Anti-noise gasket

Abstract

The present application describes an anti-noise gasket (100) comprising at least one perforated metal layer (110) and at least one high-temperature-resistant layer (120), the at least one high-temperature-resistant layer (120) and the at least one high-temperature-resistant layer (120) being arranged / connected together by mechanical bonding, wherein the perforated metal layer comprises through holes (111) and mechanical bonding devices (112); and the high-temperature-resistant layer comprises fibers, fillers and adhesives.

Description

Technical Field

[0001] The present invention relates to a noise-reducing gasket, and more specifically, to a noise-reducing gasket comprising a perforated metal layer and a high-temperature resistant layer. Background Technology

[0002] Vehicle brakes are a critical system that not only reduces vehicle speed but also prevents dangerous collisions, making them a design focus for automotive engineers. Drivers demand safer, more functional braking systems that provide effective speed reduction, and another important factor is low or zero noise emissions. Brake pads, as a key component of the braking system, are designed to generate friction with the wheel discs to reduce their speed as they contact the discs via hydraulic pistons. However, this friction generates unwanted heat, vibration, and high-pitched noise. Brake pads are designed to withstand heat and maintain their braking performance, but an element called a brake pad shim is needed to further absorb the generated heat and protect the sensitive components of the vehicle's braking system.

[0003] Brake pad spacers are assembled onto the brake pads; they maintain perfect alignment between the brake pads and the wheel disc and reduce vibrations that are effectively perceived by the human ear as high-pitched, harsh noise. In fact, brake pad spacers reduce vehicle noise pollution by absorbing vibrations. The spacers are also responsible for dissipating heat from the brake pads to prevent the brake fluid system from overheating. These capabilities are a factor in the choice of brake pad material.

[0004] Most gasket materials used in the aftermarket are designed with a focus on quality at a low cost. These inexpensive materials are ineffective at absorbing noise in the 1kHz and 20kHz frequencies to minimize braking noise. Furthermore, these lower-quality, lower-priced gasket materials cannot dissipate heat under more demanding braking conditions. This can lead to brake fluid boiling, brake pad slippage, reduced braking power, and sudden, premature brake failure.

[0005] This resulted in injuries and fatalities for car owners and pedestrians. The quality of the brake pad material coating was very poor, leading to relatively poor heat dissipation.

[0006] US6,105,736 discloses an anti-whistling pad (1) comprising a metal layer (3) having mechanically coupled devices (6, 15), one pair at the upper end of the anti-whistling pad and the other pair at the lower end of the anti-whistling pad. The metal layer is coated on one side with a high-temperature resistant layer, namely a compound layer (2). The anti-whistling pad includes holes (5) disposed through the anti-whistling pad (see Figures 1, 5, 6 and 7, column 4, lines 52-62).

[0007] JP6208336B2 discloses a noise-reducing pad (107) comprising a non-perforated metal layer (104) having a mechanical engagement device (105) with a tip (106) connected to a graphite foil layer (103) (see Figure 1 and paragraph

[0030] ).

[0008] Therefore, it is necessary to develop a new cost-competitive noise-absorbing pad with improved heat dissipation and noise absorption performance, which can rival the higher quality and higher-priced noise-absorbing pads already on the market. Summary of the Invention

[0009] This invention relates to a novel noise-reducing gasket that overcomes the shortcomings of the prior art. This is achieved through a noise-reducing gasket comprising a perforated metal layer and a high-temperature resistant layer, and related methods for its production and application as defined in the independent claims.

[0010] The noise-absorbing pad according to the invention offers advantages such as excellent heat dissipation and noise absorption performance, durability, and suitability for mass production using methods including environmentally friendly processes. Embodiments of the invention are defined in the dependent claims.

[0011] Brief description of the attached figures

[0012] Specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which are examples and not intended to limit the scope of the invention, wherein:

[0013] Figures 1a to 1b Several embodiments of noise-reducing pads are illustrated schematically.

[0014] Figure 2a and Figure 2b A method for manufacturing noise-reducing pads is illustrated schematically.

[0015] Figure 3a and Figure 3b A schematic example of a continuous perforation, bonding, and cutting process line is shown.

