted embodiment, the surface coating 109 provides a different visual appearance to the friction lining 105 such that the applied design is visually identifiable. This visual difference may advantageously allow the surface coating 109 to be applied to the friction lining 105 in a manner that allows branding beyond operational advantages. The application of the surface coating 109 may utilize any design without departing from the teachings disclosed herein. For example, the design may be sold with a particular aesthetic or trademark design to identify the brake pad as having been manufactured by a particular manufacturer.

In some embodiments, the application of the surface coating 109 may provide a geometric pattern. FIG. 2 is an illustration of a brake pad 200 that utilizes the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but the application of top coat 109 forms a geometric pattern that includes a hexagonal grid. FIG. 3 is an illustration of a brake pad 300 that utilizes the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but the application of top coat 109 forms a geometric pattern that includes a hexagonal repeating pattern. Other embodiments may have other designs without departing from the teachings disclosed herein.

FIG. 4 is an illustration of a brake pad 300 that utilizes the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but the application of top coat 109 forms a geometric pattern that includes a grid of circular contours. FIG. 5 is an illustration of a brake pad 500, the brake pad 500 utilizing the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but the application of top coat 109 forms a geometric pattern comprising a repeating pattern of circles. Although the geometric patterns refer to circles in the depicted embodiments of fig. 4 and 5, other embodiments may refer to other elliptical shapes, such as elliptical, oval, or conical cross-sections, without departing from the teachings disclosed herein.

FIG. 6 is an illustration of a brake pad 600 that utilizes the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but the application of top coat 109 forms a geometric pattern comprising a grid of parallelograms. FIG. 7 is an illustration of a brake pad 700 that utilizes the same formulation of backing plate 101, friction lining 105, and top coating 109 as brake pad 100, but the application of top coating 109 forms a geometric pattern that includes a repeating pattern of parallelograms.

FIG. 8 is an illustration of a brake pad 800, the brake pad 800 utilizing the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but the application of top coat 109 forms a geometric pattern comprising a repeating pattern of triangles. FIG. 9 is an illustration of a brake pad block 900 that utilizes the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad block 100, but the application of top coat 109 forms a geometric pattern that includes a triangular mesh. Although the geometric patterns in the depicted embodiments of fig. 8 and 9 refer to equilateral triangles, other embodiments may include other triangular shapes without departing from the teachings disclosed herein.

FIG. 10 is an illustration of a brake pad 1000 that utilizes the same formulation of backing plate 101, friction lining 105, and top coating 109 as brake pad 100, but the application of top coating 109 forms a geometric pattern that includes a repeating pattern of diamonds configured in a "diamond plate" design. FIG. 11 is an illustration of a brake pad 1100 utilizing the same formulation of backing plate 101, friction lining 105, and top coating 109 as brake pad 100, but with the application of top coating 109 forming a geometric pattern comprising a grid of diamonds configured in a "diamond plate" design.

FIG. 12 is an illustration of a brake pad 1200 that utilizes the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but the application of top coat 109 forms a geometric pattern that includes a repeating pattern of squares. FIG. 13 is an illustration of a brake pad block 1300 that utilizes the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad block 100, but the application of top coat 109 forms a geometric pattern that includes a grid of squares. Although the geometric patterns refer to squares in the depicted embodiments of fig. 12 and 13, other embodiments may include other rectangular shapes without departing from the teachings disclosed herein.

Some embodiments may include geometric patterns that utilize multiple geometric shapes.

FIG. 14 is an illustration of a brake pad 1400 utilizing the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but with the application of top coat 109 forming a geometric pattern comprising a repeating pattern of squares and triangles. FIG. 15 is an illustration of a brake pad block 1500 that utilizes the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad block 100, but the application of top coat 109 forms a geometric pattern that includes a grid of squares and triangles. Although the geometric patterns refer to squares and equilateral triangles in the depicted embodiments of fig. 14 and 15, other embodiments may include other rectangles, triangles, or other shapes without departing from the teachings disclosed herein. Although squares are depicted as having a larger area than triangles in the depicted embodiments of fig. 14 and 15, other embodiments may include shapes of different scale sizes without departing from the teachings disclosed herein.

