Noise prevention shim

Abstract

A noise prevention shim (100) comprising at least one porous metal layer (110) and at least one high temperature resistant layer (120) facing / connected to each other by a mechanical joint, the porous metal layer having through holes (111) and a mechanical joint means (112), and the high temperature resistant layer comprising fibers, fillers, and a jointing agent.

Description

[Technical Field]

[0001] The present invention relates to an anti-noise shim, and more particularly, the present invention relates to an anti-noise shim comprising a porous metal layer and a high temperature resistant layer. [Background technology]

[0002] Vehicle brakes are a critical system that not only slows a vehicle but also prevents dangerous collisions, making them a key design concern for automotive engineers. Drivers demand safer, properly functioning braking systems that effectively slow vehicle speeds, with low or no noise emissions another key factor. Brake pads, a key component of the braking system, are designed to generate friction against the wheel disc, slowing the wheel disc's speed when engaged into contact with the disc by a hydraulic piston. However, this friction generates undesirable heat energy, vibration, and high-pitched noise. Brake pads are designed to be heat-resistant and maintain their braking performance, but a component called a brake pad shim is required to further absorb this generated heat and protect the functional elements of a vehicle's braking system.

[0003] Brake pad shims are integrated into the brake pads to keep the brake pads and wheel discs perfectly aligned and also reduce brake pad vibration, which is actually perceived by the human ear as a high-pitched, piercing noise. Importantly, brake pad shims reduce noise pollution from the vehicle by absorbing vibrations. The shims also help dissipate heat from the brake pads to prevent overheating of the brake fluid system. The extent of the above functions is a factor of the material of the brake pad shim.

[0004] Most aftermarket shim materials are designed to trade off quality for low price. These cheaper materials are unable to effectively absorb noise in the 1kHz to 20kHz frequency range and minimize brake noise. Additionally, these lower-quality, lower-cost shim materials are unable to dissipate heat under more severe braking conditions. This can cause brake fluid to boil and coat the brake pads, resulting in reduced braking power and sudden, premature brake failure.

[0005] This leads to injuries and deaths of vehicle users and pedestrians.The coating quality of brake pad shim materials is extremely low, resulting in relatively poor heat dissipation properties.

[0006] U.S. Patent No. 6,105,736 discloses an anti-squeal shim (1) comprising a metal layer (3) having a pair of mechanical joining means (6, 15) at the upper end of the anti-squeal shim and another at the lower end, the metal layer being coated on one side with a compound layer (2) that is a high-temperature resistant layer, the anti-squeal shim having a hole (5) formed therethrough (see Figures 1, 5, 6, and 7, column 4, lines 52-62).

[0007] Japanese Patent No. 6208336 discloses a noise prevention shim (107) comprising a metal layer (104) without through holes, having mechanical joining means (105) with a pointed tip (106) connected to a graphite foil layer (103) (see Figure 1 and paragraph

[0030] ).

[0008] Therefore, there is a need to develop new anti-noise shims that have improved heat dissipation and noise absorption properties and are cost-competitive with those of higher quality and more expensive already available on the market. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] U.S. Patent No. 6,105,736 [Patent Document 2] Japanese Patent No. 6208336 Summary of the Invention [Means for solving the problem]

[0010] The present invention deals with a new anti-noise shim that overcomes the drawbacks of the prior art, which is realized by an anti-noise shim comprising a porous metal layer and a high-temperature resistant layer, as well as by an associated method for applying the production of an anti-noise shim, as defined in the independent claims.

[0011] An advantage of the anti-noise shim according to the invention is that it is durable and highly suitable for mass production by methods including environmentally friendly processes, while providing excellent heat dissipation and noise absorption properties. Embodiments of the invention are defined in the dependent claims.