[0016] Figure 4 A schematic example of a disc brake is shown. Specific Implementation

[0017] The applicant has unexpectedly developed a novel noise-reducing pad 100 comprising at least one perforated metal layer 110 and at least one high-temperature resistant layer 120, wherein the at least one perforated metal layer 110 and at least one high-temperature resistant layer 120 are mechanically coupled and arranged facing each other / connected together, wherein the perforated metal layer includes through-holes 111 and sharp / pointed mechanical coupling devices 112. The continuous high-temperature resistant layer 120, particularly the continuous high-temperature resistant layer 120 corresponding to the through-holes 111 of the perforated metal layer 110, such as... Figure 1a , 1b As clearly presented in sections 3a and 3b. Furthermore, the high-temperature resistant layer comprises fibers, fillers, and adhesives;

[0018] in particular,

[0019] The noise-reducing pad 100 includes at least one perforated metal layer 110 and at least one high-temperature resistant layer 120, which are mechanically joined together facing each other. The perforated metal layer includes through-holes 111 and sharp / pointed mechanical coupling devices 112. The continuous high-temperature resistant layer 120, particularly the continuous high-temperature resistant layer 120 corresponding to the through-holes 111 of the perforated metal layer 110, such as... Figure 1a , 1b As clearly presented in 3a and 3b. Furthermore, the high-temperature resistant layer comprises fibers, fillers, and adhesives. The noise-reducing pad further comprises:

[0020] - Coating layer 130, which is bonded to the other side / surface of the perforated metal layer.

[0021] or,

[0022] - The second high-temperature resistant layer is a continuous high-temperature resistant layer 120, particularly the continuous high-temperature resistant layer 120 corresponding to the through-hole 111 of the perforated metal layer 110, such as Figure 1a , 1b As clearly shown in 3a and 3b, it is mechanically bonded to the other side / surface of the perforated metal layer;

[0023] Right now,

[0024] The noise-reducing pad 100 includes at least one perforated metal layer 110 and at least one high-temperature resistant layer 120, which are mechanically coupled and connected to each other. The perforated metal layer includes through-holes 111 and sharp / pointed mechanical coupling devices 112. The high-temperature resistant layer 120 is continuous, particularly the continuous high-temperature resistant layer 120 corresponding to the through-holes 111 of the perforated metal layer 110. Figure 1a , 1b As clearly presented in 3a and 3b, and the high-temperature resistant layer comprises fibers, fillers and adhesives, and the noise-reducing pad further comprises a coating layer 130 bonded to the other side / surface of the perforated metal layer;

[0025] or,

[0026] like Figure 1a , 1bAs clearly shown in 3a and 3b, the noise-absorbing pad 100 includes at least one perforated metal layer 110 and at least one high-temperature resistant layer 120, which are mechanically coupled and connected to each other. The perforated metal layer includes through-holes 111 and sharp / pointed mechanical coupling devices 112. The continuous high-temperature resistant layer 120, particularly the continuous high-temperature resistant layer 120 corresponding to the through-holes 111 of the perforated metal layer 110, is as follows: Figure 1a , 1b As clearly presented in 3a and 3b, the high-temperature resistant layer comprises fibers, fillers, and adhesives. The noise-reducing pad further comprises a second high-temperature resistant layer 120, which is a continuous high-temperature resistant layer 120, particularly a continuous high-temperature resistant layer 120 corresponding to the through-holes 111 of the perforated metal layer 110, such as... Figure 1a , 1b As clearly shown in 3a and 3b, it is mechanically bonded to the other side / surface of the perforated metal layer.

[0027] Furthermore, in any embodiment of the noise-reducing pad according to the present invention, when connected to the perforated metal layer 110, another thin coating layer 140 may be applied on the high-temperature resistant layer 120.

[0028] As the perforated metal layer 110 of the present invention, it refers to a metal layer having through holes 111, particularly per 2 square centimeters (cm). 2 The metal layer surface has a metal layer with not less than one through hole, preferably one through hole / cm. 2 The surface of the metal layer, or 2, 3, 4, 5 or 6 through holes / cm 2 The surface of the metal layer.

[0029] Specifically, the through hole has 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.

[0030] In particular, the perforated metal layer 110 preferably has a thickness of not less than 300 μm and not more than 500 μm, and more preferably not less than 360 μm and not more than 400 μm.

[0031] Such a perforated metal layer 110 can be composed of, for example, iron, galvanized steel, stainless steel, aluminum, etc.

