Noise-reducing pad, method of producing a noise-reducing pad, noise-reducing brake pad, method for preventing noise in a disc brake, disc brake arrangement and vehicle.

Abstract

ANTI-NOISE SHIM, METHOD OF PRODUCING ANTI-NOISE SHIM, ANTI-NOISE BRAKE SHIM, METHOD FOR AVOIDING NOISE IN A DISC BRAKE, DISC BRAKE ARRANGEMENT AND VEHICLE. An anti-noise shim (100) comprising at least one perforated metal layer (110) and at least one high-temperature resistant layer (120) faced / coupled together by mechanical bonding wherein the perforated metal layer comprises through holes (111) and mechanical bonding means (112) and the high-temperature resistant layer comprises fibers, a filler and a binder.

Description

1 / 22 Noise-reducing pad, method for producing noise-reducing pads, noise-reducing brake pad, method for preventing noise in a brake. Disc brake, disc brake arrangement and vehicle. Technical field of the invention

[001] The present invention relates to a noise-reducing wedge, more specifically the invention relates to a noise-reducing wedge comprising a perforated metal layer and a high-temperature resistant layer. Fundamentals of the Invention

[002] Vehicle brakes are a critical system that not only reduce the speed of the car but also prevent dangerous collisions and are a design concern for automotive engineers. Drivers are demanding increasingly safer braking systems that, when functioning correctly, provide effective vehicle speed reduction, with another important factor being low or zero noise emission. Brake pads, an important component in braking systems, are designed to create friction against the wheel discs to reduce their speed when engaged by the hydraulic piston. However, this friction generates unwanted thermal energy, vibrations, and high-pitched noises.Brake pads are designed to withstand heat and maintain their braking performance, but an element called a brake pad shim is needed to absorb even more of this generated heat and protect the sensitive components of the car's brake system.

[003] A brake pad shim is mounted on a brake pad; this keeps the brake pad and the wheel disc perfectly aligned, also reducing their vibration, which is effectively perceived as a high-pitched, screeching noise by the human ear. Critically, brake pad shims Petition 870260017610, dated 25 / 02 / 2026, page 16 / 41 2 / 22 Brake pads, by absorbing vibration, reduce vehicle noise pollution. The pads are also responsible for dissipating heat from the brake pads to prevent overheating in the brake fluid system. The extent of these capabilities is a factor of the brake pad material.

[004] Most brake pad materials used in the aftermarket are designed with a trade-off of low price for quality. These cheap materials are unable to effectively absorb noise at frequencies of 1kHz and 20kHz to minimize brake noise. Furthermore, these lower quality and price pads are unable to dissipate heat under more demanding braking conditions. This can cause the brake fluid to boil and the brake pads to become vitrified, resulting in weakened braking power and sudden premature brake failure.

[005] This leads to injuries and fatalities among car users and pedestrians. The quality of the brake pad coating material is very poor, resulting in relatively poor heat dissipation properties.

[006] US document 6,105,736 discloses an anti-squeak wedge (1) comprising a metal layer (3), having mechanical fastening means (6, 15), one pair at the upper end and another at the lower end of the anti-squeak wedge, said metal layer coated on one side thereof by a high temperature resistant layer, a composite layer (2), said anti-squeak wedge comprising a hole (5) provided through the anti-squeak wedge (see fig. 1, 5, 6 and 7, column 4, lines 52 - 62).

[007] Document JP 6 208336 B2 discloses a noise-reducing wedge (107) comprising a metal layer (104) without through holes, having mechanical fastening means (105) with a pointed tip (106), coupled to a graphite sheet layer (103) (see fig.1 and paragraph

[0030] ). Petition 870260017610, dated 25 / 02 / 2026, page 17 / 41 3 / 22

[008] Therefore, there is a need to develop a new cost-competitive noise damper with better heat dissipation and noise absorption properties comparable to the highest quality and higher price already available on the market. Summary of the invention

[009] The present invention addresses a novel noise-reducing wedge that overcomes the drawbacks of the prior art. This is achieved by the noise-reducing wedge comprising a perforated metal layer and a high-temperature resistant layer and related methods for the production application thereof, as defined in the independent claims.

