DE102012103196B4 - Brake pad backing plate and method of manufacturing a brake pad backing plate - Google Patents

Abstract

Brake lining carrier plate (1.1, 1.2) with a piston side (3) and a lining side (2) for a disc brake of a vehicle, the piston side (3) having a peripheral depression (20) and an annular depression (17) or a circular depression (24 ) is arranged and on the lining side (2) a material recess (11,16) is arranged, which has an annular elevation (13) or a circular elevation (21).

Description

technical field

The invention relates to a brake pad carrier plate and a method for producing a brake pad carrier plate for a disc brake system of a vehicle according to the features of claims 1 and 6.

State of the art

Brake pad backing plates are the plates on which the brake pads are mounted. This connection is defined as a brake shoe. A brake shoe is designed for disc brake systems as a counterpart of the disc. In a disc brake system, a disc is mounted on an axis of rotation. This rotates with the same angular speed as the wheels. A caliper is positioned above the disc, in which the brake shoes are inserted through existing guides and mechanisms. The caliper is positioned so that the pads on the brake shoes face the disc. A brake cylinder is also provided on the brake caliper. This transmits a hydraulically boosted braking force from the brake pedal to the brake shoes. This presses the brake shoes and thus the pads onto the disc. This creates a friction torque opposite to the angular torque generated by the angular velocity. This results in a reduction in the angular velocity and thus a reduction in the driving speed. During this braking process and the resulting physical effects, a brake pad backing plate is exposed to various lateral forces, pressure and very high temperature influences. There are many known designs of brake pad backing plates and manufacturing methods for manufacturing brake pad backing plates that today make it possible to counteract these effects.

For manufacturing processes of brake lining carrier plates, for example, the DE 195 32 019 C1 and the DE 103 50 725 A1 and the casting processes described there. In the DE 195 32 019 C1 discloses a carrier plate for disc brakes of motor vehicles, which consists of a gray cast iron material and has a surface structure on a side carrying the friction lining, which is formed from shaped bodies with undercuts.

The DE 103 50 725 A1 relates to a backing plate and a method for its production. In the method, a support plate model is first provided, which has a plurality of recesses on a side surface. Pins can be introduced into these in such a way that some of the pins protrude from the support plate model. The support plate model and the sections of the pins protruding from the model are then surrounded by a molding compound and this is compressed and/or hardened. After compacting and/or hardening, the carrier plate model is removed from the molding compound in such a way that the pins remain in it and a carrier plate casting cavity is formed. A melt is poured into the cavity, with the portions of the pins protruding into the support plate cavity being surrounded by the melt. After the melt has solidified, the backing plate can be removed from the mold.

The DE 10 2004 014 858 A1 again discloses the stamping of a pad carrier plate. A lining carrier plate for receiving a friction lining with a depression running on the friction lining side, in particular for disc brakes of vehicles, is described here. In order to ensure a high holding force of the friction lining, particularly in the edge area, and reliable production with an essentially planar surface of the lining carrier plate, it is provided that the course of the indentation is interrupted.

The DE 20 2005 011 660 U1 describes a stamping method for a pad carrier for a disc brake with a main surface facing the disc brake in the installed state of a brake disc and an edge surface running around the main surface in a top view, the main surface having a region with a minimum quality. The lining carrier is characterized in that the main surface has at least one area whose quality is below the minimum quality.

The DE 103 00 585 B3 describes a manufacturing process for a friction lining by rolling. The carrier surface of the friction lining carrier is flat and has a plurality of protruding chips, which are machined out of the carrier surface in one piece by means of a first roller having cutting edges or teeth. The first roller is associated with a second roller arranged below the riding surface carrier, with the rollers being moved in opposite directions of rotation and the second roller being subjected to a braking torque. The unprocessed brake pad carriers are in a magazine and are fed into the tool by means of a pushing device. The invention also relates to a device for carrying out the method and a brake pad carrier produced using the method.

From the DE 10 2004 054 012 A1 discloses a method for manufacturing a brake pad carrier by deep-drawing. This invention relates to a friction brake pad with a pad carrier for a disc brake. The lining carrier is designed with a peripheral edge and/or with beads that form a kind of stiffening ribs and stiffen the lining carrier against bending.

The DE 10 2010 031 889 A1 describes a method for producing a brake pad carrier, in particular for a disc brake of a vehicle, wherein a plate-shaped or strip-shaped workpiece is deep-drawn in a direction perpendicular to the plane of the workpiece. To produce at least one thickened material at the edge, the workpiece is compressed transversely, in particular perpendicularly, to the deep-drawing direction, the thickness of the thickened material produced in this way being greater than the thickness of the starting material.