[0032] As described above, the high-temperature resistant layer 120, the continuous high-temperature resistant layer 120, particularly the continuous high-temperature resistant layer 120 corresponding to the through-hole 111 of the perforated metal layer 110, such as... Figure 1a , 1bAs clearly presented in 3a and 3b, it includes fibers, fillers, and adhesives. According to one embodiment, the adhesive is an elastomeric adhesive, but it can also be a non-elastomeric resin-based adhesive. Compared to conventional rubber materials, fibers give the material higher strength and less elasticity in a planar surface without significantly affecting compressive properties under normal tension. Furthermore, fibers and fillers reduce the amount of elastomeric adhesive in the layer, making the high-temperature resistant layer cheaper. According to one embodiment, the fiber content in the high-temperature resistant layer 120 is not less than 5%, or 10%, or 14%, and does not exceed 23% or 30% by weight. However, for some applications, the fiber content can be higher than 30%, for example, up to 50%, or up to 80%, or even up to 95%. Depending on the specific application, the fibers are selected from organic fibers. Examples of organic fibers include: cellulose fibers, cotton fibers (generally derived from plants), 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, phenolic fibers, etc. According to one embodiment, the fibers include aromatic polyamide fibers. More preferably, the fiber is selected from inorganic fibers, such as carbon fiber, glass fiber, ceramic fiber, rock wool, mineral wool, fused silica fiber, chemically processed high-silica fiber, fused aluminosilicate fiber, continuous alumina fiber, stabilized zirconia fiber, boron nitride fiber, basic titanate fiber, whiskers, boron fiber, wollastonite fiber, and basalt fiber.

[0033] The filler can be inorganic, such as clay, ash, talc, barium sulfate, sodium bicarbonate, graphite, lead sulfate, silica, wollastonite, or organic filler. The binder can be a rubber-type elastomer material, such as styrene-butadiene rubber (SBR), acrylonitrile-butadiene rubber (NBR), isoprene rubber (IR), chloroprene rubber (CR), butadiene rubber (BR), isobutylene-isoprene rubber (IIR), ethylene propylene rubber (EPM), fluororubber (FPM), silicone rubber (Si), chlorosulfonated polyethylene (CSM), ethylene-vinyl acetate copolymer (EVA), chlorinated polyethylene (CPE), chloroisobutane-isoprene rubber (CIIR), chloroether rubber (ECO), and acrylonitrile-isoprene rubber (NIR). Elastomers other than rubber can also be used. According to alternative embodiments, the binder is a resin-type material, such as rubber-modified phenolic resin, phenolic resin, epoxy resin, etc.

[0034] In particular, the high-temperature resistant layer 120 preferably has a thickness of not less than 50 μm and not more than 600 μm, and more preferably not less than 150 μm and not more than 300 μm.

[0035] According to one embodiment, coating layer 130 is a viscoelastic layer. The viscoelastic layer can be a latex (SBR, NBR, chloroprene, acrylic, etc.), a synthetic resin (acrylic, phenolic, etc., PTFE, polyurethane), a viscoelastic adhesive, such as an acrylic or siloxane adhesive, etc., but under the condition that the gasket is installed in a disc brake, it can be any viscoelastic material with suitable vibration absorption and thermal resistance properties.

[0036] In particular, the coating layer 130 has a thickness of preferably not less than 30 μm and not more than 200 μm, and more preferably not less than 80 μm and not more than 150 μm.

[0037] The optional thin coating 140 comprises a heat-resistant polymer material, such as PTFE, silicone, polyurethane, or synthetic resin, and in particular has 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.

[0038] The thin coating layer 140 is applied as the top layer on the high-temperature resistant layer 120.

[0039] The application or bonding of coating layer 130 and / or thin coating layer 140 can be performed in different ways: roller, bath saturation, spraying, wetting, etc.

[0040] The noise-reducing pad 100 according to any embodiment of the invention is an improved noise-reducing pad comprising multiple layers of material, used in brake pads. This noise-reducing pad is formed by mechanically bonding at least a high-temperature resistant layer 120 to a perforated metal layer 110. The at least one high-temperature resistant layer 120 comprises: an adhesive, which is an elastomer material of the latex rubber type, such as a special nitrile rubber (NBR), styrene-butadiene rubber (SBR) latex material, etc.; fibers, such as inorganic fibers; and fillers. The perforated metal layer 110 is characterized by through-holes 111 and sharp / pointed mechanical bonding devices 112. The mechanical bonding devices 112 are joined / bonded to the perforated metal layer 110 and, if present, located at the edge 113 of the through-holes 111 on at least the mechanical bonding surface 114 of the perforated metal layer 110. Furthermore, the high-temperature resistant layer 120 according to the invention is produced using gasket technology, which involves injecting fibers and fillers into an adhesive, such as unprocessed NBR (or SBR or other types) latex. The padding technology employed makes the noise-absorbing pads according to any embodiment of the present invention more heat-resistant, while the perforations in the metal layer 120 make it a perfect material for high-frequency noise absorption.

