CA2251452A1 - Disc brake backing plate with an integrally moulded locking attachment and method of manufacturing same - Google Patents
Disc brake backing plate with an integrally moulded locking attachment and method of manufacturing same Download PDFInfo
- Publication number
- CA2251452A1 CA2251452A1 CA 2251452 CA2251452A CA2251452A1 CA 2251452 A1 CA2251452 A1 CA 2251452A1 CA 2251452 CA2251452 CA 2251452 CA 2251452 A CA2251452 A CA 2251452A CA 2251452 A1 CA2251452 A1 CA 2251452A1
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- backing plate
- hole
- friction material
- section
- ridge
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Abstract
A disc brake backing plate is disclosed. The backing plate has a first surface adapted to receive a friction material. A plurality of holes are defined within the backing plate.
Each hole has a wall which is sloped such that the area of the hole at the first surface of the backing plate is smaller than the area of the hole at the second surface of the backing plate. A
preferably integral ridge protrudes upwardly from the first surface of the backing plate surrounding the hole. The backing plate is formed by first forming a raised section on the first surface of the backing plate by preferably punching the second surface of the backing plate.
Second, a hole is formed within the raised section by preferably punching the raised section from the first surface of the backing plate. The hole is configured to receive a friction material.
Each hole has a wall which is sloped such that the area of the hole at the first surface of the backing plate is smaller than the area of the hole at the second surface of the backing plate. A
preferably integral ridge protrudes upwardly from the first surface of the backing plate surrounding the hole. The backing plate is formed by first forming a raised section on the first surface of the backing plate by preferably punching the second surface of the backing plate.
Second, a hole is formed within the raised section by preferably punching the raised section from the first surface of the backing plate. The hole is configured to receive a friction material.
Description
CA 022~l4~2 l998-l0-22 Title: DISC BRAKE BACKING PLATE WITH AN INTEGRALLY MOULDED
LOCKING ATTACHMENT AND METHOD OF MANUFACTURING
SAME
h~ve"lor. Ray A.Les,--an BACKGROUND OF THE INVENTION
Field of the Invention This invention relates to disc brakes for motor vehicles, and in particular to a disc brake backing plate with an integrally molded locking attachment configured to retain a 0 conventional friction pad, as well as a method of manufacturing the backing plate.
Description of the Prior Art Although disc brakes have been used on motor vehicles for many years, their use has increased substantially in recent years. In particular, there has been a significantly increased use of disc brakes on lower priced cars and trucks, with a consequent interest in 15 methods of reducing the cost of manufacturing disc brakes and replacement parts therefor on the part of both motor vehicle manufacturers and suppliers of parts for disc brakes. This increased use has also led to a significant increase in the after-market for disc brake replacement and repair.
Disc brakes, as currently manufactured, combine two main parts, namely a 20 backing plate and a friction pad. The backing plate is mounted in a brake assembly, and may be formed by stamping a suitable metal blank to produce a backing plate with a variety of bosses, holes, or other features for receiving and retaining the friction pad. The need to use high speed low cost manufacturing methods often results in irregularities in the backing plate which may lead to difficulties in attaching and/or retaining the friction pad on the backing plate 25 during braking, when the friction pad is in contact with the rapidly turning brake rotor, or even during the pre-installation handling of the brake pad assembly.
CA 022~l4~2 l998-l0-22 There are a variety of known ways of attaching a friction pad to a backing plate.
One such way is to attach the friction pad to the backing plates using rivets. One disadvantage of the riveting process is that it creates a rigid bond between the backing plate and the friction pad, which can, as a result of a sudden impact, lead to breaking of the friction pad.
5 Furthermore, this process often requires one or more additional manufacturing steps with a consequent increase in cost. In addition, when the friction pad is worn down over time, the rivets become exposed and rub against the brake rotor, causing scoring on the rotor which is costly to repair.
Another, more recently developed method of mounting the friction pad on the 0 backing plate is to use a pressurized molding process to mold the friction pad material directly onto the backing plate. In this process, the friction pad material may be prepared by blending the components of the brake lining and loosely molding the blended components into a pre-form. A conventional pressurized molding system is used to mold the friction pad pre-form onto the backing plate. A layer of cement or glue may be applied between the backing plate and the 15 friction pad to improve the adhesion between the two.
As pressure is applied to the mold assembly, the pre-form becomes heated and begins to flow, filling the mold and covering the appropriate surface of the backing plate. In this process, the lining is intended to flow into and around the various features, such as the holes stamped into the backing plate, to improve the bond between the backing plate and the friction 20 pad.