The above methods have significant disadvantages. Casting processes are very expensive and therefore uneconomical and also involve a higher risk of breakage due to a high probability of hot cracking and brittleness. Rolling or stamping steel to make brake lining backing plates is also marginally economical because of the higher susceptibility to corrosion. Furthermore, a very thick material is designed to be able to counteract the forces and effects that occur when vehicles are braked by disc brake systems. The deep-drawing process is a very contemporary and modern manufacturing technology for brake pad carrier plates. Significant improvements in the properties of brake pad carrier plates can be seen here. This process enables material to be saved, offers greater stability against the acting lateral forces and, thanks to the reduced weight, lowers the fuel consumption of motor vehicles.

• In der US 2007/0170023 A1 wird eine Rückenplatte für einen Scheibenbremsbelag mit einer Reibmaterial-Befestigungsfläche, die an einer Oberfläche der Rückenplatte angeordnet ist offenbart. Dabei werden umfasste Erhebungen durch Pressen (z.B. Stanzen) der Rückenplatte von der anderen Oberfläche derselben an der der Reibmaterialbefestigungsfläche gegenüberliegenden Seite in einer fortschreitenden Bearbeitung auf der Basis einer Feinschneidpresse gebildet, so dass die betreffenden Erhebungen aus der Reibmaterialbefestigungsfläche herausgedrückt werden.

Against this background, the following publications should also be cited:

• In the U.S. 2007/0170023 A1 discloses a backing plate for a disc brake pad having a friction material attachment surface disposed on a surface of the backing plate. Thereby, captured bumps are formed by pressing (eg, stamping) the backing plate from the other surface thereof on the side opposite the friction material mounting surface in progressive machining on a fineblanking press base so that the respective bumps are forced out of the friction material mounting surface.

In the EP 1 391 628 B1 discloses a caliper including a backing plate brake pad, the backing plate having friction material attached to one side and a load surface on an opposite side, the caliper including a piston for applying a force to the load surface, the brake pad being releasably attached to the Piston is attached and wherein the brake pad includes a locating feature.

In the U.S. 2008/0099174 A1 Finally, a brake caliper is disclosed which includes an actuator, a moveable brake pad having a brake pad backing plate, the brake pad backing plate having a generally planar portion, and a braking material attached to the brake pad backing plate.

object of the invention

The object of this invention is to provide a brake pad backing plate and a method for producing a brake pad backing plate which eliminates the disadvantages mentioned above. The method should be easy and inexpensive to handle. The brake pad carrier plate to be produced should have a significantly smaller thickness, which should also reduce the material and weight. In addition, the rigidity of the brake lining carrier plate in the longitudinal and transverse direction should not be impaired, but should even be increased. At the same time, the risk of rusting underneath the brake lining should be reduced.

The features of claims 1 and 6 lead to the solution of the problem.

In typical exemplary embodiments, the method for producing a brake pad carrier plate for a disc brake system of a vehicle from a blank is drop forging or fine stamping forming (deep drawing). When comparing the processes of casting, stamping and rolling with the process of drop forging or fine stamping forming (deep drawing), this has the advantage that the brake pad carrier plate can be designed thinner. As a result, the plate has less material and is therefore lighter. Another advantage of drop forging or fine stamping (deep drawing) is that the brake pad carrier plate is not brittle.

During the manufacture of the brake lining carrier plate, a recess for a piston of a brake cylinder is formed into the brake lining carrier plate. This recess can be ring-shaped or circular. These are 3D deformations that give the brake pad backing plate greater rigidity in both the longitudinal and transverse directions. Shapes other than a circular area or a ring are conceivable and should be encompassed by the present invention. Advantageously, these forms can also serve as a receptacle for the brake piston.

If the recess is ring-shaped, an inner surface of the recess preferably lies in one plane with a piston side of the brake lining carrier plate.

Furthermore, a material cutout is formed in a pad side of the brake pad carrier plate that is opposite the piston side and serves to accommodate a brake pad. An elevation is formed in the material recess, the elevation preferably being provided in the middle on the lining side. Furthermore, the elevation is preferably ring-shaped or circular. These are 3D deformations that give the brake pad backing plate greater rigidity in both the longitudinal and transverse directions. Shapes other than a circular area or a ring are conceivable and should be encompassed by the present invention.