FIG. 16 is an illustration of a brake pad 1600 that utilizes the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but the application of top coat 109 forms a geometric pattern that includes a grid depicting a pattern of squares, hexagons, and triangles. FIG. 17 is an illustration of a brake pad 1700, the brake pad 1700 utilizing the same formulation of backing plate 101, friction lining 105, and surface coating 109 as brake pad 100, but the application of the surface coating 109 forms a geometric pattern comprising a repeating pattern of squares, hexagons, and triangles. Although in the depicted embodiments of fig. 16 and 17 the geometric patterns relate to squares, regular hexagons, and equilateral triangles, other embodiments may include other rectangles, polygons, triangles, or other shapes without departing from the teachings disclosed herein. Although the hexagons are depicted as having a larger area than squares and the squares are depicted as having a larger area than triangles in the depicted embodiments of fig. 16 and 17, other embodiments may include shapes of different scale sizes without departing from the teachings disclosed herein.

Some embodiments may include designs having geometric patterns beyond repetitive application of shapes.

FIG. 18 is an illustration of a brake pad 1800 utilizing the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but with the application of top coat 109 forming a geometric pattern comprising a series of concentrically arranged circular cross-sections. Some embodiments may include a "reverse" application of the surface coating 109 as depicted in figure 18, wherein the surface coating 109 forms a circular cross-section having an area that is smaller than the area of the friction lining 105 without the coating. Such embodiments will not depart from the teachings disclosed herein.

FIG. 19 is an illustration of a brake pad 1900 that utilizes the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but the application of top coat 109 forms a geometric pattern that includes a series of repeating "zig-zag" shapes. Some embodiments may include a "reverse" application of the surface coating 109 as depicted in figure 19, wherein the surface coating 109 forms a zigzag having an area that is smaller than the area of the friction lining 105 without the coating. Such embodiments will not depart from the teachings disclosed herein.

Some embodiments may include asymmetric application of a surface coating without departing from the teachings disclosed herein.

FIG. 20 is an illustration of a brake pad 2000, the brake pad 2000 utilizing the same formulation of backing plate 101, friction lining 105, and surface coating 109 as brake pad 100, but with the application of surface coating 109 being applied asymmetrically to the tribological surface of friction lining 105. Specifically, the surface coating 109 varies with respect to position along the length x of the friction lining 105. The variation in application in the depicted embodiment varies along the length x relative to the width y of the friction lining 105. At the proximal end x1 of the length x, all associated widths y are covered by the surface coating 109. At the distal end x2 of length x, at any point along width y, no friction lining 105 is covered by surface coating 109. The coverage of the surface coating 109 with respect to the width y tapers between the proximal end x1 and the distal end x 2. In the depicted embodiment, the coverage of the surface coating 109 is linearly tapered, but other embodiments may include other arrangements without departing from the teachings disclosed herein. In some embodiments, the brake pad 2000 may be most effectively utilized in a particular braking position within the vehicle. In such embodiments, the brake pads may be utilized cooperatively in a tandem bicycle to provide effective braking on all wheels of the vehicle, wherein each brake pad, when installed in the vehicle, has a dedicated design suitable for its particular location without departing from the teachings disclosed herein.

Other asymmetric designs may be utilized. FIG. 21 is an illustration of a brake pad 2100, the brake pad 2100 utilizing the same formulation of backing plate 101, friction lining 105, and surface coating 109 as brake pad 100, but with the application of surface coating 109 being applied in a "hot bar flame" like design. The design of the surface coating 109 may be utilized to provide a visually distinct look of the brake pad and may be used to distinguish a particular brake pad from a potential purchaser when displayed in a retail environment. Other designs may be used without departing from the teachings disclosed herein. Other embodiments may utilize designs comprised of logos, approved characters, graphical designs, text, photo-realistic images, or any combination thereof, without departing from the teachings disclosed herein.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the disclosed apparatus and methods. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure as claimed. Features of the various embodiment can be combined to form additional embodiments of the disclosed concept.