There is a need for a backing plate which provides improved shear and tensile strength in the bond between the friction pad and backing plate, than the strength which is provided by features, such as holes and bosses, stamped into the backing plate. Furthermore, CA 022~l4~2 l998-l0-22 when additional features are stamped into prior art backing plates o increase bond strength, additional manufacturing steps are required, adding to the cost.
The backing plate is subjected to a number of forces, such as the jarring of themoving vehicle, as well as vibration caused by the rotor and noise. Accordingly, there is a need for a backing plate which provides improved structural strength, and is able to reduce the likelihood of premature failure.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a backing plate which, while having a 0 simpler and less expensive design, provides improved shear and tensile strength in the connection between it and the friction pad. In addition, it is an object of the invention to provide a method of manufacturing the backing plate which reduces time and cost by requiring fewer manufacturing steps, while at the same time improving the structural strength of the backing plate.
In the invention, a disc brake backing plate has a first surface adapted to receive a friction material. A plurality of holes is defined within the backing plate. Each hole has a wall which is sloped such that the area of the hole at the first surface of the backing plate is smaller than the area of the hole at the second surface of the backing plate. A preferably integral ridge protrudes upwardly from the first surface of the backing plate surrounding the hole.
The backing plate, according to the present invention, is formed by first forming a raised section on the first surface of the backing plate by preferably punching the backing plate from the second surface. Second, a hole is formed within the raised section by preferably punching the hole from the first surface of the backing plate. The hole is adapted to receive a CA 022~l4~2 l998-l0-22 friction material.
Further features of the invention will be described or will become apparent in the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more clearly understood, the preferred embodiment thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which:
Fig. 1 is a perspective view of a preferred embodiment of the invention;
0 Fig. 2 is a partial cross-sectional view of the backing plate showing the first step in the method according to a preferred embodiment of the invention;
Fig. 3 is a partial cross-sectional view of the backing plate showing the secondstep in the method;
Fig. 4 is a partial cross-sectional view of the preferred embodiment; and Fig. 5 is a partial cross-sectional view of the preferred embodiment showing a conventional friction pad attached;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Fig. 1 shows a disc brake backing plate 1 of a conventional shape and thickness 20 (1/8 to 1/2 of an inch), made preferably from metal or a metal composite adapted to withstand the rigors of a conventional disc braking system. The backing plate has a first surface 2 on which a friction pad 9 (shown in Fig. 5) is to be mounted by a conventional molding process. Any suitable number of preferably circular holes 3 are defined within the backing plate. Each hole CA 022~l4~2 l998-l0-22 has a wall 4.
As best seen in Fig. 4, the wall is sloped such that the area of each hole at the first surface is smaller than the corresponding area at the second surface 5. A section 10 of the wall preferably has a rough surface which facilitates a strong bond with the friction pad during 5 the molding process. A ridge 6 protrudes outwardly from the first surface surrounding each hole. The inner side 7 of the ridge facing the hole is rounded to permit the friction pad material to flow easily into the hole. The outer side 8 of the ridge facing away from the hole has a rough surface and projects outwardly, generally perpendicular to the first surface 2.
Fig. 2 shows the first step in the process of manufacturing the backing plate 0 according to the present invention. A generally round raised section 15 is formed on the first surface 2 of the backing plate 1 by any suitable means, such as, for example, being cold-formed by driving a first punching tool 16 into the second surface 5 of the backing plate. The impact surface at the distal end 17 of the first punching tool preferably has a generally hemispherical shape in order to produce a circular ridge and hole.
Fig. 3 shows the final step in the process according to the present invention. A
hole 3 (shown in Fig. 4) is formed by any suitable means, such as, for example, being cold-formed by driving a second punching tool 18, having a generally cylindrical impact surface at its distal end 19, into the raised section 15 of the backing plate 1 with sufficient force to create the hole. As shown in Fig. 4, a ridge 6, as described above, remains on the first surface 2 of the 20 backing plate surrounding the hole. Because the ridge is preferably conserved from material that would otherwise form part of the slug punched out of the backing plate, the structural strength of the backing plate, according to the present invention, is increased 10-20% from backing plates manufactured by prior art processes.
CA 022~l4~2 l998-l0-22 The shape of the second punching tool is configured and the force of the impact is applied in such a way that a smooth shear section 20 is formed on the section of the wall 4 adjacent to the first surface 2, followed by a rough section 10, as described above. The shape of the second punching tool and the force of the impact also provides the slope in the wall, as described above.