Furthermore, the above-mentioned surfaces, whether indentations or elevations, can simultaneously serve as a receptacle for noise-damping measures (damping plate/foil). This is thus embedded so that it cannot be displaced without any further fastening measures, such as, for example, wobbling or the like. This in turn opens up the possibility of using cold glue, which often has better noise dampening than hot glue.

The noise dampening measure thus does not increase the overall thickness of the lining, since it is immersed in the brake lining carrier plate, so to speak. This higher total friction lining thickness means increased wear, i.e. a longer service life of the brake lining.
The brake pad itself is preferably embedded in a form-fitting manner in the material recess. This offers additional support in the edge area and reduces the risk of rusting underneath. Furthermore, this has the advantage that the brake pad is secured against lateral forces.

A significant benefit is the 30% weight saving achieved by reducing the material of the brake pad backing plate. This is made possible by the introduced 3-D deformations with the multiple use described.

A further exemplary embodiment provides that retaining bolts are arranged in the material recess. These are fasteners for the brake pad. They are materially connected to the brake pad carrier plate and transfer the lateral forces of the brake pad to the brake pad carrier plate. The shape and the number of the retaining bolts is not of great importance in the present case and can be chosen freely. Advantageously, only as many retaining bolts are selected as are actually necessary for fastening the brake lining. This prevents unnecessary material from being added to the brake pad carrier plate via the retaining bolts.

Furthermore, the brake lining carrier plate has an outer contour. This also includes guides in the form of an indentation, at least two lugs and an indentation, which is designed for the form-fitting insertion of the brake pad carrier plate into a brake caliper.

In typical exemplary embodiments, an indentation on the edge is also formed in the brake lining carrier plate. This indentation serves to further stabilize the brake pad carrier plate. Depending on the desired strength and need, it can run around either a certain edge length or the entire edge. The edges of the edge profile are rounded to increase strength.

In typical embodiments, a brake pad backing plate is used in a disc brake system of an automobile, truck, utility vehicle, motorcycle, and bicycle.

character list

• 1 eine Schnittansicht durch eine erfindungsgemässe Bremsbelagträgerplatte nach 2 entlang der Schnittlinie I - I;
• 2 eine Draufsicht auf die erfindungsgemässe Bremsbelagträgerplatte;
• 3 eine Schnittansicht durch die Bremsbelagträgerplatte nach 2 entlang der Schnittlinie III - III;
• 4 eine schematische, isometrische Ansicht einer Kolbenseite der Bremsbelagträgerplatte nach 2;
• 5 eine schematische, isometrische Ansicht einer Belagseite der Bremsbelagträgerplatte nach 2;
• 6 eine Schnittansicht durch ein weiteres Ausführungsbeispiel einer erfindungsgemässen Bremsbelagträgerplatte nach 7 entlang der Schnittlinie VI - VI;
• 7 eine Draufsicht auf die erfindungsgemässe Bremsbelagträgerplatte;
• 8 eine Schnittansicht durch die Bremsbelagträgerplatte nach 7 entlang der Schnittlinie VIII - VIII der;
• 9 eine schematische, isometrische Ansicht einer Kolbenseite der Bremsbelagträgerplatte nach 7;
• 10 eine schematische, isometrische Ansicht einer Belagseite der Bremsbelagträgerplatte nach 7;

Further advantages, features and details of the invention result from the following description of preferred exemplary embodiments and from the drawing; this shows in

• 1 a sectional view through a brake lining carrier plate according to the invention 2 along the cutting line I - I;
• 2 a top view of the brake pad carrier plate according to the invention;
• 3 a sectional view through the brake lining carrier plate 2 along the cutting line III - III;
• 4 a schematic, isometric view of a piston side of the brake pad carrier plate 2 ;
• 5 a schematic, isometric view of a pad side of the brake pad carrier plate 2 ;
• 6 a sectional view through a further embodiment of a brake pad carrier plate according to the invention 7 along the cutting line VI - VI;
• 7 a top view of the brake pad carrier plate according to the invention;
• 8th a sectional view through the brake lining carrier plate 7 along the section line VIII - VIII of the;
• 9 a schematic, isometric view of a piston side of the brake pad carrier plate 7 ;
• 10 a schematic, isometric view of a pad side of the brake pad carrier plate 7 ;

example

The 1 until 5 represent a first brake lining carrier plate 1.1 according to the invention. The brake lining carrier plate preferably has the external dimensions 95.3×74.15×5.5 (length×width×height). The brake lining carrier plate 1.1 has a lining side 2, a piston side 3 and an outer contour 4.

