Printing brake wear sensor

Abstract

The present disclosure provides a printed brake wear sensor. A brake pad may include: a brake lining configured to engage with a brake disc operably coupled to a wheel of the vehicle to apply friction to decelerate the vehicle; the back plate is used for providing support for the brake lining; and a wear indication circuit operably coupled to the brake lining to detect brake lining wear. The wear indicating circuit may be externally printed on the brake pad via a conductive ink.

Description

Technical Field

[0001] The example embodiment generally relates to wheel assembly components, and more specifically, to a brake pad for detecting increased brake wear. Background Technology

[0002] Brake pads are crucial to braking system performance and overall vehicle performance. Therefore, detecting and accurately indicating brake pad wear is an important part of monitoring braking system performance and, consequently, vehicle performance.

[0003] Typically, mechanical brake wear sensors perform standard wear detection and indication in brake pads by emitting noise in response to brake wear. Furthermore, mechanical brake wear sensors, and even electric brake wear sensors, often require embedding within the brake pad and / or altering the physical construction of the brake pad to sense and transmit brake wear. Therefore, there is a need for an electronic brake wear sensor that detects and indicates brake pad wear without altering the brake pad's construction or design. Summary of the Invention

[0004] According to an example embodiment, a brake pad for a vehicle braking system can be provided. The brake pad may include: a brake liner configured to engage with a brake disc operably coupled to a wheel of the vehicle to apply friction to decelerate the vehicle; a backing plate providing support for the brake liner; and a wear indicator circuit operably coupled to the brake liner to detect brake liner wear. The wear indicator circuit may be externally printed on or within the brake pad via conductive ink.

[0005] In another example embodiment, a braking system for a vehicle of the example embodiment may be provided. The braking system may include: a brake disc operatively coupled to a wheel of the vehicle; and brake pads engaging with the brake disc to decelerate the vehicle. The brake pads may include: brake linings engaging with the brake disc to apply friction to decelerate the vehicle; a backing plate providing support for the brake linings; and a wear indicator circuit operatively coupled to the brake linings to detect brake lining wear. The wear indicator circuit may be externally printed on the brake pads via conductive ink. Attached Figure Description

[0006] Having thus generally described the invention, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in the drawings: Figure 1 A block diagram of a braking system for a vehicle according to an example embodiment is depicted; Figure 2 A perspective view of the brake pads of a braking system according to an example embodiment is shown; Figure 3 A perspective view of the brake pads of a braking system according to an example embodiment is depicted; Figure 4 A perspective view of the brake pads of a braking system according to an example embodiment is shown; Figure 5 A perspective view of the brake pads of a braking system according to an example embodiment is depicted; Figure 6 A perspective view of a braking system according to an example embodiment is shown; Figure 7 A perspective view of a braking system according to an example embodiment is depicted; and Figure 8 A printed assembly for a brake pad is shown according to an example embodiment. Detailed Implementation

[0007] Some exemplary embodiments will be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, exemplary embodiments. In fact, the examples described and depicted herein should not be construed as limiting the scope, applicability, or configuration of this disclosure. Rather, these exemplary embodiments are provided so that this disclosure will satisfy applicable requirements. The same reference numerals always refer to the same elements. Furthermore, as used herein, the term “or” will be interpreted as a logical operator that produces a true result whenever one or more of its operands are true. As used herein, an operable connection should be understood to involve direct or indirect connections, in either case of which the connection enables functional interconnection of components operably linked to each other.

[0008] Furthermore, as used herein, terms such as “about,” “approximately,” and “substantially” when referring to the variability of a parameter should be understood as definite approximations that take into account variations in measurements that cannot be precisely measured or are generally not precisely measured as known to those skilled in the art. Therefore, for example, a parameter with a given value or characteristic that is “about,” “approximately,” or “substantially” should be understood as sufficiently close to the given value or characteristic such that, from the perspective of a person of ordinary skill in the art, the performance of the object or product to which the parameter is applied is the same as that of the object or product having the exact given value or characteristic.

[0009] Some exemplary embodiments described herein can address the aforementioned problems. In this regard, for example, some embodiments can provide a brake pad with additional wear indicator circuitry that does not alter the design or structure of the brake pad. Some embodiments can provide wear indicator circuitry applied to the entire brake pad via additive manufacturing. Therefore, the installation of wear indicator circuitry for the brake pad may require less work, less invasive construction, and less time, and is thus potentially more efficient.

[0010] Figure 1 A block diagram of a braking system 100 for a vehicle 110 according to an example embodiment is shown. Figure 1 As shown, in some embodiments, vehicle 110 may include a chassis or frame 120. The chassis or frame 120 may support vehicle 110 and may form the basic structure of the vehicle. In example embodiments, the chassis and frame 120 may be formed from one or more cast or welded metal subframes, or may be a one-piece construction.

[0011] In some cases, the frame 120 may be operatively coupled to the suspension assembly 130, and the suspension assembly 130 may be operatively coupled to one or more wheel assemblies 160. The suspension assembly 130 may include suspension dampers or other suspension elements. Depending on the vehicle 110, the suspension assembly 130 may include multiple suspension dampers. The suspension dampers can be used to absorb compressive and rebound loads along the longitudinal axis of the suspension damper. In this respect, the suspension dampers can significantly limit the oscillations and vibrations of the vehicle 110 by suppressing the articulated movement of one or more wheel assemblies 160 so that the articulation of one or more wheel assemblies 160 is not directly transmitted to the frame 120 of the vehicle 110.

[0012] The suspension assembly 130 can be operatively coupled to one or more wheel assemblies 160 via a steering knuckle 140 of the vehicle 110. The steering knuckle 140 can also be operatively coupled to a wheel hub 150. The wheel hub 150 can be directly operatively coupled to one or more wheel assemblies 160 to connect one or more wheel assemblies 160 to the suspension assembly 130. The wheel hub 150 may include fasteners for operatively coupling to the rims of one or more wheel assemblies 160.

[0013] In an example embodiment, braking system 100 may be operatively coupled to wheel hub 150. Braking system 100 may include brake disc 170, brake caliper 180, and brake pads 200. In some cases, brake pads 200 may include multiple brake pads, but a single brake pad 200 is also possible. Braking system 100 may assist in decelerating, stopping, and / or holding vehicle 110 upon actuation of the brake pedal or upon receiving a brake trigger from vehicle 110. Brake trigger may be a signal (e.g., an electrical signal, hydraulic signal, etc.) from vehicle control system of vehicle 110 indicating that vehicle 110 intends to initiate braking. Braking system 100 may apply negative torque to vehicle 110 by applying friction to brake disc 170 via brake pads 200. If braking system 100 has two instances of brake pads 200, each brake pad 200 may engage opposite sides of brake disc 170 to assist in decelerating vehicle 110.

[0014] Brake pads 200 can be operatively coupled to brake calipers 180. Brake calipers 180 can also be used to operatively engage two brake pads with each other. Upon actuation of the brake pedal or receipt of a brake trigger, brake calipers 180 can push brake pads 200 against brake discs 170. In some cases, brake calipers 180 may include a piston, which is a drive mechanism for pushing brake pads 200 against brake discs 170. The piston may be powered via hydraulic fluid supplied through brake hoses or lines. In some embodiments, brake calipers 180 may be electrically powered.

[0015] Figures 2 to 7 A brake pad and braking system according to an exemplary embodiment are shown, and a side view of the brake pad and braking system according to the exemplary embodiment is depicted primarily. The brake pad 200 may include a backing plate 210 and a brake pad 220. The backing plate 210 may provide support for the brake pad 220. The backing plate 210 may be operatively coupled to a brake caliper 180, and the brake caliper 180 may push the backing plate 210 to apply force to the brake pad 200. The backing plate 210 may be made of a metal or other robust material that can suitably support the brake pad 220.

[0016] Brake pad 220 may be made of a friction material, and brake pad 220 may be attached to backing plate 210 via adhesive or other coupling means. When the brake pedal is actuated or the braking system 100 is otherwise actuated, brake pad 220 may selectively engage with brake disc 170 to apply friction to decelerate vehicle 110. In some cases, the engagement of brake pad 220 and brake disc 170 may be responsive to a force applied to backing plate 210 by brake caliper 180. The friction material of brake pad 220 may be ceramic, carbon composite, fiber-based, semi-metallic, or any number of materials that provide a desired level of friction to brake disc 170 and maintain the durability of brake pad 220. In example embodiments, brake pad 220 may have a smaller length and width compared to backing plate 210. In some cases, the thickness T of brake pad 220 may be greater than the thickness of backing plate 210.

[0017] Brake pad 200 may also include a wear indicator circuit 230. The wear indicator circuit 230 helps identify the amount of wear on the brake pad 200 and its expected performance time. The wear indicator circuit 230 may be a circuit extending along the brake pad 200. The wear indicator circuit 230 may be disposed on or within the brake pad 220 to detect wear of the friction material of the brake pad 220. A portion of the wear indicator circuit 230 may be substantially parallel to the outer edge 221 of the brake pad 220 closest to the brake disc 170. This substantially parallel alignment may deviate from parallelism by + / - 5 degrees. In some cases, the arrangement of the wear indicator circuit 230 parallel to the outer edge 221 can ensure consistent measurement or sensing capability along a substantial length of the brake pad 220 (and the outer edge 221), i.e., the dimension perpendicular to the thickness T. Therefore, for example, if the brake pad 220 wears more at one part of the length of the outer edge 221 than at another part, the wear indication circuit 230 can notify the operator of the wear condition more quickly than if the wear indication circuit 230 happens to be more localized at one part of the brake pad 220 and that localized part is not exactly where wear occurs faster.

[0018] In response to brake pad wear, the wear indicator circuit 230 can be disrupted, interrupted, or disconnected to break the circuit. Thus, for example, the wear indicator circuit 230 can be a closed circuit until the brake pad experiences sufficient wear, causing the wear indicator circuit 230 itself to begin wearing and eventually wear down to the point where the closed circuit breaks. In response to the wear indicator circuit 230 breaking, a specific level of brake pad wear can be determined (i.e., the depth from the outer edge 221 to the break point in the wear indicator circuit 230).

[0019] The wear indicator circuit 230 can be located at a specific thickness or percentage of the brake pad 220. For example, the wear indicator circuit 230 can be located at 50% of the thickness T of the brake pad 220. In some cases, multiple wear indicator circuits can be provided on the brake pad 200. Figure 3 As shown, according to an example embodiment, a first wear indicator circuit 231, a second wear indicator circuit 232, and a third wear indicator circuit 233 may be disposed on the brake pad 200. The first wear indicator circuit 231, the second wear indicator circuit 232, and the third wear indicator circuit 233 may be spaced apart (uniformly or non-uniformly) to define distinct wear thresholds at corresponding different known depths. For example, the first wear indicator circuit 231 may be disposed at 40% of the thickness of the brake pad 220, the second wear indicator circuit 232 may be disposed at 60% of the thickness of the brake pad 220, and the third wear indicator circuit 233 may be disposed at 80% of the thickness of the brake pad 220.

[0020] Multiple wear indicator circuits may not need to be evenly spaced on the brake pads 220. Multiple wear indicator circuits can be positioned at significant wear thresholds or brake pad conditions to assess the performance of the braking system 100. For example, a wear threshold may represent different time ranges or estimated remaining durability of the brake pads 200. For instance, a first wear indicator circuit 231 may be positioned to indicate expected performance for the remaining three months, a second wear indicator circuit 232 may be positioned to indicate expected performance for the remaining one month, and a third wear indicator circuit 233 may be positioned to indicate the expected performance limit.

[0021] At one end of the wear indicator circuit 230, a ground connection can be positioned to provide an electrical path to complete the circuit relative to a power source. The ground connection can be located at either end of the wear indicator circuit 230. In some cases, if multiple wear indicator circuits exist, they can share a ground connection. For example, as... Figure 4 As shown, the first wear indicator circuit 231, the second wear indicator circuit 232, and the third wear indicator circuit 233 can share a common ground connection 234.

[0022] Wear indicator circuit 230 can be added to brake pad 200 via conductive ink printing. In some cases, such as Figure 8As shown, conductive ink printing can be performed via printing system 800. Printing system 800 can use inkjet printer 820 to apply highly precise circuitry to a variety of objects, including fabrics and rigid objects. The conductive ink can be a liquid-based ink. Using conductive ink printing, computer-aided design (CAD) of the circuitry or electronics can be directly incorporated during or after the main manufacturing or assembly process of brake pad 200 or brake system 100 without loss of specificity. Conductive ink printing can include conductive inks composed of conductive metal fillers and polymer resins. The conductive metal filler can provide the desired electrical and thermal properties. For example, the conductive metal filler can be silver, as conductive inks need to be easily liquefied at relatively low temperatures (i.e., 500℉ or lower) while maintaining their conductivity throughout the printing process and application. In some cases, depending on the application, the temperature threshold can be higher (i.e., 2000℉ or lower). The polymer resin can provide mechanical strength and flexibility when applying conductive ink printing. For example, silver nitrate can be a commonly used ink for conductive ink printing. Forming the wear indicator circuit 230 via conductive ink printing allows for increased flexibility in the brake pad 200 and the braking system 100. Furthermore, conductive ink printing increases the ease of integral formation of the wear indicator circuit 230. Conductive ink printing can also be a conductive ink coating process.

[0023] In the example embodiment, thermocouple 235 (see...) Figure 5 Thermocouple 235 can be integrally formed and / or embedded within wear indicator circuit 230. Thermocouple 235 can measure the temperature of brake pad 200 and / or braking system 100. In some cases, thermocouple 235 can consist of two wires integrally formed within wear indicator circuit 230, and thermocouple 235 can use the temperature gradient between the two wires to generate a proportional voltage. The proportional voltage can then be used to determine the temperature at thermocouple 235. Conductive ink printing can facilitate the integral formation of thermocouple 235 within wear indicator circuit 230.

[0024] In some cases, thermocouple 235 can provide a first set of data indicating the temperature at brake pad 200. The controller or control module of vehicle 110 can use this first set of data to help indicate brake failure. This is particularly relevant in braking systems 100 utilizing electronic brake boosters (EBB), where brake failure can be difficult to detect. The controller or control module of vehicle 110 can use the brake pad temperature from the first set of data to monitor or even adjust the braking system 100. Upon detection of brake failure, an indication can be delivered to the operator of vehicle 110 and / or parameters of vehicle 110 can be adjusted.

[0025] In an example embodiment, the controller or control module of vehicle 110 may include one or more controllers or control modules. The controller may include a processing circuitry system comprising a processor and memory. The processing circuitry system may be configured to provide electronic control of inputs to one or more functional units of braking system 100 and to process data received at or generated by one or more functional units of the vehicle control system. Therefore, according to the example embodiment, the processing circuitry system may be configured to perform data processing, control function execution, and / or other processing and management services. In some embodiments, the processing circuitry system may embody a semiconductor chip or chipset. In other words, the processing circuitry system may include one or more physical packages (e.g., chips) comprising materials, components, and / or wires on a structural assembly (e.g., a substrate). The structural assembly may provide physical strength, size savings, and / or electrical interaction limitations for the component circuitry system included thereon. Therefore, in some cases, the processing circuitry system may be configured to implement embodiments of the invention on a single chip or as a single "system-on-a-chip." For this purpose, in some cases, the chip or chipset may constitute means for performing one or more operations to provide the functionality described herein.

[0026] Adjustments to the braking system 100 can be made via the results of an algorithm that utilizes a first set of data and a second set of data potentially received from other vehicle sensors. The algorithm can monitor the brake pads 200 and brake temperature to adjust the braking system 100 based on the brake temperature and the determined or detected use of the vehicle 110. For example, if the vehicle 110 is towing a load, the algorithm can monitor the brake temperature and adjust the parameters of the braking system 100 in a manner different from when the vehicle is not towing a load.

[0027] The wear indication circuit 230 may include additional sensors. For example, a thermocouple 235 may be part of a sensor suite embedded and / or integrally formed within the wear indication circuit 230. The additional sensors in the sensor suite may include, but are not limited to, position sensors, force sensors, and speed sensors.

[0028] In some cases, the wear indicator circuit 230 may be integrally formed on top of or inside the first insulating layer 241 applied to the brake pad 200. The first insulating layer 241 may be ceramic, thermoplastic, or other material providing electrical insulation for the wear indicator circuit 230. In an example embodiment, the brake pad 200 may have a second insulating layer 242. The first insulating layer 241 may be disposed on the brake pad 220, and the second insulating layer 242 may be disposed on the backplate 210. The second insulating layer 242 may be ceramic, thermoplastic, or other material providing electrical insulation for the wear indicator circuit 230. The first insulating layer 241 and the second insulating layer 242 may be formed of the same material.

[0029] Wear indicator circuit 230, first insulating layer 241, and second insulating layer 242 can all be applied after the initial construction of brake pad 200. For example, wear indicator circuit 230, first insulating layer 241, and second insulating layer 242 can be added to the complete brake pad via additive manufacturing. First insulating layer 241 and second insulating layer 242 can be applied via printing press system 800. First insulating layer 241 and second insulating layer 242 can be applied via nanojet printer 810 of printing press system 800, while wear indicator circuit 230 can be applied via inkjet printer 820 of printing press system 800. In some cases, nanojet printer 810 and inkjet printer 820 can be separate components of a larger single printing press, or alternatively, multiple separate printing presses. Nanojet printer 810 and inkjet printer 820 can also be operatively coupled to and operated via printing press controller 830. In an example embodiment, the nanojet printer 810 may add a first insulating layer 241 and / or a second insulating layer 242 before the wear indicator circuit 230 is added to the inkjet printer 820. In some cases, the mobile device 840 may move the brake pad 200 from the nanojet printer 810 to the inkjet printer 820 and vice versa. The mobile device 840 may be a conveyor system or other device / system that can move the brake pad 200 throughout the production process.

[0030] The wear indicator circuit 230, the first insulating layer 241, and the second insulating layer 242 can be applied directly to the top of the surface of the brake pad 200. This application can be made directly to the top of the surface of the brake pad 200, either on the outside of the brake pad 200 or directly on the outer surface of the brake pad 200. The surface of the brake pad can be an edge of the main surface of the brake pad that does not engage with the brake caliper 180 and the brake disc 170. In practice, the surface of the brake pad 200 to which the wear indicator circuit 230, the first insulating layer 241, and the second insulating layer 242 are applied can be the surface of both a portion of the brake pad 220 and the backing plate 210. Applying the wear indicator circuit 230 directly to the surface of the brake pad 200 may not require any physical alteration, modification, or adjustment to the brake pad 200 (i.e., without adding notches or slots to integrally form the wear indicator circuit 230).

[0031] In some cases, the backplate 210 can be skipped during the application of the wear indicator circuit 230 and the insulating layer. In this respect, the wear indicator circuit 230 and the insulating layer can be applied only to the brake pad 220. The backplate 210 can be skipped to limit any interference or additional assembly time. In summary, the application of the wear indicator circuit 230, the first insulating layer 241, and the second insulating layer 242 can be designed so that no modifications to the backplate 210 or the brake pad 220 are required.

[0032] The wear indication circuit 230 can be operatively coupled to an external system 250. The external system 250 may include other vehicle sensors / circuits, power supplies, communication devices, and controllers / control modules. For example, such as... Figure 6 As shown, the external system 250 includes a first control module 251 and a power supply 252. The first control module 251 may be a main control module for the vehicle 110 or a braking system control module. In some cases, the first control module 251 may receive a first set of data from a thermocouple 235. The power supply 252 may be a braking system-specific power supply, the vehicle 110's battery, or any other power source for the vehicle 110. The wear indicator circuit 230 may be directly connected to the external system 250 via an electrical connector 260. The electrical connector 260 may be a plug or other connector that directly engages with the external system 250 (i.e., the first control module 251 and the power supply 252). In some cases, the wear indicator circuit 230 may have multiple instances of the electrical connector 250. In some cases, the backplate 210 may have a structure with holes, openings, or slots, and the wear indicator circuit 230 and / or the insulating layer may utilize the structure of the backplate 210 for use during the assembly of the braking system 100.

[0033] Other vehicle sensors may include wheel assembly sensors / circuits and suspension sensors / circuits. For example, wear indication circuit 230 may be operatively coupled to tire pressure monitoring circuitry, and wear indication circuit 230 may share features of tire pressure monitoring circuitry, including but not limited to communication systems and power supplies. Wear indication circuit 230 may share power supplies, communication systems / devices, and controllers with other vehicle components and subsystems.

[0034] In some cases, the wear indicator circuit 230 may be powered by a power source 252. The power source 252 may be operatively connected to the wear indicator circuit 230 via a wired connection, and may be one or more on-board power sources for the vehicle 110. Specifically, if the wear indicator circuit 230 is not operatively connected to other sensors or systems, it may be powered by a very small power source. Only a small potential may be required to detect a closed circuit (or to detect an open circuit when it is open). One or more on-board power sources for the vehicle 110 may be the vehicle 110's main battery or other batteries. In example embodiments, one or more on-board power sources may be a main power source for other vehicle components, including but not limited to control modules, vehicle sensor suites, and other power suspension assemblies / vehicle components. In some cases, one or more on-board power sources may be integrally formed within the braking system 100. For example, the braking system 100 may include its own battery or power source 252.

[0035] In some cases, power source 252 may include a piezoelectric element. The piezoelectric element may utilize the movement or displacement of braking system 100 and / or vehicle 110 and convert said movement or displacement into electrical energy. In an example embodiment, the movement or displacement of braking system 100 may be compression, relaxation, and / or displacement of brake pads 200, and may be converted into electrical energy via a piezoelectric element; therefore, the electrical energy may not necessarily be provided continuously, but may instead be provided discretely or in response to certain events. Wear detection may then be provided discontinuously or discretely when power is provided or in response to certain events.

[0036] In some cases, power supply 252 may include a thermoelectric element. The thermoelectric element can utilize heat generated via braking system 100 and convert that heat into electrical energy. In an example embodiment, movement or displacement of the brake pad 200 and brake disc 170 can generate heat, and this heat can be converted into electricity via a thermoelectric element. In some cases, power supply 252 may include a radio frequency (RF) power element. The RF power element may be a wireless power delivery element that picks up low-intensity radio frequency waves from a source and converts the energy of the waves into electricity. Therefore, as described above, wear indication circuit 230 may only require discontinuous power and / or low power levels. For example, wear indication circuit 230 may periodically receive power only when the wear level of brake pad 200 is desired.

[0037] The construction and materials of the wear indicator circuit 230, the first insulating layer 241, and the second insulating layer 242 may depend on and vary based on the specifications of the brake pad 200. For example, the materials of the backplate 210 and / or the brake pad 220 may lead to variations in the materials or application process of the wear indicator circuit 230, the first insulating layer 241, and the second insulating layer 242.

[0038] Therefore, a brake pad for a vehicle braking system can be provided. The brake pad may include: a brake pad configured to engage with a brake disc operably coupled to a wheel of the vehicle to apply friction to decelerate the vehicle; a backing plate providing support for the brake pad; and a wear indicator circuit operably coupled to the brake pad to detect brake pad wear. The wear indicator circuit may be externally printed on or inside the brake pad using conductive ink.

[0039] In some embodiments, the brake pads of a vehicle's braking system may include additional features, modifications, extensions, etc., to achieve further objectives or enhance the performance of the suspension assembly. These additional features, modifications, extensions, etc., can be added in any combination of each other. The following is a list of various additional features, modifications, and extensions, which can be added individually or in any combination of each other. For example, a thermocouple may be integrally formed into a wear indicator circuit. In some cases, the thermocouple may provide a first set of data indicating the temperature of the brake pads, and this first set of data may be transmitted to the vehicle's control module. The control module may adjust vehicle parameters based on the first set of data. In an example embodiment, the thermocouple may be part of a sensor suite integrally formed into the wear indicator circuit. In some cases, the wear indicator circuit may be printed on or within an insulating layer. In an example embodiment, the insulating layer may be ceramic, and the insulating layer may be printed via a nano-jet printer. Conductive ink may be printed via an inkjet printer. In some cases, the wear indicator circuit may be powered by continuous electrical current. In an example embodiment, the wear indicator circuit may be one of multiple wear indicator circuits. In some cases, multiple wear indicator circuits may be spaced apart according to the depth of the brake pads to indicate different corresponding wear thresholds. In an example embodiment, the wear detection circuit may disconnect in response to reaching the wear threshold of the brake pads. In some cases, the wear detection circuit may share a power supply with a separate vehicle component. In an example embodiment, an insulating layer may extend to both the brake pads and the backing plate, and the brake pads may have a first type of insulating layer. The backing plate may have a second type of insulating layer.

[0040] Therefore, a braking system for a vehicle, as exemplified by this embodiment, can be provided. The braking system may include: a brake disc operatively coupled to a wheel of the vehicle; and brake pads engaging with the brake disc to decelerate the vehicle. The brake pads may include: brake linings engaging with the brake disc to apply friction to decelerate the vehicle; a backing plate providing support for the brake linings; and a wear indicator circuit operatively coupled to the brake linings to detect brake lining wear. The wear indicator circuit may be externally printed on the brake pads using conductive ink.

[0041] Those skilled in the art to which this invention pertains will conceive of many modifications and other embodiments of the invention set forth herein, benefiting from the teachings presented in the foregoing description and associated drawings. Therefore, it should be understood that the invention is not limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Furthermore, while exemplary embodiments have been described in the context of certain exemplary combinations of elements and / or functions in the foregoing description and associated drawings, it should be understood that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, combinations of elements and / or functions different from those explicitly described above are also contemplated, for example, as may be set forth in some of the appended claims. Where advantages, benefits, or solutions to problems are described herein, it should be understood that such advantages, benefits, and / or solutions may be applicable to some exemplary embodiments but not necessarily to all exemplary embodiments. Therefore, any advantages, benefits, or solutions described herein should not be considered critical, essential, or necessary for all embodiments or the embodiments claimed herein. Although specific terminology is used herein, it is used only in a general and descriptive sense and not for limiting purposes.

[0042] According to the present invention, a brake pad for a braking system of a vehicle is provided, comprising: a brake pad configured to engage with a brake disc operably coupled to a wheel of the vehicle to apply friction to decelerate the vehicle; a backing plate providing support for the brake pad; and a wear indicator circuit operably coupled to the brake pad to detect wear of the brake pad, wherein the wear indicator circuit is printed on the exterior of the brake pad via conductive ink.

[0043] According to an embodiment, the thermocouple is integrally formed into the wear indication circuit.

[0044] According to an embodiment, the thermocouple provides a first set of data indicating the temperature of the brake pads, wherein the first set of data is transmitted to the vehicle's control module, and wherein the control module adjusts the vehicle's parameters based on the first set of data.

[0045] According to an embodiment, the thermocouple is part of a sensor suite integrally formed into the wear indication circuit.

[0046] According to an embodiment, the wear indicator circuit is printed on or within an insulating layer.

[0047] According to an embodiment, the insulating layer is ceramic, wherein the insulating layer is printed via a nanojet printer, and wherein the conductive ink is printed via an inkjet printer.

[0048] According to an embodiment, the insulating layer extends to the brake pad and the backing plate, wherein the brake pad has a first type of insulating layer and the backing plate has a second type of insulating layer.

[0049] According to an embodiment, the wear indicator circuit is powered via discontinuous power.

[0050] According to an embodiment, the wear indicator circuit is one of a plurality of wear indicator circuits.

[0051] According to an embodiment, the plurality of wear indicator circuits are spaced apart at corresponding intervals according to the depth of the brake pad to indicate different corresponding wear thresholds.

[0052] According to an embodiment, the wear detection circuit disconnects in response to reaching the wear threshold of the brake pad.

[0053] According to an embodiment, the wear detection circuit shares a power supply with individual vehicle components.

[0054] According to the present invention, a braking system for a vehicle is provided, comprising: a brake disc operably coupled to a wheel of the vehicle; and a brake pad engaging with the brake disc to decelerate the vehicle, the brake pad further comprising: a brake lining configured to engage with the brake disc to apply friction to decelerate the vehicle; a backing plate providing support for the brake lining; and a wear indicator circuit operably coupled to the brake lining to detect brake lining wear, wherein the wear indicator circuit is printed on the exterior of the brake pad via conductive ink.

[0055] According to an embodiment, the thermocouple is integrally formed into the wear indication circuit.

[0056] According to an embodiment, the thermocouple provides a first set of data indicating the temperature of the brake pads, wherein the first set of data is transmitted to the vehicle's control module, and wherein the control module adjusts the vehicle's parameters based on the first set of data.

[0057] According to an embodiment, the thermocouple is part of a sensor suite integrally formed into the wear indication circuit.

[0058] According to an embodiment, the wear indicator circuit is printed on or within an insulating layer.

[0059] According to an embodiment, the insulating layer is ceramic, wherein the insulating layer is printed via a nanojet printer, and wherein the conductive ink is printed via an inkjet printer.

[0060] According to an embodiment, the wear indicator circuit is one of a plurality of wear indicator circuits.

[0061] According to an embodiment, the wear detection circuit disconnects in response to reaching the wear threshold of the brake pad.

Claims

1. A brake pad for a brake system of a vehicle, the brake pad comprising: a brake pad face configured to interface with a brake disc operably coupled to a wheel of the vehicle to apply friction to slow the vehicle; a backing plate providing support for the brake pad face; and a wear indicator circuit operably coupled to the brake pad face to detect brake pad wear, wherein the wear indicator circuit is printed externally to the brake pad via a conductive ink.

2. The brake pad of claim 1, wherein a thermocouple is integrally formed into the wear indicator circuit.

3. The brake pad of claim 2, wherein the thermocouple provides a first set of data indicative of a temperature of the brake pad, wherein the first set of data is communicated to a control module of the vehicle, and wherein the control module adjusts a parameter of the vehicle based on the first set of data.

4. The brake pad of claim 2, wherein the thermocouple is part of a sensor suite integrally formed into the wear indicator circuit.

5. The brake pad of claim 1, wherein the wear indicator circuit is printed on or within an insulating layer.

6. The brake pad of claim 5, wherein the insulating layer is ceramic, wherein the insulating layer is printed via a nanofountain printer, and wherein the conductive ink is printed via an inkjet printer.

7. The brake pad of claim 5, wherein the insulating layer extends onto the brake pad face and the backing plate, and wherein the brake pad face has a first type of the insulating layer and the backing plate has a second type of the insulating layer.

8. The brake pad of claim 1, wherein the wear indicator circuit is powered via discrete power.

9. The brake pad of claim 1, wherein the wear indicator circuit is one of a plurality of wear indicator circuits.

10. The brake pad of claim 9, wherein the plurality of wear indicator circuits are spaced apart at respective intervals by a depth of the brake pad to indicate different corresponding wear thresholds.

11. The brake pad of claim 1, wherein the wear detection circuit is disconnected in response to reaching a wear threshold of the brake pad, or wherein the wear detection circuit shares a power source with a separate vehicle component.

12. A brake system for a vehicle, the brake system comprising: a brake disc operably coupled to a wheel of the vehicle; and a brake pad interfacing with the brake disc to slow the vehicle, the brake pad further comprising: a brake pad face configured to interface with the brake disc to apply friction to slow the vehicle; a backing plate providing support for the brake pad face; and a wear indicator circuit operably coupled to the brake pad face to detect brake pad wear, wherein the wear indicator circuit is printed externally to the brake pad via a conductive ink. ​ 13. The brake system of claim 12, wherein a thermocouple is integrally formed into the wear indicator circuit, wherein the thermocouple provides a first set of data indicative of a temperature of the brake pad, wherein the first set of data is communicated to a control module of the vehicle, and wherein the control module adjusts a parameter of the vehicle based on the first set of data, or the thermocouple is part of a sensor package integrally formed into the wear indicator circuit.

14. The brake system of claim 12, wherein the wear indicator circuit is printed on or within an insulating layer, wherein the insulating layer is ceramic, wherein the insulating layer is printed via a nanojet printer, and wherein the conductive ink is printed via an inkjet printer.

15. The brake system of claim 12, wherein the wear indicator circuit is one of a plurality of wear indicator circuits, or wherein the wear detection circuit is open in response to reaching a wear threshold of the brake pad.

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