Testing has indicated that the required bonding strength is obtained at minimal cost and while maintaining the required structural strength for the backing plate, by punching preferably four holes 3 with an average diameter of ranging from 318-3/4 Of an inch. The diameter of each hole at the second surface is 10-15% larger than the corresponding diameter at the first 0 surface. The optimal range for the width of the ridges 6 surrounding each hole is 0.04-0.12 inches and the optimal range for the height of the ridges is 1/16-1/8 Of an inch. The optimal curvature range to facilitate flow of the pre-form material into each hole is a curvature radius of 0.04-0.12 inches. It will be understood by those skilled in the art that these dimensions and numbers of holes may be varied, and such variations are within the scope of this invention.
During the molding process (not shown) to attach the friction pad, the pre-form material flows around each ridge 6 and into each hole 3. The rounded side 7 of each ridge facilitates the flow of the pre-form material into each hole. After the pre-form material solidifies and a bond with the backing plate is formed, as best shown in Fig. 5, the widening of each hole toward the second surface 5 provides improved tensile strength, while the outer, upwardly 20 projecting side 8 of each ridge provides improved shear resistance. These improvements are accomplished using a two step process, and without the need of adding additional features, such as bosses or knobs, leading to a decreased manufacturing time and significant cost savings.
CA 022~14~2 1998-10-22 It will be appreciated that the above description relates to the preferred embodiment by way of example only. Many variations on the invention will be obvious to those knowledgeable in the field, and such obvious variations are within the scope of the invention as described and claimed, whether or not expressly described.
LOCKING ATTACHMENT AND METHOD OF MANUFACTURING
SAME
h~ve"lor. Ray A.Les,--an BACKGROUND OF THE INVENTION
Field of the Invention This invention relates to disc brakes for motor vehicles, and in particular to a disc brake backing plate with an integrally molded locking attachment configured to retain a 0 conventional friction pad, as well as a method of manufacturing the backing plate.
Description of the Prior Art Although disc brakes have been used on motor vehicles for many years, their use has increased substantially in recent years. In particular, there has been a significantly increased use of disc brakes on lower priced cars and trucks, with a consequent interest in 15 methods of reducing the cost of manufacturing disc brakes and replacement parts therefor on the part of both motor vehicle manufacturers and suppliers of parts for disc brakes. This increased use has also led to a significant increase in the after-market for disc brake replacement and repair.
Disc brakes, as currently manufactured, combine two main parts, namely a 20 backing plate and a friction pad. The backing plate is mounted in a brake assembly, and may be formed by stamping a suitable metal blank to produce a backing plate with a variety of bosses, holes, or other features for receiving and retaining the friction pad. The need to use high speed low cost manufacturing methods often results in irregularities in the backing plate which may lead to difficulties in attaching and/or retaining the friction pad on the backing plate 25 during braking, when the friction pad is in contact with the rapidly turning brake rotor, or even during the pre-installation handling of the brake pad assembly.
CA 022~l4~2 l998-l0-22 There are a variety of known ways of attaching a friction pad to a backing plate.
One such way is to attach the friction pad to the backing plates using rivets. One disadvantage of the riveting process is that it creates a rigid bond between the backing plate and the friction pad, which can, as a result of a sudden impact, lead to breaking of the friction pad.
5 Furthermore, this process often requires one or more additional manufacturing steps with a consequent increase in cost. In addition, when the friction pad is worn down over time, the rivets become exposed and rub against the brake rotor, causing scoring on the rotor which is costly to repair.
Another, more recently developed method of mounting the friction pad on the 0 backing plate is to use a pressurized molding process to mold the friction pad material directly onto the backing plate. In this process, the friction pad material may be prepared by blending the components of the brake lining and loosely molding the blended components into a pre-form. A conventional pressurized molding system is used to mold the friction pad pre-form onto the backing plate. A layer of cement or glue may be applied between the backing plate and the 15 friction pad to improve the adhesion between the two.
As pressure is applied to the mold assembly, the pre-form becomes heated and begins to flow, filling the mold and covering the appropriate surface of the backing plate. In this process, the lining is intended to flow into and around the various features, such as the holes stamped into the backing plate, to improve the bond between the backing plate and the friction 20 pad.
There is a need for a backing plate which provides improved shear and tensile strength in the bond between the friction pad and backing plate, than the strength which is provided by features, such as holes and bosses, stamped into the backing plate. Furthermore, CA 022~l4~2 l998-l0-22 when additional features are stamped into prior art backing plates o increase bond strength, additional manufacturing steps are required, adding to the cost.