[0041] The noise-reducing pad according to the present invention is an improved noise-reducing pad comprising a multilayer composite material. A perforated metal layer / sheet 110 is mechanically bonded to at least one high-temperature resistant layer 120, or mechanically sandwiched between two high-temperature resistant layers 120. The high-temperature resistant layer comprises: an adhesive; a rubber-type elastomer material, such as a specialized nitrile rubber (NBR) material; fibers, such as organic and inorganic fibers; and fillers.

[0042] Perforation of the metal layer / sheet facilitates the mechanical bonding of different gasket layers. Noise absorption performance is achieved by leaving gaps in the metal. Due to the through-holes 111 in the perforated metal layer 110, the vibration of air molecules within the gaps helps dissipate high-frequency noise generated by the vibration of the brake disc and brake pads, thereby suppressing noise.

[0043] The high-temperature resistant layer 120 according to the invention is produced using a padding technology, which involves injecting fibers, preferably organic fibers, and fillers into an adhesive. The adhesive is a rubber-type elastomeric material, preferably unprocessed NBR (or SBR or other types) latex. NBR (or SBR, etc.) latex is a white liquid emulsion of synthetic rubber latex. Generally, the padding technology is more heat-resistant than a 100% NBR coating. Furthermore, the concept of a perforated metal layer makes the distribution of high-frequency vibrations more efficient and easier to absorb in the composite material. The mechanical bonding step on the perforated metal layer 110 (according to the invention, pressing the high-temperature resistant layer / sheet 120 onto the perforated metal layer 110, characterized by through-holes 111 and sharp / pointed mechanical bonding devices 112. These mechanical bonding devices 112 are coupled / bonded to the perforated metal layer 110 and, where present, located at the edge 113 of the through-holes 111 on at least the mechanical bonding surface 114 of the perforated metal layer 110) does not require the formation of a strong bond with an adhesive or solvent during this process. This eliminates the need for solvents used in the actual technology used for gasket production. In the mechanical bonding step, the applied pressure is sufficient to cause the sharp / pointed mechanical bonding device 112 to fold over itself to clamp the perforated metal layer / sheet and the high-temperature resistant layer / sheet together.

[0044] The mechanical connection device 112 or mechanical connection device 112 according to the present invention refers to a connection device / mechanical restraint device 112 or a connecting device 112 or a fastening device 112 for making a mechanical connection between the perforated metal layer 110 and the high-temperature resistant layer 120 to which it is connected.

[0045] The technical advantages resulting from the noise-reducing pad, its manufacturing method, and its use in disc brake devices according to any one of the embodiments of the present invention are as follows:

[0046] - The noise-reducing pad according to the invention has improved heat resistance and increased noise absorption;

[0047] - The noise-reducing gaskets according to the present invention are produced using a new, low-cost, energy-saving, solvent-free continuous method, making them reasonably priced, readily available, and with a reliable supply of raw materials;

[0048] - The noise-reducing pad according to the present invention acts as a thermal barrier to prevent excessive heat from reaching the brake fluid, thereby causing the brake fluid to boil and resulting in brake loss; and to prevent brake fade.

[0049] Another object of the present invention is the use of a noise-reducing shim in a disc brake assembly according to any embodiment of the present invention, the disc brake assembly including a caliper (brake caliper) and a brake block, wherein the noise-reducing shim / noise-reducing brake shim is configured to function between the caliper and the brake block.

[0050] Figure 1a and 1b Several embodiments of the noise-reducing pad 100 according to the present invention are schematically shown, wherein at least one perforated metal layer 110 and at least one high-temperature resistant layer 120 are mechanically coupled and disposed facing each other, wherein the perforated metal layer includes through holes 111.

[0051] The attached diagram is for illustrative purposes only; the relative dimensions of different layers are meaningless.

[0052] Specifically, as an embodiment of the noise-reducing pad according to the present invention, Figure 1a A noise-reducing pad 100 is shown having at least one perforated metal layer 110 and at least one high-temperature resistant layer 120, wherein the at least one perforated metal layer 110 and at least one high-temperature resistant layer 120 are arranged / connected to each other by mechanical bonding, wherein the perforated metal layer includes through holes 111, and the noise-reducing pad further includes a coating layer 130 bonded to the other side / face of the perforated metal layer.

[0053] In particular, Figure 1a The diagram shows a perforated metal layer 110, characterized by through-holes 111 and sharp / pointed mechanical coupling devices 112, which preferably have a hook shape, with each through-hole corresponding to at least one, two, three, or four mechanical coupling devices. The mechanical coupling device 112 is joined / bonded to the perforated metal layer 110 and, where present, located at the edge 113 of the through-hole 111 on at least the mechanical coupling surface 114 of the perforated metal layer 110. The mechanical coupling surface on the perforated metal layer 110 is mechanically bonded to a high-temperature resistant layer 120, while a coating layer 130 is bonded to the other side / surface of the perforated metal layer.

[0054] Specifically, as an embodiment of the noise-reducing pad according to the present invention, Figure 1bA noise-reducing pad 100 is shown having at least one perforated metal layer 110 and at least one high-temperature resistant layer 120, wherein the at least one perforated metal layer 110 and at least one high-temperature resistant layer 120 are arranged facing each other / connected together by mechanical bonding, wherein the perforated metal layer includes through holes 111, and the noise-reducing pad further includes a second high-temperature resistant layer 120 mechanically bonded to the other side / face of the perforated metal layer.

[0055] In particular, Figure 1b The diagram shows a perforated metal layer 110, characterized by through-holes 111 and sharp / pointed mechanical coupling devices 112, which preferably have a hook shape, with each through-hole corresponding to at least one, two, three, or four mechanical coupling devices. The mechanical coupling device 112 is joined / bonded to the perforated metal layer 110 and, where present, located at the edge 113 of the through-hole 111 on at least the mechanical coupling surface 114 of the perforated metal layer 110. Mechanical coupling surfaces on the high-temperature resistant layer 120 are mechanically bonded. Furthermore, a thin coating layer 140 may be applied as a top layer onto the high-temperature resistant layer 120.

[0056] A method for producing noise-reducing pads of the type disclosed herein is also provided.

[0057] The steps of the method are as follows: Figure 2a and 2b It is shown schematically in the middle.

[0058] Another object of the present invention is a method for producing a noise-reducing pad 100 according to any embodiment of the present invention, the method comprising the following steps:

[0059] - Provides a perforated metal sheet 110 including through holes 111 and mechanical coupling devices 112;

[0060] - By applying pressure or pressure and temperature, a high-temperature resistant sheet 120 is mechanically bonded to at least one side of a perforated metal sheet to form a noise-reducing pad sheet, wherein the high-temperature resistant sheet 120 is a continuous high-temperature resistant layer 120, particularly a continuous high-temperature resistant layer 120 corresponding to the through-holes 111 of the perforated metal layer 110, such as... Figure 1a , 1b As clearly presented in 3a and 3b, the high-temperature resistant sheet comprises fibers, fillers, and adhesives.

[0061] As another method for producing the noise-reducing pad 100 according to any embodiment of the present invention, the method includes the following steps:

[0062] - Provides a perforated metal sheet 110 including through holes 111 and mechanical coupling devices 112;

[0063] - By applying pressure or pressure and temperature, a high-temperature resistant sheet 120 is mechanically bonded to at least one side of a perforated metal sheet, wherein the high-temperature resistant sheet 120 is a continuous high-temperature resistant layer 120, particularly a continuous high-temperature resistant layer 120 corresponding to the through-holes 111 of the perforated metal layer 110, such as... Figure 1a , 1b As clearly presented in 3a and 3b, the high-temperature resistant sheet comprises fibers, fillers, and adhesives;

[0064] - Another high-temperature resistant sheet 120 is available;

[0065] -By applying pressure or pressure and temperature, the other high-temperature resistant sheet is bonded to at least one non-bonded side of the perforated metal sheet;

[0066] This forms a noise-absorbing pad sheet, i.e., a method in which another high-temperature resistant sheet is mechanically bonded to the opposite side of the perforated metal sheet that is mechanically bonded to the high-temperature resistant sheet 120, or a method in which two high-temperature resistant sheets 120 are mechanically bonded to opposite sides / two sides of the perforated metal sheet 110 to form a noise-absorbing pad.

[0067] As another method for producing the noise-reducing pad 100 according to any embodiment of the present invention, the method includes the following steps:

[0068] - Provides a perforated metal sheet 110 including through holes 111 and mechanical coupling devices 112;

[0069] - By applying pressure or pressure and temperature, a high-temperature resistant sheet 120 is mechanically bonded to at least one side of a perforated metal sheet, wherein the high-temperature resistant sheet 120 is a continuous high-temperature resistant layer 120, particularly a continuous high-temperature resistant layer 120 corresponding to the through-holes 111 of the perforated metal layer 110, such as... Figure 1a , 1b As clearly presented in 3a and 3b, the high-temperature resistant sheet comprises fibers, fillers, and adhesives;

[0070] - Provide coated sheet 130;

[0071] - The coated sheet is bonded to at least one non-bonded side of the perforated metal sheet.

[0072] To form a noise-reducing pad sheet, i.e., a method in which a coated sheet 130 is bonded to the opposite side of a perforated metal sheet 110 that is mechanically bonded to a heat-resistant material 120 to form a noise-reducing pad.

[0073] Each of the above methods according to the invention may optionally further include the step of applying / bonding another thin coating layer 140 on the high-temperature resistant layer / sheet 120, particularly when the high-temperature resistant layer / sheet 120 is mechanically bonded / has been mechanically bonded to the perforated metal layer 110.

[0074] The method of manufacturing all types of noise-absorbing pads according to the present invention is characterized by providing at least one perforated metal sheet 110, which is obtained by perforating a metal sheet (perforating with a perforating machine, such as one or two perforating rollers or a high-power hydraulic press with a specially designed perforating die, perforating the metal when the perforating die or perforating roller is pressed against the surface / side of the metal layer, i.e., the perforation process), the manufactured perforated metal sheet having through holes 111 with sharp / pointed mechanical coupling devices 112, which preferably have a hook shape. Each through hole corresponds to at least one, two, three or four mechanical coupling devices. The mechanical coupling device 112 is joined / bonded to the perforated metal layer 110 and, if present, located at the edge 113 of the through hole 111 on at least the mechanically coupled surface 114 of the perforated metal layer 110. The perforation can be achieved only on one or both sides of the metal layer / sheet.

[0075] Therefore, the perforated metal layer / sheet 110 has through holes 111 with sharp / pointed mechanical coupling devices 112, which are preferably hook-shaped. Each through hole corresponds to at least one, two, three, or four mechanical coupling devices. The mechanical coupling device 112 is joined / bonded to the perforated metal layer / sheet 110 and, where present, is located at the edge 113 of the through hole 111 on at least the mechanical coupling surface 114 of the perforated metal layer 110.

[0076] The perforation step, when present in any embodiment of the method for manufacturing noise-absorbing pads according to the type of the present invention, precedes the step of providing the perforated metal sheet 110.

[0077] In the piercing step, the specially designed piercing roller or piercing die has a piercing tip, preferably but not limited to a star-shaped tip (at least per cm). 2 It has one pointed tip and is designed to create through-holes 111 in a metal layer / sheet, as well as a sharp / pointed mechanical bonding device 112. The mechanical bonding device 112 is joined / bonded to the perforated metal layer 110 and is located at the edge 113 of the through-hole 111 on the surface / side 114 of the perforated metal layer / sheet 110, wherein the surface / side 114 is opposite to the surface / side of the perforated metal layer / sheet that has been pressed through by a perforating roller or perforating die.

[0078] When both surfaces / sides of the perforated metal layer / sheet have sharp / pointed mechanical coupling devices 112 (i.e., both mechanical coupling surfaces 114), the sharp / pointed mechanical coupling device on one surface / side is displaced relative to the sharp / pointed mechanical coupling device on the other surface / side, that is, each through hole 111 has a sharp / pointed mechanical coupling device 112 at its edge 113 on only one surface / side of the perforated metal layer / sheet (see...). Figure 1b Therefore, in the corresponding piercing step, both surfaces / sides of the metal layer / sheet are pierced by pressing each surface / side with a piercing die / roller, wherein the piercing tip of one piercing die / roller is displaced relative to the piercing tip of the other piercing die / roller.

[0079] The different sheets are joined together: This can be achieved by mechanically joining a perforated metal sheet to a high-temperature resistant sheet, or by mechanically joining a perforated metal sheet to a high-temperature resistant sheet and then using an adhesive, such as resin, cyano glue, acrylic adhesive, etc., or by vulcanization with a coated sheet, in any suitable manner to provide a sufficiently strong bond between them. The joining process includes applying pressure, or pressure and heat, or heat only. To make the method effective, the joining process may include continuous rolling, whereby the perforated metal sheet and the high-temperature resistant film / sheet are respectively provided / manufactured in the form of coils 210 or rolls 200. Simultaneously, the coated film / sheet 130 is applied / jointed by printing rollers, spraying, wetting, bath saturation, etc. Furthermore, when a thin coating layer / sheet / film 140 is present, this thin coating layer / sheet / film 140 is applied / jointed by printing rollers, spraying, wetting, bath saturation, etc.

[0080] The noise-reducing gasket of the type according to the invention is obtained as a noise-reducing gasket sheet of the type according to the invention, and the noise-reducing gasket sheet of the type according to the invention can be rolled up to form a roll.

[0081] Another optional step of cutting individual noise-reducing brake pads from the noise-reducing pad sheet can be performed by any suitable method such as stamping or a similar method. According to one embodiment, the method includes a step of cutting the spool 240 into a narrow spool after joining steps 230 / 270. The individual brake pads are then cut from the narrow spool.

[0082] To achieve a strong bond and minimize the steps in the bonding process, the perforated metal sheet can be pretreated with an adhesive before bonding steps 230 / 270.

[0083] The pretreatment step 221 can also be performed in a continuous process.

[0084] Figures 3a-3b A schematic example of a continuous perforation, bonding, and optional cutting process line 300 is shown.

[0085] Figure 3a A schematic example of a continuous perforation, bonding, and optional cutting process line 300 is shown, wherein a perforated metal sheet 110, obtained by a perforator 310 acting on a metal sheet provided in the form of a spool (not shown), and a high-temperature resistant sheet 120 to be bonded together are provided in the form of a spool or roll (not shown). The sheets 110 and 120 are pressed together and bonded by a pair of calendering rolls 330 to form a layered noise-reducing gasket sheet according to the invention. Optionally, a thin coating layer 140 is applied to the surface of the high-temperature resistant layer of the layered noise-reducing gasket sheet by a wet application process 340.

[0086] As an alternative step, a separate noise-reducing brake pad 350 is cut from the noise-reducing pad sheet using a stamping press 360.

[0087] Figure 3b A schematic example of a continuous perforation, bonding, and optional cutting process line 300 is shown, wherein a perforated metal sheet 110, obtained by a perforator 310 acting on a metal sheet provided in the form of a spool (not shown), and a high-temperature resistant sheet 120 to be bonded together, are provided in the form of a spool or roll (not shown). Sheets 110 and 120 are pressed together and bonded by a pair of calendering rolls 330 to form a layered sheet. A coating layer 130 is applied to the non-bonded surface of the perforated metal layer 110 of the layered sheet by a wet coating process 370 to form an anti-noise pad sheet according to the invention. As another optional step, individual anti-noise brake pads 350 are cut from the anti-noise pad sheet by a stamping press 360.

[0088] Figure 4A schematic example of a disc brake 10 is shown, as an example of those disc brakes known in the art, which includes a disc 20 arranged to rotate about an axis CC. A pair of brake pads 30 each have a backplate 40 supporting a friction member 50 on its disc side. A caliper housing 60 supports the brake pads 30 movably toward and away from the opposing friction surfaces of the disc 20, and a hydraulic actuation device is in the form of a brake piston 70 for pressing the brake pads against the disc. The brake piston 70 is hydraulically actuated via a fluid path 80 connected to a hydraulic braking system of the vehicle. In the disclosed embodiment, the caliper housing 60 is movable in the actuation direction of the brake piston, whereby the brake pads on the non-piston side are pressed against the disc by the caliper fingers 90 of the caliper housing 60. Noise-damping shims 100 are arranged adjacent to the backplate 40 of each disc pad 30, and braking forces from the brake piston 70 and the caliper fingers 90 are transmitted to the brake pads 30 via the noise-damping shims 100, respectively.

[0089] Throughout this specification, the term "brake block side" refers to the side of the noise-reducing pad 100 facing the backplate 40 of the brake block 30, and the term "piston side" refers to the non-brake block side, i.e., the side facing the piston 70 or caliper finger 90. In some disc brake designs, the caliper finger 90 is omitted, and the caliper 60 has brake pistons 70 on both sides of the disc 20. However, throughout this specification, the above descriptions include any such non-disclosed disc brake assembly.

[0090] A disc brake device is also provided, which includes a noise-reducing pad disposed between the caliper and the brake pad according to any of the above embodiments, and the disc brake can be disposed in a suitable vehicle, such as a car, truck, train, motorcycle, bicycle, etc.

[0091] To fully utilize the noise-reducing shim according to the invention, a method for preventing noise in a disc brake is also provided, the method comprising the step of arranging a noise-reducing shim according to any of the above embodiments between the caliper and the brake block.

Claims

1. A noise-absorbing pad (100), comprising: At least one perforated metal layer (110) and at least one high-temperature resistant layer (120) are arranged / connected to each other by mechanical bonding; wherein the perforated metal layer includes a through hole (111) and a mechanical bonding device (112), and the high-temperature resistant layer includes fibers, fillers and adhesive materials, wherein the at least one perforated metal layer (110) is characterized by a through hole (111) and a sharp / pointed mechanical bonding device (112); wherein the mechanical bonding device (112) is joined / bonded to the perforated metal layer (110), and, if present, is located at the edge (113) of the through hole (111) on at least the mechanical bonding surface (114) of the perforated metal layer (110).

2. The noise-reducing pad according to claim 1, further comprising a coating layer (130) bonded to the other side / surface of the perforated metal layer.

3. The noise-reducing pad according to claim 1, further comprising: The second high-temperature resistant layer (120) is mechanically bonded to the other side / surface of the perforated metal layer.

4. The noise-reducing pad according to claim 3, wherein, A thin coating layer (140) is applied / bonded onto the second high-temperature resistant layer (120).

5. The noise-reducing pad according to claim 1, wherein, The fiber content in the high-temperature resistant layer is 95% or less.

6. The noise-reducing pad according to claim 1, wherein, The fibers include: Synthetic organic fibers, including cellulose fibers, cotton fibers, 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, and phenolic fibers; and / or Inorganic fibers include carbon fiber, glass fiber, ceramic fiber, rock wool, mineral wool, fused silica fiber, chemically processed high-silica fiber, fused aluminosilicate fiber, continuous alumina fiber, stabilized zirconia fiber, boron nitride fiber, basic titanate fiber, whiskers, boron fiber, wollastonite fiber, and basalt fiber.

7. The noise-reducing pad according to claim 1, wherein, The filler material includes: inorganic filler material or organic filler material, wherein the inorganic filler material is clay, ash, talc, barium sulfate, sodium bicarbonate, graphite, lead sulfate, silica and wollastonite.

8. The noise-reducing pad according to claim 1, wherein, The adhesive material includes the following latex / rubber type elastomer materials: 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), fluororubber (FPM), silicone rubber (Si), chlorosulfonated polyethylene (CSM), ethylene-vinyl acetate copolymer (EVA), chlorinated polyethylene (CPE), chloroisobutane-isoprene rubber (CIIR), chloroether rubber (ECO), acrylonitrile-isoprene rubber (NIR); or, the adhesive material includes the following resin type materials: rubber-modified phenolic resin, phenolic resin, epoxy resin.

9. The noise-reducing pad according to claim 2 or 4, wherein, The coating layer is a viscoelastic layer.

10. A method for producing the noise-absorbing pad (100) according to claim 1, the method comprising the following steps: A perforated metal layer (110) is provided, the perforated metal layer (110) including a through hole (111) and a mechanical bonding device (112). By applying pressure or pressure and temperature, the high-temperature resistant layer (120), comprising fibers, fillers and adhesives, is mechanically bonded to at least one side of the perforated metal layer to form a noise-reducing gasket sheet.

11. The method of claim 10, comprising the following steps: Provide another high-temperature resistant layer (120). The other high-temperature resistant sheet is mechanically bonded to at least one non-bonded side of the perforated metal sheet by applying pressure or pressure and temperature.

12. The method of claim 10, comprising the following steps: Provide a coating layer (130). The coated sheet is bonded to at least one non-bonded side of the perforated metal layer.

13. The method according to any one of claims 10-12, wherein, The combination includes continuous rolling.

14. A noise-reducing brake pad comprising the noise-reducing pad according to any one of claims 1 to 9.

15. A method for preventing noise in a disc brake, comprising: The step of arranging the noise-reducing brake pad according to claim 14 between the brake caliper and the brake block.

16. A disc brake device (10) comprising a noise-reducing brake pad according to claim 14, the noise-reducing brake pad being disposed between a caliper and a brake block.

17. A vehicle comprising a disc brake device according to claim 16.

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