The outer contour 4 of the brake lining carrier plate 1.1 has an indentation 6 on one side 5 . The outer contour 4 is provided with two lugs 8 and 9 on a side 7 opposite the indentation 6 . The lugs 8 and 9 form an indentation 10 of the outer contour 4 between them, which runs symmetrically to the horizontal axis.

The lining side 2 of the brake lining carrier plate 1.1 is provided with a material recess 11 which runs parallel to the outer contour 4 and is preferably at a distance of 3 to 4 mm from the outer contour, whereby an edge 19 and an inner contour 12 are formed. Approximately in the middle of this material recess 11 there is an annular elevation 13 which rests with an outer circumference 14 on the inner contour 12 in the area of the indentation 6 and on an opposite side in the area of the indentation 10 . An inner surface 15 is lowered inward for reasons of material reinforcement. A bottom 16 of the material recess 11 and the inner surface 15 are preferably on one level.

On the opposite side of the pad side 2, ie the piston side 3, the annular elevation 13 is provided in accordance with an annular depression 17 with an outwardly facing inner surface 18. However, the inner surface 18 is still in one plane with the piston side 3 itself.

Furthermore, the piston side 3 has a recess 20 on the edge which is preferably about 1 mm thick and about 2.97 mm wide. The depression 20 is arranged symmetrically to a center line M, as is the entire brake lining carrier plate 1.1.

According to the 6 until 10 another exemplary embodiment of a brake lining carrier plate 1.2 is shown. The same elements are provided with the same reference symbols. There is therefore no repetition.

In addition, the pad side 2 of the brake pad carrier plate 1.2 has a circular elevation 21 approximately in the middle of the material recess 11, which rests against the inner contour 12 with an outer circumference 22 in the area of the indentation 6 and on the opposite side in the area of the indentation 10. Furthermore, retaining bolts 23 are arranged in the material recess 11 . The retaining bolts 23 are used to mount a brake pad, not shown in detail, on the pad side 2 of the brake pad carrier plate 1.2.

On the opposite side of the lining side 2, ie the piston side 3, a circular depression 24 is provided corresponding to the circular elevation 21, which serves to accommodate a brake piston not shown in detail.

Reference List

1.1, 1.2

brake pad backing plate

2

lining side

3

piston side

4

outer contour

5

Page

6

indentation

7

Page

8th

first nose

9

second nose

10

indentation

11

material recess

12

molding

13

annular elevation

14

outer circumference

15

Inner surface

16

Floor

17

annular indentation

18

Inner surface

19

edge

20

deepening

21

circular elevation

22

outer circumference

23

retaining bolt

24

Circular indentation

Claims (7)

Brake lining carrier plate (1.1, 1.2) with a piston side (3) and a lining side (2) for a disc brake of a vehicle, the piston side (3) having a peripheral depression (20) and an annular depression (17) or a circular depression (24 ) is arranged and on the lining side (2) a material recess (11,16) is arranged, which has an annular elevation (13) or a circular elevation (21). Brake pad carrier plate (1.1, 1.2) according to claim 1 , characterized in that an outer contour (4) on one side (5) has an indentation (6) and on an opposite side (7) a first lug (8) and two lugs (9) are arranged, wherein between the first Nose (8) and the second nose (9) is arranged an indentation (10). Brake pad carrier plate (1.1, 1.2) according to claim 1 , characterized in that in the material recess (11) retaining bolts (23) are arranged. Brake pad carrier plate (1.1, 1.2) according to claim 3 , characterized in that in the material recess (11) six retaining bolts (23) are arranged. Brake lining carrier plate (1.1, 1.2) according to one of claims 2 until 4 , characterized in that the ring-shaped elevation (13) or the circular elevation (21) with an outer circumference (14, 22) on an inner contour (12) in the area of the indentation (6) and on an opposite side in the area of the indentation (10 ) is present. Method for producing a brake lining carrier plate (1.1, 1.2). claim 1 until 5 for a disc brake system of a vehicle from a blank, characterized by the following steps: drop forging or fine stamping forming of the blank; and - molding an annular indentation (17) or circular indentation (24) on the piston face (3) for a piston of a brake cylinder, an inner surface (18) of the annular indentation (17) being coplanar with the piston face (3). becomes; - And wherein on the pad side (2) a material recess (11) for a brake pad is formed which has an annular elevation (13) or a circular elevation (21); - and wherein retaining bolts (23) are formed in the material recess (11). Use of a brake pad carrier plate (1.1, 1.2) according to claims 1 until 5 , which by a method according to the claim 6 is manufactured, in passenger cars, trucks, commercial vehicles, motorcycles and bicycles.

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