The backing plate is subjected to a number of forces, such as the jarring of themoving vehicle, as well as vibration caused by the rotor and noise. Accordingly, there is a need for a backing plate which provides improved structural strength, and is able to reduce the likelihood of premature failure.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a backing plate which, while having a 0 simpler and less expensive design, provides improved shear and tensile strength in the connection between it and the friction pad. In addition, it is an object of the invention to provide a method of manufacturing the backing plate which reduces time and cost by requiring fewer manufacturing steps, while at the same time improving the structural strength of the backing plate.
In the invention, a disc brake backing plate has a first surface adapted to receive a friction material. A plurality of holes is defined within the backing plate. Each hole has a wall which is sloped such that the area of the hole at the first surface of the backing plate is smaller than the area of the hole at the second surface of the backing plate. A preferably integral ridge protrudes upwardly from the first surface of the backing plate surrounding the hole.
The backing plate, according to the present invention, is formed by first forming a raised section on the first surface of the backing plate by preferably punching the backing plate from the second surface. Second, a hole is formed within the raised section by preferably punching the hole from the first surface of the backing plate. The hole is adapted to receive a CA 022~l4~2 l998-l0-22 friction material.
Further features of the invention will be described or will become apparent in the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more clearly understood, the preferred embodiment thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which:
Fig. 1 is a perspective view of a preferred embodiment of the invention;
0 Fig. 2 is a partial cross-sectional view of the backing plate showing the first step in the method according to a preferred embodiment of the invention;
Fig. 3 is a partial cross-sectional view of the backing plate showing the secondstep in the method;
Fig. 4 is a partial cross-sectional view of the preferred embodiment; and Fig. 5 is a partial cross-sectional view of the preferred embodiment showing a conventional friction pad attached;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Fig. 1 shows a disc brake backing plate 1 of a conventional shape and thickness 20 (1/8 to 1/2 of an inch), made preferably from metal or a metal composite adapted to withstand the rigors of a conventional disc braking system. The backing plate has a first surface 2 on which a friction pad 9 (shown in Fig. 5) is to be mounted by a conventional molding process. Any suitable number of preferably circular holes 3 are defined within the backing plate. Each hole CA 022~l4~2 l998-l0-22 has a wall 4.
As best seen in Fig. 4, the wall is sloped such that the area of each hole at the first surface is smaller than the corresponding area at the second surface 5. A section 10 of the wall preferably has a rough surface which facilitates a strong bond with the friction pad during 5 the molding process. A ridge 6 protrudes outwardly from the first surface surrounding each hole. The inner side 7 of the ridge facing the hole is rounded to permit the friction pad material to flow easily into the hole. The outer side 8 of the ridge facing away from the hole has a rough surface and projects outwardly, generally perpendicular to the first surface 2.
Fig. 2 shows the first step in the process of manufacturing the backing plate 0 according to the present invention. A generally round raised section 15 is formed on the first surface 2 of the backing plate 1 by any suitable means, such as, for example, being cold-formed by driving a first punching tool 16 into the second surface 5 of the backing plate. The impact surface at the distal end 17 of the first punching tool preferably has a generally hemispherical shape in order to produce a circular ridge and hole.
Fig. 3 shows the final step in the process according to the present invention. A
hole 3 (shown in Fig. 4) is formed by any suitable means, such as, for example, being cold-formed by driving a second punching tool 18, having a generally cylindrical impact surface at its distal end 19, into the raised section 15 of the backing plate 1 with sufficient force to create the hole. As shown in Fig. 4, a ridge 6, as described above, remains on the first surface 2 of the 20 backing plate surrounding the hole. Because the ridge is preferably conserved from material that would otherwise form part of the slug punched out of the backing plate, the structural strength of the backing plate, according to the present invention, is increased 10-20% from backing plates manufactured by prior art processes.
CA 022~l4~2 l998-l0-22 The shape of the second punching tool is configured and the force of the impact is applied in such a way that a smooth shear section 20 is formed on the section of the wall 4 adjacent to the first surface 2, followed by a rough section 10, as described above. The shape of the second punching tool and the force of the impact also provides the slope in the wall, as described above.
Testing has indicated that the required bonding strength is obtained at minimal cost and while maintaining the required structural strength for the backing plate, by punching preferably four holes 3 with an average diameter of ranging from 318-3/4 Of an inch. The diameter of each hole at the second surface is 10-15% larger than the corresponding diameter at the first 0 surface. The optimal range for the width of the ridges 6 surrounding each hole is 0.04-0.12 inches and the optimal range for the height of the ridges is 1/16-1/8 Of an inch. The optimal curvature range to facilitate flow of the pre-form material into each hole is a curvature radius of 0.04-0.12 inches. It will be understood by those skilled in the art that these dimensions and numbers of holes may be varied, and such variations are within the scope of this invention.