[0012] Specific embodiments of the present invention are described in detail herein below, by way of example and not limitation, with reference to the accompanying figures. [Brief explanation of the drawings]

[0013] [Figure 1a] 1A and 1B are schematic diagrams illustrating an embodiment of an anti-noise shim. [Figure 1b] 1A and 1B are schematic diagrams illustrating an embodiment of an anti-noise shim. [Figure 2a] 1 shows a schematic diagram of a method for producing an anti-noise shim; [Figure 2b] 1 shows a schematic diagram of a method for producing an anti-noise shim; [Figure 3a] FIG. 1 shows a schematic illustration of a continuous drilling, joining, and cutting process line. [Figure 3b] FIG. 1 shows a schematic illustration of a continuous drilling, joining, and cutting process line. [Figure 4] FIG. 1 shows a schematic illustration of a disc brake. DETAILED DESCRIPTION OF THE INVENTION

[0014] The applicant has surprisingly and unexpectedly developed a new anti-noise shim 100 comprising at least one porous metal layer 110 and at least one high-temperature resistant layer 120 facing / connected to each other by a mechanical joint, the porous metal layer comprising through-holes 111 and sharp / pointed mechanical joint means 112, the continuous high-temperature resistant layer 120 being specifically the continuous high-temperature resistant layer 120 corresponding to the through-holes 111 of the porous metal layer 110 as clearly reported in figures such as Figures 1a, 1b, 3a, 3b, and the high-temperature resistant layer comprising fibres, fillers and binders. in particular, The noise prevention shim 100 comprises at least one porous metal layer 110 and at least one high-temperature resistant layer 120 facing / connected to each other by mechanical bonding, the porous metal layer having through holes 111 and sharp / pointed mechanical bonding means 112, the continuous high-temperature resistant layer 120 specifically corresponding to the through holes 111 of the porous metal layer 110 as clearly reported in figures such as Figures 1a, 1b, 3a, 3b, etc., the high-temperature resistant layer comprising fibers, fillers, and bonding agents, and the noise prevention shim further comprises: a coating layer 130 bonded to the other side / face of the porous metal layer; or a second high-temperature-resistant layer, a continuous high-temperature-resistant layer 120, in particular a continuous high-temperature-resistant layer 120 corresponding to the through holes 111 of the porous metal layer 110, which is mechanically bonded to the other side / face of the porous metal layer, as clearly reported in figures such as Figs. 1a, 1b, 3a, 3b, etc. In other words The anti-noise shim 100 comprises at least one porous metal layer 110 and at least one high-temperature resistant layer 120 facing / connected to each other by mechanical bonding, the porous metal layer having through holes 111 and sharp / pointed mechanical bonding means 112, the continuous high-temperature resistant layer 120 specifically corresponding to the through holes 111 of the porous metal layer 110 as clearly reported in figures such as Figures 1a, 1b, 3a, 3b, etc., the high-temperature resistant layer including fibers, fillers, and binders, the anti-noise shim further comprising a coating layer 130 bonded to the other side / face of the porous metal layer, or or The noise prevention shim 100 comprises at least one porous metal layer 110 and at least one high-temperature resistant layer 120 facing / connected to each other by mechanical bonding, the porous metal layer having through holes 111 and sharp / pointed mechanical bonding means 112, the continuous high-temperature resistant layer 120 being specifically a continuous high-temperature resistant layer 120 corresponding to the through holes 111 of the porous metal layer 110 as clearly reported in figures such as Figures 1a, 1b, 3a, 3b, etc., the high-temperature resistant layer comprising fibers, fillers, and binders, the noise prevention shim further comprising a second high-temperature resistant layer 120, specifically a continuous high-temperature resistant layer 120 corresponding to the through holes 111 of the porous metal layer 110, mechanically bonded to the other side / face of the porous metal layer as clearly reported in figures such as Figures 1a, 1b, 3a, 3b, etc.

[0015] Furthermore, in the anti-noise shim according to any of the embodiments of the present invention, an additional thin coating layer 140 may be applied to the high temperature resistant layer 120 when the high temperature resistant layer 120 is coupled with the porous metal layer 110 .

[0016] The porous metal layer 110 according to the present invention is a metal layer having through-holes 111, specifically, a metal layer having through-holes 111 within 2 square centimeters (cm 2 ) and preferably 1 through-hole / cm 2 through holes or 2, 3, 4, 5, or 6 holes / cm on the surface of the metal layer 2 The term "metal layer" refers to a metal layer having through holes.

[0017] Specifically, the through-hole has a diameter of 0.5 mm or more and 3.0 mm or less, and preferably 1.0 mm or more and 1.5 mm or less.

[0018] Specifically, the porous metal layer 110 preferably has a thickness of 300 μm or more and 500 μm or less, and more preferably 360 μm or more and 400 μm or less.

[0019] Such a porous metal layer 110 may be constructed from, for example, iron, galvanized steel, stainless steel, aluminum, or the like.

[0020] As described above, the continuous high-temperature-resistant layer 120, specifically the continuous high-temperature-resistant layer 120 corresponding to the through-holes 111 of the porous metal layer 110 as clearly shown in Figures 1a, 1b, 3a, and 3b, includes fibers, fillers, and a binder. According to one embodiment, the binder is an elastomeric binder, but a non-elastomeric resin-type binder may also be used. Compared to conventional rubber materials, the fibers make the material stronger and less elastic in-plane without significantly affecting the normal compression properties. Furthermore, the fibers and fillers reduce the amount of elastomeric binder in the layer, thereby lowering the cost of the layer. According to one embodiment, the fiber content in the high-temperature-resistant layer 120 is 5%, 10%, or 14% by weight or more, and 23% or 30% by weight or less. However, the fiber content may exceed 30% in some applications, such as up to 50%, 80%, or even 95%. The fibers may be selected from organic fibers depending on the specific application. Examples of organic fibers include cellulose fibers, cotton linters (generally plant-derived fibers), 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, and phenolic fibers. According to one embodiment, the fibers include aromatic polyamide fibers. More preferably, the fibers are selected from inorganic fibers such as carbon fibers, glass fibers, ceramic fibers, rock wool, mineral wool, fused quartz fibers, chemically treated high-silica fibers, fused alumina silicate fibers, continuous alumina fibers, stabilized zirconia fibers, boron nitride fibers, alkali titanate fibers, whiskers, boron fibers, wollastonite, and basalt fibers.

[0021] The filler may be inorganic, such as clay, ash, talc, barium sulfate, sodium bicarbonate, graphite, lead sulfate, diatomaceous earth, or wollastonite, or organic. The binder may be a rubber-type elastomeric material, 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), fluororubber (FPM), silicone rubber (Si), chlorosulfonated polyethylene (CSM), ethylene vinyl acetate copolymer (EVA), chlorinated polyethylene (CPE), chloroisobutane isoprene rubber (CIIR), epichlorohydrin rubber (ECO), or nitrile isoprene rubber (NIR). Elastomers other than rubber may also be used. According to an alternative embodiment, the bonding agent is a resin-type material, such as a rubber-modified phenolic resin, a phenolic resin, or an epoxy resin.

[0022] Specifically, the high temperature resistant layer 120 preferably has a thickness of 50 μm or more and 600 μm or less, and more preferably 150 μm or more and 300 μm or less.

[0023] According to one embodiment, the coating layer 130 is a viscoelastic layer. The viscoelastic layer may be latex (SBR, NBR, chloroprene, acrylic, etc.), synthetic resin (acrylic, phenolic, etc.), PTFE, polyurethane, viscoelastic adhesive such as an acrylic or silicone based adhesive, or any viscoelastic material with suitable vibration absorption and heat resistance properties for the conditions to which the shim will be exposed when mounted in a disc brake.

[0024] Specifically, the coating layer 130 preferably has a thickness of 30 μm or more and 200 μm or less, and more preferably 80 μm or more and 150 μm or less.

[0025] The optional thin coating layer 140 specifically includes a heat-resistant polymer material such as PTFE, silicone, polyurethane, synthetic resin, etc., having a thickness of 10 μm to 100 μm, preferably 20 μm to 80 μm.

[0026] The thin coating layer 140 is applied as a top layer onto the high temperature resistant layer 120 .

[0027] The stepwise application or bonding of coating layer 130 and / or thin coating layer 140 can be performed in a variety of ways, such as by rolling, bath saturation, spraying, wetting, and the like.

[0028] The anti-noise shim 100 according to any one of the embodiments of the present invention is a high-performance anti-noise shim including a multilayer material for use in brake shims. The anti-noise shim 100 is made by mechanically bonding at least one high-sound-resistant layer 120, which includes a binder, which is a latex rubber-type elastomer material such as a special nitrile butadiene rubber (NBR) or styrene-bonded rubber (SBR)-based latex material, fibers, such as inorganic fibers, and fillers, to a porous metal layer 110. The porous metal layer 110 is characterized by through-holes 111 and sharp mechanical bonding means 112, if present, that are integral with the porous metal layer 110 and located at the edges 113 of the through-holes 111 on at least one mechanical bonding surface 114 of the porous metal layer 110. The porous metal layer 110 with through-holes 111 absorbs resonant frequencies better than a solid metal layer. Furthermore, the high temperature resistant layer 120 according to the present invention is produced by adapting gasket technology, which involves injecting fibers and fillers into a binder such as virgin NBR (or SBR, or other type) latex. The adapted gasket technology makes the anti-noise shim according to any of the embodiments according to the present invention more temperature resistant, while the perforations in the metal layer 120 make the anti-noise shim a perfect material for absorbing high frequency noise.

[0029] The noise prevention shim of the present invention is a high-performance noise prevention shim comprising a multi-layer composite in which a porous metal layer / sheet 110 is mechanically bonded to at least one high-temperature resistant layer 120 or sandwiched between two high-temperature resistant layers 120 by mechanical bonding, and the high-temperature resistant layer 120 includes a bonding agent, which is a rubber-type elastomer material such as a special nitrile butadiene rubber (NBR) material, fibers such as organic fibers and inorganic fibers, and fillers.

[0030] Perforating the metal layer / sheet facilitates the mechanical joining step of the various layers of the shim. Noise absorption properties by leaving voids in the metal. Thanks to the through holes 111 in the perforated metal layer 110, the vibration of air molecules in the voids helps to dissipate high frequency noise generated by the vibration of the brake disc and brake pads, thus attenuating the noise.

[0031] The high-temperature-resistant layer 120 according to the present invention is produced by adapting gasket technology, which involves injecting fibers, preferably inorganic fibers, and fillers into a binder, which is a rubber-type elastomeric material, preferably virgin NBR (or SBR, or other type) latex. NBR (or SBR, etc.) latex is a milky white liquid emulsion of synthetic rubber. Gasket technology generally tolerates higher temperatures than 100% NBR-coated layers. Furthermore, the concept of a porous metal layer disperses high-frequency vibrations much more effectively and allows them to be more easily absorbed within the composite. The mechanical bonding step (a step of pressing the high-temperature resistant layer / sheet 120 according to the present invention onto the porous metal layer 110 characterized by the through holes 111 and sharp / pointed mechanical bonding means 112 that are integral / integral with the porous metal layer 110 and, if present, located on the edges 113 of the through holes 111 of at least one mechanical bonding surface 114 of the porous metal layer 110) does not require any adhesives or solvents to form a strong bond during the process, thereby eliminating the need for solvents used in actual shim production techniques. In the mechanical bonding step, the applied pressure is sufficient to bend the sharp / pointed mechanical bonding means 112 inward and grip the porous metal layer / sheet and the high-temperature resistant layer / sheet together.

[0032] By "mechanical joining means" 112 or "mechanical joining means 112" according to the present invention is meant joining / mechanical restraining means 112, linking means 112, or fastening means 112 for mechanical attachment between the porous metal layer 110 and the high heat resistant layer 120 to which it is connected.

[0033] The technical advantages of the anti-noise shim according to any of the embodiments of the present invention, the method for producing the anti-noise shim, and the use of the anti-noise shim in a disc brake device are as follows: The anti-noise shim according to the invention has high heat resistance and improved noise absorption. The anti-noise shims of the present invention are produced using a novel low-cost, energy-saving, solvent-free continuous process, making the anti-noise shims affordable, readily available, and ensuring a secure supply of raw materials. The anti-noise shim according to the present invention acts as a thermal barrier, preventing excessive heat from reaching the brake fluid and boiling it, resulting in loss of braking, i.e. preventing brake fade.

[0034] Another object of the present invention is to use an anti-noise shim according to any of the embodiments according to the invention in a disc brake device comprising a caliper (brake caliper / brake caliper) and brake pads, the anti-noise shim / anti-noise brake shim being configured to act between the caliper and the brake pads.

[0035] 1a and 1b show schematically some embodiments of a noise prevention shim 100 according to the present invention, in which at least one porous metal layer 110 and at least one high temperature resistant layer 120 are faced / connected to each other by a mechanical joint, and the porous metal layer is provided with through holes 111.

[0036] These figures are to be regarded as illustrative purposes only and the relative dimensions of the various layers are not to be taken as meaningless.

[0037] FIG. 1a specifically shows an example of a noise prevention shim according to the present invention, in which at least one porous metal layer 110 and at least one high-temperature resistant layer 120 face / connect to each other by mechanical bonding, the porous metal layer having through holes 111, and the noise prevention shim further comprises a coating layer 130 bonded to the other side / face of the porous metal layer.

[0038] 1a specifically shows a porous metal layer 110 characterized by through holes 111 and sharp / pointed mechanical connection means 112, preferably hook-shaped, at least one, two, three or four mechanical connection means per through hole, which are integral / integrated with the porous metal layer 110 and, if present, are located on at least one mechanical connection surface 114 of the porous metal layer 110, at the edge 113 of the through hole 111, where the mechanical connection surface of the porous metal layer is mechanically bonded to the high-temperature resistant layer 120, while the coating layer 130 is bonded to the other side / face of the porous metal layer.

[0039] FIG. 1b specifically shows an example of a noise prevention shim according to the present invention, in which at least one porous metal layer 110 and at least one high temperature resistant layer 120 are facing / connected to each other by mechanical bonding, the porous metal layer having through holes 111, and the noise prevention shim further comprises a second high temperature resistant layer 120 mechanically bonded to the other side / face of the porous metal layer.

[0040] 1b specifically shows a porous metal layer 110 characterized by through holes 111 and sharp / pointed mechanical connection means 112, preferably hook-shaped, at least one, two, three, or four mechanical connection means per through hole. The mechanical connection means are integral / integrated with the porous metal layer 110 and, if present, are located on the mechanical connection surface 114 of the porous metal layer 110 at the edge 113 of the through hole 111, mechanically connecting the mechanical connection surface of the porous metal layer and the high-temperature resistant layer 120. Furthermore, a thin coating layer 140 is or may be applied as a top layer on the high-temperature resistant layer 120.

[0041] A method for producing an anti-noise shim of the type disclosed herein is also provided.

[0042] The steps of this method are shown diagrammatically in Figures 2a and 2b.

[0043] A further object of the invention is a method for producing an anti-noise shim 100 according to any embodiment of the invention, the method comprising the following steps: - providing a perforated metal sheet 110 with through holes 111 and mechanical joining means 112; - mechanically joining, by applying pressure or pressure and temperature, a continuous high-temperature resistant layer 120, which is a high-temperature resistant sheet 120, in particular a continuous high-temperature resistant layer 120 corresponding to the through holes 111 of the porous metal layer 110 as clearly reported in figures such as Figures 1a, 1b, 3a, 3b, etc., wherein the high-temperature resistant sheet comprises fibers, fillers and bonding agents on at least one side of the porous metal sheet to form a noise prevention shim sheet;

[0044] As an alternative method for producing an anti-noise shim 100 according to any embodiment of the present invention, the method includes the following steps. - providing a perforated metal sheet 110 with through holes 111 and mechanical joining means 112; - mechanically joining, by applying pressure or pressure and temperature, a continuous high-temperature resistant layer 120, which is a high-temperature resistant sheet 120, in particular a continuous high-temperature resistant layer 120 corresponding to the through holes 111 of the porous metal layer 110, as clearly reported in figures such as Figures 1a, 1b, 3a, 3b, and the like, wherein the high-temperature resistant sheet comprises fibers, fillers, and a bonding agent on at least one side of the porous metal sheet; - providing a further high temperature resistant sheet 120; - mechanically bonding a further high temperature resistant sheet to at least one unbonded side of the perforated metal sheet by applying pressure or pressure and temperature. That is, a method in which a further high temperature resistant sheet is mechanically joined to the opposite side of the perforated metal sheet to which the temperature resistant material sheet 120 is mechanically joined to form a noise prevention shim sheet, or a method in which two high temperature resistant sheets 120 are mechanically joined to opposite / both sides of the perforated metal sheet 110 to form a noise prevention shim.

[0045] As an alternative method for producing an anti-noise shim 100 according to any embodiment of the present invention, the method includes the following steps. - providing a perforated metal sheet 110 with through holes 111 and mechanical joining means 112; - mechanically joining, by applying pressure or pressure and temperature, a continuous high-temperature resistant layer 120, which is a high-temperature resistant sheet 120, in particular a continuous high-temperature resistant layer 120 corresponding to the through holes 111 of the porous metal layer 110, as clearly reported in figures such as Figures 1a, 1b, 3a, 3b, and the like, wherein the high-temperature resistant sheet comprises fibers, fillers, and a bonding agent on at least one side of the porous metal sheet; - preparing a coating sheet 130; - bonding a coating sheet to at least one unbonded side of the perforated metal sheet. That is, in order to form a noise prevention shim sheet, a coating sheet 130 is bonded to the opposite side of the perforated metal sheet 110 where the temperature-resistant material 120 is mechanically bonded, thereby forming a noise prevention shim.

[0046] All of the above described methods according to the present invention may optionally further comprise the step of applying / bonding a further thin coating layer 140 to the high temperature resistant layer / sheet 120, particularly when the high temperature resistant layer / sheet 120 is / is already mechanically bonded to the porous metal layer 110.

[0047] All methods for producing anti-noise shims of the type according to the invention are characterized by the step of preparing at least one perforated metal sheet 110. Said perforated metal sheet 110 is obtained by perforating the metal sheet (perforation is achieved using a punching machine, such as one or two perforation rolls, or a high-power hydraulic press equipped with specially designed perforation dies that perforate the metal, when said perforation dies / rolls are pressed against the surface / side of the metal layer (perforation step)), producing a perforated metal sheet with through holes 111 and sharp / pointed mechanical joining means 112, preferably hook-shaped, at least one, two, three or four mechanical joining means per through hole. Said mechanical joining means are integral / integral with the perforated metal layer 110 and, if present, are located at the edges 113 of the through holes 111, on at least one mechanical joining surface 114 of the perforated metal layer 110. This perforation can be realized on only one side or on both sides of the metal layer / sheet.

[0048] Thus, the porous metal layer / sheet 110 has through holes 111 and sharp / pointed mechanical joining means 112, preferably hook-shaped, at least one, two, three or four mechanical joining means per through hole, said mechanical joining means being integral / integrated with the porous metal layer / sheet 110 and, if present, located on the edge 113 of the through hole 111 on at least one mechanical joining surface 114 of the porous metal layer 110.

[0049] The step of providing the perforated metal sheet 110 is always preceded by a perforation step, whichever is present in any embodiment of the method for producing anti-noise shims of the type according to the invention.

[0050] In the perforation step, a specially designed perforation roll / die is provided with perforation tips, preferably but not limited to star-shaped tips (1 cm) designed to create through holes 111 in the metal layer / sheet. 2Sharp / pointed mechanical joining means 112 having at least one tip per hole are integral / integral with the porous metal layer / sheet 110 and are located at the edges 113 of the through holes 111 on a surface / side 114 of the porous metal layer / sheet opposite to the surface / side of the porous metal layer / sheet against which the perforating roll / die is pressed.

[0051] When both surfaces / sides of the porous metal layer / sheet have sharp / pointed mechanical joining means 112 (i.e., both mechanical joining surfaces 114), the sharp / pointed mechanical joining means of one surface / side is offset relative to the sharp / pointed mechanical joining means of the other surface / side. That is, each through-hole 111 has sharp / pointed mechanical joining means 112 at the edge 113 of the through-hole on only one surface / side of the porous metal layer / sheet (see FIG. 1b). Therefore, in the corresponding perforation step, both surfaces / sides of the metal layer / sheet are perforated by pressing with a perforation die / roll on each surface / side, and the perforation tip of one perforation die / roll is offset relative to the perforation tip of the other perforation die / roll.

[0052] The step of joining the different sheets, i.e., mechanically joining the perforated metal sheet with the high-temperature resistant sheet, or mechanically joining the perforated metal sheet with the high-temperature resistant sheet and the coated sheet with bonding or vulcanization, including the use of a bonding agent such as a resin, cyanide, or acrylic type adhesive, can be carried out in any suitable manner to provide a sufficiently strong bond between the sheets. The joining step can include the application of pressure, pressure and heat, or simply heat. To make the method efficient, the joining step can include continuous rolling, whereby the perforated metal sheet and the high-temperature resistant film / sheet are prepared / produced in the form of a coil 210 or roll 200, respectively. In the bonding step 230 / 270, which includes a mechanical bonding step, the applied pressure is sufficient to fold the sharp / pointed mechanical bonding means 112 of the porous metal layer / sheet 110 inward and grip the porous metal layer / sheet 110 and the high temperature resistant layer / sheet 120 together, while the coating film / sheet 130 is applied / bonded by print rolling, spraying, wetting, bath wetting, etc. Also, the thin coating layer / sheet / film 140, if present, is applied / bonded by print rolling, spraying, wetting, bath wetting, etc.

[0053] An anti-noise shim of the type according to the invention can be obtained as an anti-noise shim sheet of the type according to the invention, said anti-noise shim sheet of the type according to the invention being capable of being enrolled to form a coil.

[0054] The further optional step of cutting individual anti-noise brake shims from the anti-noise shim sheet can be performed by any suitable method, such as stamping or the like. According to one embodiment, the method includes a step 240 of scoring the coil into a narrow coil after the joining step 230 / 270. Individual anti-noise brake shims are then cut from the narrow coil.

[0055] To achieve a strong bond and minimize the number of steps in the bonding process, the perforated metal sheets may be pre-treated with a bonding agent prior to the bonding step 230 / 270.

[0056] The pre-processing step 221 may also be performed in a continuous process.

[0057] 3a-3b show a schematic illustration of a process line 300 for sequential drilling, joining, and optionally cutting.

[0058] 3a shows a schematic illustration of a continuous perforating, joining, and optionally cutting process line 300, in which a perforated metal sheet 110 is obtained by a perforator 310 acting on a metal sheet provided in the form of a coil (not shown), and a high-temperature-resistant sheet 120 to be joined together is provided in the form of a coil or roll (not shown). Sheets 110 and 120 are pressed together and joined by a pair of calendar rolls 330 to form a layered anti-noise shim 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 anti-noise shim sheet by a wet application process 340.

[0059] As another optional step, individual anti-noise brake shims 350 are cut from the anti-noise shim sheet using a die cutter 360 .

[0060] FIG. 3b shows a schematic illustration of a continuous perforating, joining, and optionally cutting process line 300, in which perforated metal sheet 110 is obtained by a perforating machine 310 operating on a metal sheet provided in the form of a coil (not shown), and high-temperature-resistant sheet 120 is prepared to be joined together. Sheets 110 and 120 are pressed together and joined by a pair of calendar rolls 330 to form a layered sheet. Coating layer 130 is applied to the unjoined surface of layered sheet perforated metal layer 110 by a wet application process 370 to form an anti-noise shim sheet according to the present invention. As another optional step, individual anti-noise brake shims 350 are cut out of the anti-noise shim sheet using a die-cutting machine 360.

[0061] FIG. 4 shows a schematic illustration of a disc brake 10, an example of a disc brake known in the art, comprising a disc 20 arranged to rotate about an axis CC. The disc brake 10 includes a pair of brake pads 30, each having a backing plate 40 supporting a friction member 50 on a side of the disc of the disc brake; a brake caliper 60 supporting the brake pads 30 for movement toward and away from the opposing friction surface of the disc 20; and hydraulic actuation means 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 communicating with the vehicle's hydraulic braking system. In the disclosed embodiment of the disc brake 10, the caliper housing 60 is movable in the direction of brake piston actuation, causing the brake pad on the side without the piston to be pressed against the disc by caliper fingers 90 of the caliper housing 60. An anti-noise shim 100 is positioned adjacent to the backing plate 40 of each disc pad 30, and braking forces from the brake piston 70 and caliper fingers 65, respectively, are transmitted to the brake pads 30 through the anti-noise shim 100.

[0062] Throughout this description, the term "brake pad side" refers to the side of the anti-noise shim 100 that faces the backing plate 40 of the brake pad 30, and the term "piston side" refers to the non-pad side, i.e., the side that faces the piston 70 or caliper fingers 90. In some disc brake designs, the caliper fingers 90 are omitted, and the caliper 60 is provided with a brake piston 70 on each side of the disc 20. However, throughout this description, the above terms are inclusive of any such undisclosed disc brake device.

[0063] There is also provided a disc brake device comprising an anti-noise shim according to any one of the above embodiments between a caliper and a brake pad, the disc brake being arranged on a suitable vehicle such as a car, truck, train, motorbike, bicycle, etc.

[0064] In order to make full use of the anti-noise shim according to the present invention, there is further provided a method for preventing noise in a disc brake, comprising the step of placing an anti-noise shim according to any one of the above embodiments between a caliper and a brake pad.

Claims

1. 1. A noise prevention shim (100) comprising at least one porous metal layer (110) and at least one high-temperature resistant layer (120) facing / connected to each other by a mechanical joint, the porous metal layer comprising through holes (111) and mechanical joint means (112), the high-temperature resistant layer comprising fibers, fillers, and binder materials, the porous metal layer (110) being characterized by the through holes (111) and the mechanical joint means (112) being sharp / pointed and integral with the porous metal layer (110) and, if present, located at the edge (113) of the through holes (111) of at least a mechanical joint surface (114) of the porous metal layer (110).

2. The anti-noise shim of claim 1 further comprising a coating layer (130) bonded to the other side / face of the porous metal layer.

3. The anti-noise shim of claim 1 further comprising a second high temperature resistant layer (120) mechanically bonded to the other side / face of the porous metal layer.

4. 4. An anti-noise shim according to any one of claims 1 to 3, wherein a further thin coating layer (140) is applied / bonded onto the high temperature resistant layer (120).

5. 5. The noise prevention shim according to claim 1, wherein the content of the fibers in the high temperature resistant layer is 95% by weight or less, preferably 50% by weight or less, more preferably 30% by weight or less, and even more preferably 23% by weight or less.

6. 6. The noise prevention shim according to any one of claims 1 to 5, wherein the fibers comprise synthetic organic fibers and / or inorganic fibers.

7. 7. The anti-noise shim of claim 1, wherein the filler comprises an inorganic filler material or an organic filler.

8. 8. The anti-noise shim of any one of claims 1 to 7, wherein the cement material comprises a latex / rubber type elastomeric material, or the cement material comprises a resin type material.

9. The anti-noise shim of claim 2 , wherein the coating layer is a viscoelastic layer.

10. A method for producing the noise prevention shim (100) of claim 1, comprising: Providing a porous metal layer (110) with through holes (111) and mechanical joining means (112); mechanically bonding a high temperature resistant sheet (120) comprising fibers, fillers, and binders to at least one side of the porous metal layer by applying pressure or pressure and temperature to form a noise shim sheet; A method comprising:

11. A method for producing a noise prevention shim (100) according to claim 3, comprising: Providing a porous metal layer (110) with through holes (111) and mechanical joining means (112); mechanically bonding a high temperature resistant sheet (120) comprising fibers, fillers, and binders to at least one side of the porous metal layer by applying pressure or pressure and temperature to form a noise prevention shim sheet; Providing a further high temperature resistant sheet (120); mechanically bonding the additional high temperature resistant sheet to at least one unbonded side of the porous metal layer by applying pressure or pressure and temperature; A method comprising:

12. A method for producing the noise prevention shim (100) of claim 2, comprising: Providing a porous metal layer (110) with through holes (111) and mechanical joining means (112); mechanically bonding a high temperature resistant sheet (120) comprising fibers, fillers, and binders to at least one side of the porous metal layer by applying pressure or pressure and temperature to form a noise prevention shim sheet; Providing a coating sheet (130); bonding the coating sheet to at least one unbonded side of the porous metal layer; A method comprising:

13. 13. The method of any one of claims 10 to 12, wherein the bonding step comprises continuous rolling.

14. An anti-noise brake shim comprising an anti-noise shim according to any one of claims 1 to 9.

15. 15. A method of preventing noise in disc brakes, comprising the step of disposing the anti-noise brake shim of claim 14 between a brake caliper and a brake pad.

16. A disc brake device (10) comprising an anti-noise brake shim according to claim 14 between a caliper and a brake pad.

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

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