[010] The advantages of the noise-reducing wedge according to the present invention are that it provides excellent heat dissipation and noise absorption properties, while being durable and well-suited for mass production by a method comprising an environmentally friendly process. Embodiments of the invention are defined in the dependent claims. Brief description of the drawings

[011] The particular embodiments of the invention are described in detail below in the present invention, by way of example and not limited to, with reference to the accompanying figures, wherein: Figures 1a and 1b schematically show a number of types of noise-reducing wedges. Figures 2a and 2b schematically show methods for producing noise-reducing shims. Figures 3a and 3b show schematic examples of a continuous drilling, cutting and connection process line. Figure 4 shows a schematic example of a disc brake. Detailed description of the invention. Petition 870260017610, dated 25 / 02 / 2026, page 18 / 41 4 / 22

[012] The applicant has surprisingly and unexpectedly developed a new noise-reducing wedge 100 comprising at least one perforated metal layer 110 and at least one high-temperature resistant layer 120 faced / coupled together by mechanical bonding wherein the perforated metal layer comprises through holes 111 and sharp / pointed mechanical bonding means 112, a continuous high-temperature resistant layer 120, in particular a continuous high-temperature resistant layer 120 corresponding to the through holes 111 of the perforated metal layer 110, as clearly reported in the figures, such as fig. 1a, 1b, 3a, 3b, and the high-temperature resistant layer comprises fibers, a filler and a binder, and in particular,

[013] Noise-dampening wedge 100 comprising at least one perforated metal layer 110 and at least one high-temperature resistant layer 120 faced / coupled together by mechanical bonding wherein the perforated metal layer comprises through holes 111 and sharp / pointed mechanical bonding means 112, a continuous high-temperature resistant layer 120, in particular a continuous high-temperature resistant layer 120 corresponding to the through holes 111 of the perforated metal layer 110, as clearly shown in the figures, such as fig. 1a, 1b, 3a, 3b, and the high-temperature resistant layer comprises fibers, fillers and a binder, said noise-dampening wedge further comprising: - a 130 coating layer bonded to the other side / face of the perforated metal layer or - a second layer resistant to high temperatures, a layer resistant to continuous high temperatures 120, in particular a layer Petition 870260017610, dated 25 / 02 / 2026, p. 19 / 41 5 / 22 resistant to continuous high temperatures 120 corresponding to the through holes 111 of the perforated metal layer 110, as clearly reported in the figures, such as fig. 1a, 1b, 3a, 3b, mechanically connected on the other side / face of the perforated metal layer; that is,

[014] Noise-dampening wedge 100 comprising at least one perforated metal layer 110 and at least one high-temperature resistant layer 120 faced / coupled together by mechanical bonding wherein the perforated metal layer comprises through holes 111 and sharp / pointed mechanical bonding means 112, a continuous high-temperature resistant layer 120, in particular a continuous high-temperature resistant layer 120 corresponding to the through holes 111 of the perforated metal layer 110, as clearly reported in the figures, such as fig. 1a, 1b, 3a, 3b, and the high-temperature resistant layer comprises fibers, a filler and a binder, said noise-dampening wedge further comprising a coating layer 130 bonded to the other side / face of the perforated metal layer; or

[015] Noise-dampening wedge 100 comprising at least one perforated metal layer 110 and at least one high-temperature resistant layer 120 faced / coupled together by mechanical bonding wherein the perforated metal layer comprises through holes 111 and sharp / pointed mechanical bonding means 112, a continuous high-temperature resistant layer 120, in particular a continuous high-temperature resistant layer 120 corresponding to the through holes 111 of the perforated metal layer 110, as clearly reported in figures such as fig. 1a, 1b, 3a, 3b, and the high-temperature resistant layer comprises fibers, a Petition 870260017610, dated 25 / 02 / 2026, page 20 / 41 6 / 22 filling and a binder, said noise-dampening pad further comprising a second high-temperature resistant layer 120, a continuous high-temperature resistant layer 120, in particular a continuous high-temperature resistant layer 120 corresponding to the through holes 111 of the perforated metal layer 110, as clearly reported in the figures, such as fig. 1a, 1b, 3a, 3b, mechanically bonded to the other side / face of the perforated metal layer.

[016] Furthermore, in the noise-reducing wedge according to any of the embodiments according to the present invention, an additional thin coating layer 140 can be applied to the high-temperature resistant layer 120 when coupled with the perforated metal layer 110.

[017] A perforated metal layer 110 according to the present invention means a metal layer having through holes 111, in particular a metal layer with not less than 1 through hole per 2 square centimeters (cm2) of the surface of the metal layer, preferably 1 through hole / cm2, or 2, 3, 4, 5 or 6 through holes / cm2 of the surface of the metal layer.

[018] In particular, through holes have a diameter of not less than 0.5 mm and not more than 3.0 mm, preferably not less than 1.0 mm and not more than 1.5 mm.

[019] In particular, the perforated metal layer 110 has a thickness preferably not less than 300 pm and not more than 500 pm, more preferably not less than 360 pm and not more than 400 pm.

[020] Such a perforated metal layer 110 may, for example, be composed of iron, galvanized steel, stainless steel, aluminum or similar materials.

[021] As mentioned, the high-temperature resistant layer 120, a continuous high-temperature resistant layer 120, in particular Petition 870260017610, dated 25 / 02 / 2026, page 21 / 41 7 / 22 A continuous high-temperature resistant layer 120 corresponding to the through holes 111 of the perforated metal layer 110, as clearly shown in the figures, such as figs. 1a, 1b, 3a, 3b, comprises fibers, a filler, and a binder. According to one embodiment, the binder is an elastomeric binder, but it can also be a non-elastomeric resin-type binder. Compared to conventional rubber materials, the fibers make the material stronger and less elastic in the plane without significantly affecting the compression characteristics in the normal direction. Furthermore, the fibers and fillers reduce the amount of elastomeric binder in the layer, thus making the layer less expensive. According to one embodiment, the fiber content in the high-temperature resistant layer 120 is not less than 5% or 10% or 14% and not more than 23% or 30% by weight.However, for some applications the fiber content may be more than 30%, such as up to 50%, up to 80%, or even up to 95%. The fibers are selected from organic fibers depending on the specific application. Examples of organic fibers include: cellulose fibers, cotton linter fibers (fibers derived from plants in general), aromatic polyamide fibers, polyamide fibers other than aromatic polyamide fibers, polyolefin fibers, polyester fibers, polyacrylonitrile fibers, polyvinyl alcohol fibers, polyvinyl chloride fibers, polyurea fibers, polyurethane fibers, polyfluorocarbon fibers, phenol fibers, or similar fibers. According to one embodiment, the fibers comprise aromatic polyamide fibers.More preferably, the fibers are selected from inorganic fibers, such as carbon fibers, glass fiber, ceramic fiber, rock wool, mineral wool, fused quartz fiber, chemically processed high silica fiber, fused alumina silicate fiber, continuous alumina fiber, stabilized zirconia fiber, boron nitride fiber, alkali titanate fiber, whiskers, fiber. Petition 870260017610, dated 25 / 02 / 2026, page 22 / 41 8 / 22 boron, wollastonite, basalt fiber.

[022] The filler may be an inorganic filler such as clay, ash, talc, barium sulfate, sodium bicarbonate, graphite, lead sulfate, tripoli, wollastonite or an organic filler. The binder may be an elastomeric material of the rubber type, such as styrene-butadiene rubber (SBR), acrylonitrile-butadiene rubber (nitrile butadiene rubber, NBR), isoprene rubber (IR), chloroprene rubber (CR), butadiene rubber (BR), isobutylene-isoprene rubber (IIR), ethylene propylene rubber (EPM), fluorine rubber (FPM), silicone rubber (Si), chlorosulfonated polyethylene (CSM), ethylene vinyl acetate copolymers (EVA), chlorinated polyethylene (CPE), chloroisobutane-isoprene rubber (CIIR), epichlorohydrin rubber (ECO), nitrile isoprene rubber (NIR) or similar. Elastomers other than rubber can also be used.According to alternative embodiments, the binder is a resin-type material, such as a rubber-modified phenolic resin, a phenolic resin, an epoxy resin, or similar materials.

[023] In particular, the high temperature resistant layer 120 has a thickness preferably not less than 50 pm and not more than 600 pm, more preferably not less than 150 pm and not more than 300 pm.

[024] According to one embodiment, the coating layer 130 is a viscoelastic layer. The viscoelastic layer may be a latex (SBR, NBR, chloroprene, acrylic or similar), synthetic resins (acrylic, phenolic or similar, PTFE, polyurethanes), a viscoelastic adhesive, such as an acrylic or silicone-based adhesive or similar, but may be any viscoelastic material with adequate vibration absorption and thermal resistance properties under the conditions to which a shim is subjected when mounted on a disc brake.

[025] In particular, the coating layer 130 has a thickness Petition 870260017610, dated 25 / 02 / 2026, p. 23 / 41 9 / 22 preferably no earlier than 3:30 pm and no later than 2:00 pm, more preferably no earlier than 8:00 pm and no later than 1:50 pm.

[026] The aforementioned optional thin coating layer 140 comprises heat-resistant polymeric material, such as PTFE, silicones, polyurethanes, synthetic resins, in particular with a thickness of not less than 10 µm and not more than 100 µm, preferably not less than 20 µm and not more than 80 µm.

[027] The aforementioned thin coating layer 140 is applied to the high-temperature resistant layer 120 as a top layer.

[028] The step-by-step application or bonding of coating layer 130 and / or thin coating layer 140 can be carried out in different ways: rollers, bath saturation, spraying, wetting, etc.

[029] The noise-reducing pad 100 according to any of the embodiments according to the present invention is an advanced noise-reducing pad comprising multilayer material with its application in brake pads. It is made by mechanically bonding at least one high-temperature resistant layer 120 comprising binders, an elastomeric material of the latex rubber type, such as specialized latex material of Nitrile Butadiene Rubber (NBR), Styrene Binder Rubber (SBR) or similar, fibers, such as inorganic fibers and fillers, with a perforated metal layer 110. Said perforated metal layer 110 is characterized by through holes 111 and sharp / pointed mechanical bonding means 112, joined / attached to the perforated metal layer 110 and, when present, located on the edge 113 of the through holes 111 on at least one mechanical bonding surface 114 of the perforated metal layer 110.The perforated metal layer 110 having through holes 111 absorbs resonant frequencies better than a solid metal layer. Furthermore, the layer is resistant to... Petition 870260017610, dated 25 / 02 / 2026, p. 24 / 41 10 / 22 high temperatures 120 according to the present invention is produced from the adaptation of gasket technology, which involves the infusion of the binder, such as raw NBR latex (or SBR or other types) with fibers and fillers. Said adapted gasket technology makes the noise-absorbing pads according to any of the embodiments according to the present invention more resistant to temperature while the perforations of the metal layer 120 make it a perfect material for high-frequency noise absorption.

[030] The noise-dampening wedge according to the present invention is an advanced noise-dampening wedge comprising a multi-layered composite in which the perforated metal layer / sheet 110 is mechanically bonded with at least one, or sandwiched by mechanical bonding between two, high-temperature resistant layers 120 comprising binders, an elastomeric material of the rubber type, such as specialized Nitrile Butadiene Rubber (NBR) material, fibers, such as organic and inorganic fibers, and fillers.

[031] Perforating the metal layer / sheet facilitates the mechanical bonding step of the different shim layers. The noise absorption properties by leaving voids in the metal. The vibration of air molecules within the voids, due to the through holes 111, of the perforated metal layer 110, helps to dissipate the high-frequency noise being generated by the vibrations of the brake disc and pads, thus dampening the noise.

[032] The high-temperature resistant layer 120, according to the present invention, is produced from the adaptation of gasket technology, which involves the infusion of the binder, an elastomeric material of the rubber type, preferably raw NBR latex (or SBR or other types), with fibers, preferably inorganic fibers and fillers. NBR latex (or SBR or similar) is a milky white liquid emulsion of synthetic rubber. In Petition 870260017610, dated 25 / 02 / 2026, page 25 / 41 11 / 22 In general, the gasket technology is more resistant to higher temperatures than a 100% NBR coated layer. Additionally, the perforated metal layer concept makes the distribution of high-frequency vibrations much more effective and more easily absorbed in the composite material. The mechanical bonding step (pressing the high-temperature resistant layer / sheet 120, according to the present invention, into the perforated metal layer 110 characterized by through holes 111 and sharp / pointed mechanical bonding means 112, joined together with the perforated metal layer 110 and, when present, located on the edge 113 of the through holes 111 on at least one mechanical bonding surface 114 of the perforated metal layer 110) does not require bonding agent or solvents to form a strong bond during the process. This eliminates the need for solvents used in current technology for the production of shims.In the mechanical bonding stage, the applied pressure is sufficient to cause the sharp / pointed mechanical bonding means 112 to bend over themselves in order to adhere the perforated metal layer / sheet and the high-temperature resistant layer / sheet to each other.

[033] For “mechanical bonding means” 112 or “mechanical bonding means 112” according to the present invention, it means mechanical bonding / gripping means 112 or connection means 112 or fastening means 112 for the mechanical joining between the perforated metal layer 110 coupled with the high thermal resistance layer(s) 120.

[034] The technical advantages due to the noise-reducing pads according to any of the embodiments according to the present invention, the method for producing them and their use in a disc brake arrangement are as follows: - the noise-reducing wedge according to the present invention has improved the Petition 870260017610, dated 25 / 02 / 2026, page 26 / 41 12 / 22 heat resistance and increased noise absorption; - The noise-reducing wedge according to the present invention is produced using an innovative, low-cost, energy-saving, continuous, solvent-free process, making it affordable, readily available, and with a reliable supply of raw materials; - The noise-dampening pad according to the present invention acts as a thermal barrier, preventing excessive heat from reaching the brake fluid, causing it to boil and resulting in brake failure, thus preventing brake deterioration.

[035] It is a further objective of the present invention to use the noise-dampening pads according to any of the embodiments according to the present invention in a disc brake arrangement comprising a caliper (brake caliper / brake pad) and a brake pad, the noise-dampening pad / noise-dampening brake pad being configured to act between the caliper and the brake pad.

[036] Figs. 1a and 1b schematically show a number of embodiments of noise-reducing wedges 100 according to the present invention having at least one perforated metal layer 110 and at least one high-temperature resistant layer 120 faced / coupled together by mechanical bonding wherein the perforated metal layer comprises through holes 111.

[037] The figures are to be considered for illustrative purposes only, and the relative dimensions of the different layers are not meaningful.

[038] In particular, as an embodiment of the noise-dampening wedge according to the present invention, Fig. 1a shows a noise-dampening wedge 100 with at least one perforated metal layer 110 and at least one high-temperature resistant layer 120 faced / coupled together by mechanical bonding wherein the perforated metal layer comprises through holes Petition 870260017610, dated 25 / 02 / 2026, p. 27 / 41 13 / 22 111, the said noise-reducing wedge further comprising a second high-temperature resistant layer 130 mechanically bonded to the other side / face of the perforated metal layer.

[039] In particular, in fig. 1a is shown the perforated metal layer 110 characterized by through holes 111 and sharp / pointed mechanical bonding means 112, preferably hook-shaped, at least one or two or three or four mechanical bonding means for each through hole, said mechanical bonding means being joined / attached to the perforated metal layer 110 and, when present, located on the edge 113 of the through holes 111 on at least one mechanical bonding surface 114 of the perforated metal layer 110, mechanical bonding surface to which the high-temperature resistant layer 120 is mechanically bonded, while the coating layer 130 is bonded to the other side / face of the perforated metal layer.

[040] In particular, as an embodiment of the noise-dampening wedge according to the present invention, Fig. 1b shows a noise-dampening wedge 100 with at least one perforated metal layer 110 and at least one high-temperature resistant layer 120 faced / coupled together by mechanical bonding wherein the perforated metal layer comprises through holes 111, said noise-dampening wedge further comprising a second high-temperature resistant layer 120 mechanically bonded to the other side / face of the perforated metal layer.

[041] In particular, fig. 1b shows the perforated metal layer 110 characterized by through holes 111 and sharp / pointed mechanical fastening means 112, preferably hook-shaped, at least one or two or three or four mechanical fastening means for each through hole, said mechanical fastening means joined together with the Petition 870260017610, dated 25 / 02 / 2026, page 28 / 41 14 / 22 perforated metal layer 110 and, when present, located on the edge 113 of the through holes 111 on the mechanical bonding surfaces 114 of the perforated metal layer 110, mechanical bonding surfaces to which the high-temperature resistant layers 120 are mechanically bonded. Furthermore, a thin coating layer 140 is, or may be, applied as a top layer on a high-temperature resistant layer 120.

[042] There are also provided methods for producing noise-reducing wedges of the type disclosed in the present invention.

[043] The steps of the methods are shown schematically in figures 2a and 2b.

[044] A further objective of the present invention is a method for producing noise-reducing wedges 100 according to any embodiment of the present invention, said method comprising the steps: - to supply a perforated metal sheet 110 comprising through holes 111 and mechanical fastening means 112, - mechanically bonding, by applying pressure or pressure and temperature to a high-temperature resistant plate 120, a continuous high-temperature resistant layer 120, in particular a continuous high-temperature resistant layer 120 corresponding to the through holes 111 of the perforated metal layer 110, as clearly reported in the figures, such as fig. 1a, 1b, 3a, 3b, comprising fibers, a filler and a binder on at least one side of the perforated metal plate to form a noise-dampening wedge plate.

[045] As an additional method of producing noise-reducing wedge 100 according to any embodiment of the present invention, said method comprises the steps: - provide a perforated metal sheet 110 comprising holes Petition 870260017610, dated 25 / 02 / 2026, page 29 / 41 15 / 22 through holes 111 and mechanical connection means 112, - mechanically bonding by applying pressure or pressure and temperature to a high-temperature resistant sheet 120, a continuous high-temperature resistant layer 120, in particular a continuous high-temperature resistant layer 120 corresponding to the through holes 111 of the perforated metal layer 110, as clearly reported in the figures, such as fig. 1a, 1b, 3a, 3b, comprising fibers, a filler and a binder on at least one side of the perforated metal sheet, - provide an additional 120 high-temperature resistant plate, - mechanically bonding by applying pressure or additional pressure and temperature to a high-temperature resistant plate on at least one unbonded side of the perforated metal sheet, to form a noise-reducing shim plate, i.e., a method in which the additional high-temperature resistant plate is mechanically bonded to the opposite side of the perforated metal sheet relative to where the temperature-resistant material plate 120 is mechanically bonded, or a method in which two high-temperature resistant plates 120 are mechanically bonded to opposite sides / both sides of the perforated metal sheet 110, to form noise-reducing shims.

[046] As an additional method of producing noise-reducing wedge 100 according to any embodiment of the present invention, said method comprises the steps: - to supply a perforated metal sheet 110 comprising through holes 111 and mechanical fastening means 112, - mechanically bonding by applying pressure or pressure and temperature to a high-temperature resistant plate 120, a continuous high-temperature resistant layer 120, in particular a high-temperature resistant layer Petition 870260017610, dated 25 / 02 / 2026, pp. 30 / 41 16 / 22 continuous temperatures 120 corresponding to the through holes 111 of the perforated metal layer 110, as clearly reported in the figures, such as fig. 1a, 1b, 3a, 3b, comprising fibers, a filler and a binder on at least one side of the perforated metal sheet, - provide a 130 cladding sheet, - to attach the cladding plate to at least one unattached side of the perforated metal sheet, to form a noise-dampening shim, that is, a method in which a cladding plate 130 is attached to the opposite side of the perforated metal sheet 110 with respect to where the temperature-resistant material 120 is mechanically attached, to form a noise-dampening shim.

[047] Each of the methods mentioned above according to the present invention may optionally further comprise a step in which an additional thin coating layer 140 is applied / bonded to the high-temperature resistant layer / sheet 120, in particular when the high-temperature resistant layer / sheet 120 is mechanically bonded / already mechanically bonded to the perforated metal layer 110.

[048] All methods of producing noise-reducing wedges of the type according to the present invention are characterized by providing at least one perforated metal sheet(s) 110. Said perforated sheet 110 is obtained by perforating sheet metal (The perforation is applied with a perforating machine, such as 1 or 2 perforating rolls or a high-power hydraulic press which, with a specifically designed perforating die(s), perforates the metal when said perforating die(s) is / are pressed onto a surface / side of the metal layer: perforation step) producing a perforated metal sheet with through holes 111 with sharp / pointed mechanical bonding means 112, preferably Petition 870260017610, dated 25 / 02 / 2026, pp. 31 / 41 17 / 22 with hook shape, at least one or two or three or four mechanical connection means for each through hole, said mechanical connection means joined together with the perforated metal layer 110 and, when present, located on the edge 113 of the through hole 111 on at least one mechanical connection surface 114 of the perforated metal layer 110. This perforation may be carried out on only one side or on both sides of the metal layer / sheet.

[049] Therefore, the perforated metal layer / sheet 110 has through holes 111 with sharp / pointed mechanical fastening means 112, preferably hook-shaped, at least one or two or three or four mechanical fastening means for each through hole, said mechanical fastening means being joined / attached to the perforated metal layer / sheet 110 and, when present, located on the edge 113 of the through holes 111 on at least one mechanical fastening surface 114 of the perforated metal layer 110.

[050] The aforementioned drilling step, when present in any embodiment of the noise-reducing shim production method of the type according to the present invention, always precedes the step of supplying the perforated metal sheet 110.

[051] In the drilling stage, the specifically designed drilling roller(s) / mold(s) have / have drilling tip(s), preferably but not only star-shaped tip(s) (at least 1 tip per cm2), designed to produce through holes 111 in the metal layer / sheet and sharp / pointed mechanical bonding means 112, joined / attached to the perforated metal layer 110, located on the edge 113 of the through holes 111, on the surface / side 114 of the perforated metal layer / sheet, which is opposite to the surface / side of the perforated metal layer / sheet. Petition 870260017610, dated 25 / 02 / 2026, pp. 32 / 41 18 / 22 onto which the punching roller / mold(s) is pressed.

[052] When both surfaces / sides of the perforated metal layer / sheet have sharp / pointed mechanical bonding means 112 (i.e., both mechanical bonding surfaces 114), the sharp / pointed mechanical bonding means on one surface / side are offset relative to the sharp / pointed mechanical bonding means on the other surface / side, i.e., each through hole 111 has sharp / pointed mechanical bonding means 112 on its edge 113 on only one surface / side of the perforated metal layer / sheet (see fig. 1b). Consequently, in the corresponding perforation step, both surfaces / sides of the metal layer / sheet are perforated by pressing each face / side with a perforation die / roller wherein the perforation points of one perforation die / roller are offset relative to the perforation points of the other perforation die / roller.

[053] Bonding different sheets together: bonding perforated metal sheet to high-temperature resistant sheet(s) by mechanical bonding, or bonding perforated metal sheet to high-temperature resistant sheet by mechanical bonding and to cladding sheet by bonding involving the use of a bonding agent, such as resin, cyanoacrylate, acrylic type adhesive or the like, or by vulcanization, may be carried out in any suitable manner providing a sufficiently strong bond between them. The bonding involves the step of applying pressure or pressure and heat or heat only. In order for the method to be efficient, the bonding may involve continuous lamination, whereby the perforated metal sheet and the high-temperature resistant film / sheet(s) are supplied / produced in the form of coils 210 or rolls 200, respectively.In the 230 / 270 bonding stage, comprising the mechanical bonding stage, the applied pressure is sufficient to cause the sharp / pointed mechanical bonding means 112, of the metal layer / sheet. Petition 870260017610, dated 25 / 02 / 2026, pp. 33 / 41 19 / 22 perforated 110, fold over themselves to adhere the perforated metal layer / sheet 110 and the high-temperature resistant layer / sheet 120 to each other, while the coating film / sheet 130 is applied / bonded by roller printing, spraying, wetting, bath saturation, etc. Also, the thin coating layer / sheet / film 140 is applied / bonded by roller printing, spraying, wetting, bath saturation, etc., when present.

[054] Noise-dampening wedges of the type according to the present invention are obtained as a noise-dampening wedge sheet of the type according to the present invention, said noise-dampening wedge sheet of the type according to the present invention can be rolled to form coils.

[055] An optional additional step of cutting individual anti-noise brake pads from the anti-noise pad sheet can be carried out by any suitable method, such as stamping or similar methods. According to one embodiment, the method comprises the cutting step 240 of the coils into narrow coils after the joining step 230 / 270. After that, the individual anti-noise brake pads are cut from the narrow coils.

[056] In order to achieve a strong bond and minimize the steps in the bonding operation, the perforated metal sheet can be pre-treated with a bonding agent before the bonding step 230 / 270.

[057] The pre-treatment stage 221 can also be carried out in a continuous process.

[058] Figs. 3a - 3b show schematic examples of continuous drilling, bonding and optionally 300 cutting process line.

[059] Fig. 3a shows a schematic example of a continuous drilling, bonding and optionally cutting process line. Petition 870260017610, dated 25 / 02 / 2026, pp. 34 / 41 20 / 22 300, wherein the perforated metal sheet 110, obtained by a perforating machine 310 acting on a metal sheet supplied in the form of coils, not shown, and the high-temperature resistant sheets 120 to be joined together, are supplied in the form of coils or rolls, not shown. The sheets 110 and 120 are pressed together and joined by a pair of calender rolls 330 to form a layered noise-dampening sheet according to the present invention. Optionally, a thin coating layer 140 is applied to the surface of the high-temperature resistant layer of the layered noise-dampening sheet by a wet application process 340.

[060] As an optional additional step, individual 350 noise-reducing brake pads are cut from the noise-reducing pad sheet by a 360 stamping machine.

[061] Fig. 3b shows a schematic example of a continuous perforation, bonding and optionally a cutting process line 300, wherein perforated metal sheet 110, obtained by a perforation machine 310 acting on a sheet of metal supplied in the form of coils, not shown, and a high-temperature resistant sheet 120 to be bonded, are provided. The sheets 110 and 120 are pressed together and bonded by a pair of calender rolls 330 to form a layered sheet. The coating layer 130 is applied to the unbonded surface of the perforated metal layer 110 of the layered sheet by a wet application process 370 to form a noise-dampening shim sheet according to the present invention. As an optional additional step, individual noise-dampening shims 350 are cut from the noise-dampening shim sheet by a stamping machine 360.

[062] Fig. 4 shows a schematic example of a disc brake 10, as an example of those disc brakes already known in the state of the art, the Petition 870260017610, dated 25 / 02 / 2026, pages 35 / 41 21 / 22 said disc brake 10 known in the state of the art comprising a disc 20 arranged to rotate about the axis C—C. A pair of brake pads 30, each having a backing plate 40 supporting a friction member 50 on the disc side thereof, a brake caliper 60 supporting the brake pads 30 movably towards and away from the opposite friction surfaces of the disc 20 and hydraulic actuation means in the form of a brake piston 70 to impel the brake pads against the disc. The brake piston 70 is hydraulically actuated via the fluid path 80 connected to the hydraulic brake system of a vehicle. In the disclosed version, the disc brake 10, the caliper housing 60 is movable in the direction of actuation of the brake piston, by means of which the brake pad on the non-piston side is pushed against the disc by a caliper finger 90 of the caliper housing 60.A noise-dampening shim 100 is arranged adjacent to the backing plate 40 of each disc pad 30, and the braking force from the brake piston 70 and caliper finger 65, respectively, is transferred to the brake pads 30 through the noise-dampening shims 100.

[063] Throughout this descriptive report, the term “brake pad side” refers to the side of a shim 100 facing the backing plate 40 of a brake pad 30 and the term “piston side” refers to the side without pad, i.e., the side facing piston 70 or caliper finger 90. In some disc brake designs, caliper finger 90 is omitted and caliper 60 is provided with brake pistons 70 on both sides of disc 20. However, throughout this descriptive report, the above terms include any such undisclosed disc brake arrangements.

[064] There is also provided a disc brake arrangement comprising a noise-dampening shim according to any of the above embodiments between the caliper and the brake pad, and the disc brake may be Petition 870260017610, dated 25 / 02 / 2026, pp. 36 / 41 22 / 22 arranged in a suitable vehicle - such as a car, truck, train, motorcycle, bicycle, etc.

[065] In order to fully utilize the noise-reducing pads according to the invention, a method for preventing noise in a disc brake has additionally been provided, comprising the step of arranging a noise-reducing pad according to any of the above embodiments between the caliper and the brake pad. Petition 870260017610, dated 25 / 02 / 2026, pp. 37 / 41

Claims

1 / 4 CLAIMS 1. Noise-dampening wedge (100) comprising at least one perforated metal layer (110) and at least one high-temperature resistant layer (120) faced / coupled together by mechanical bonding, wherein the perforated metal layer comprises through holes (111) and mechanical bonding means (112), and the high-temperature resistant layer comprises fibers, a filler and a binding material, said perforated metal layer (110) is characterized in that sharp / pointed through holes (111) and mechanical bonding means (112), together / joined with the perforated metal layer (110) and, when present, located on the edge (113) of the through holes (111) on at least one mechanical bonding surface (114) of the perforated metal layer (110).

2. Anti-noise wedge, according to claim 1, characterized in that it further comprises a coating layer (130) bonded to the other side / face of the perforated metal layer.

3. Anti-noise wedge, according to claim 1, characterized in that it further comprises a second high-temperature resistant layer (120) mechanically bonded to the other side / face of the perforated metal layer.

4. Noise-dampening wedge, according to any one of claims 1 to 3, characterized in that an additional thin coating layer (140) is applied / bonded to the high-temperature resistant layer (120).

5. Noise-dampening wedge, according to any one of claims 1 to 4, characterized in that the fiber content by weight in the high-temperature resistant layer is 95% or less, preferably 50% or less, more preferably 30% or less, and even more preferably 23% or less. Petition 870260017610, dated 25 / 02 / 2026, p. 38 / 41 2 / 4 6. Noise-dampening wedge, according to any one of claims 1 to 5, characterized in that the heat-resistant fibers comprise synthetic organic fibers, such as cellulose fibers, cotton linter fibers (fibers derived from plants in general), aromatic polyamide fibers, aramid fibers, polyamide fibers other than aromatic polyamide fibers, polyolefin fibers, polyester fibers, polyacrylonitrile fibers, polyvinyl alcohol fibers, polyvinyl chloride fibers, polyurea fibers, polyurethane fibers, polyfluorocarbon fibers, phenol fibers and / or inorganic fibers, such as carbon fibers, glass fiber, ceramic fiber, rock wool, mineral wool, fused quartz fiber, chemically processed high silica fiber, fused alumina silicate fiber, continuous alumina fiber, stabilized zirconia fiber, boron nitride fiber, titanate fiber alkaline, whiskers, boron fiber,wollastonite, basalt fiber., 7. Noise-dampening wedge, according to any one of claims 1 to 6, characterized in that the filling material comprises an inorganic filling material, such as clay, ash, talc, barium sulfate, sodium bicarbonate, graphite, lead sulfate, tripoli, wollastonite or an organic filling.

8. Noise-dampening wedge, according to any one of claims 1 to 7, characterized in that the binding material comprises an elastomeric material of the latex / rubber type, such as styrene-butadiene rubber (SBR), acrylonitrile-butadiene rubber (nitrile rubber, NBR), isoprene rubber (IR), chloroprene rubber (CR), butadiene rubber (BR), isobutylene-isoprene rubber (IIR), ethylene propylene rubber (EPM), fluorine rubber (FPM), silicone rubber (Si), chlorosulfonated polyethylene (CSM), ethylene-vinyl acetate copolymers (EVA), chlorinated polyethylene (CPE), chloro-isobutane-isoprene rubber (CIIR), rubber of Petition 870260017610, dated 25 / 02 / 2026, page. 39 / 41 3 / 4 epichlorohydrin (ECO), nitrile isoprene rubber (NIR) or similar, or the binder material comprises a resin-type material, such as a rubber-modified phenolic resin, a phenolic resin, an epoxy resin or similar.

9. Noise-reducing wedge, according to any one of claims 1 to 8, characterized in that the coating layer is a viscoelastic layer.

10. Method of producing noise-reducing wedges (100), defined in any one of claims 1 to 3, said method characterized in that it comprises the steps: - providing a perforated metal sheet (110) comprising through holes (111) and mechanical bonding means (112), - mechanically bonding by applying pressure or pressure and temperature a high-temperature resistant sheet (120) comprising fibers, a filler and a binder on at least one side of the perforated metal sheet to form a noise-reducing wedge sheet.

11. Method according to claim 10, characterized in that it comprises the steps: - providing an additional high-temperature resistant plate (120), - mechanically bonding by applying pressure or pressure and temperature to the additional high-temperature resistant plate on at least one unbonded side of the perforated metal plate.

12. Method according to claim 10, characterized in that it comprises the steps: - providing a cladding plate (130), - attaching the cladding plate to at least one unattached side of the perforated metal sheet. Petition 870260017610, dated 25 / 02 / 2026, pp. 40 / 41 4 / 4 13. Method, according to any one of claims 10 to 12, characterized in that the bonding involves continuous lamination.

14. Anti-noise brake pad, characterized in that it comprises an anti-noise pad defined in any one of claims 1 to 9.

15. Method for avoiding noise in a disc brake, characterized in that it comprises the step of arranging the noise-reducing brake pad, defined in claim 14, between the brake caliper and the brake pad.

16. Disc brake arrangement (10), characterized in that it comprises the anti-noise brake pad, defined in claim 14, between the caliper and the brake pad.

17. Vehicle, characterized in that it comprises a disc brake arrangement defined in claim 16. Petition 870260017610, dated 25 / 02 / 2026, page 41 / 41

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