During the molding process (not shown) to attach the friction pad, the pre-form material flows around each ridge 6 and into each hole 3. The rounded side 7 of each ridge facilitates the flow of the pre-form material into each hole. After the pre-form material solidifies and a bond with the backing plate is formed, as best shown in Fig. 5, the widening of each hole toward the second surface 5 provides improved tensile strength, while the outer, upwardly 20 projecting side 8 of each ridge provides improved shear resistance. These improvements are accomplished using a two step process, and without the need of adding additional features, such as bosses or knobs, leading to a decreased manufacturing time and significant cost savings.
CA 022~14~2 1998-10-22 It will be appreciated that the above description relates to the preferred embodiment by way of example only. Many variations on the invention will be obvious to those knowledgeable in the field, and such obvious variations are within the scope of the invention as described and claimed, whether or not expressly described.
Claims (14)
1. A method of manufacturing a disc brake backing plate having a first surface adapted to receive a friction material, the method comprising the steps of:
(a) forming a raised section of material on the first surface of said backing plate; and (b) forming a hole within the raised section, the hole being surrounded by a ridge protruding outwardly from the first surface, the hole being adapted to receive the friction material.
(a) forming a raised section of material on the first surface of said backing plate; and (b) forming a hole within the raised section, the hole being surrounded by a ridge protruding outwardly from the first surface, the hole being adapted to receive the friction material.
2. The method of claim 1, wherein the ridge is cold formed.
3. The method of claim 2, wherein the raised section is formed by a first punching tool.
4. The method of claim 3, wherein the raised section is formed by impacting a second surface of the backing plate by the first punching tool.
5. The method of claim 4, wherein the hole and the ridge is formed by a punching the raised section with the second punching tool.
6. A disc brake backing plate comprising:
(a) a plate having a first surface and a second surface, said first surface being adapted to receive a friction material;
(b) the plate defining a plurality of holes therein, each hole having a wall, said wall being sloped such that the area of each hole at the first surface is smaller than the area of each hole at the second surface; and (c) a plurality of ridges protruding outwardly from said first surface, each ridge surrounding each hole.
(a) a plate having a first surface and a second surface, said first surface being adapted to receive a friction material;
(b) the plate defining a plurality of holes therein, each hole having a wall, said wall being sloped such that the area of each hole at the first surface is smaller than the area of each hole at the second surface; and (c) a plurality of ridges protruding outwardly from said first surface, each ridge surrounding each hole.
7. The backing plate of claim 6, wherein each ridge has a rounded inner surface, the inner surface being adapted to facilitate the flow of the friction material into the hole.
8. The backing plate of claim 7, wherein each ridge has a rough outer surface, said outer surface being positioned substantially perpendicular to said first surface.
9. The backing plate of claim 8, wherein the wall comprises a rough section proximate to the second surface, said rough section being adapted to facilitate bonding with the friction material.
10. The backing plate of claim 9, wherein the wall further comprises a substantially smooth section proximate to the first surface, the substantially smooth section being adapted to facilitate the flow of the friction material further into the hole.
11. The backing plate of claim 10, wherein each hole is substantially circular.
12. The backing plate of claim 6, wherein the wall comprises a rough section proximate to the second surface, said rough section being adapted to facilitate bonding with the friction material.
13. The backing plate of claim 12, wherein the wall further comprises a substantially smooth section proximate to the first surface, the substantially smooth section being adapted to facilitate the flow of the friction material further into the hole.
14. The backing plate of claim 6, wherein the wall further comprises a substantially smooth section proximate to the first surface, the substantially smooth section being adapted to facilitate the flow of the friction material further into the hole.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US6366297P | 1997-10-28 | 1997-10-28 | |
| US60/063,662 | 1997-10-28 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2251452A1 true CA2251452A1 (en) | 1999-04-28 |
Family
ID=29547817
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2251452 Abandoned CA2251452A1 (en) | 1997-10-28 | 1998-10-22 | Disc brake backing plate with an integrally moulded locking attachment and method of manufacturing same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2251452A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104690505A (en) * | 2015-02-10 | 2015-06-10 | 天津宝骏科技发展有限公司 | Process for machining reinforced plate in beam on radiator cabinet frame |
-
1998
- 1998-10-22 CA CA 2251452 patent/CA2251452A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104690505A (en) * | 2015-02-10 | 2015-06-10 | 天津宝骏科技发展有限公司 | Process for machining reinforced plate in beam on radiator cabinet frame |
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| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |