Multi-Layer Brake Dust Sheet for Airborne Noise Damping
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Solution Overview
Problem
Existing solutions for reducing brake noise in vehicles have been expensive and ineffective, focusing primarily on vibration reduction rather than airborne sound attenuation.
Innovation Solution
A dust sheet for vehicle brakes comprising multiple layers, strategically arranged and tuned for optimal damping, including varying thicknesses, materials, and web configurations to effectively attenuate airborne sound, with the layers positioned to face the brake disk opposite to the brake pad engagement point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If multiple layers are arranged at a distance to form cavities, then airborne sound attenuation is improved, but device complexity increases
Solution Approach 1:
The dust sheet is segmented into multiple layers (first layer, second layer, third layer) with cavities between them. This segmentation creates a multi-chamber structure that attenuates airborne sound through multiple interfaces and air gaps, while each individual layer remains relatively simple in design.
Solution Approach 2:
The dust sheet employs a nested layer structure where multiple layers are stacked within the same spatial envelope. The first, second, and third layers are nested sequentially, with cavities formed between adjacent layers. This nesting approach achieves complex sound attenuation functionality within a compact structure without significantly increasing overall device complexity.
2Object-affected harmful factors
If layers are made of different materials, then damping performance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The dust sheet utilizes composite material construction with at least two different materials: a first material for the first layer and a second material for the second layer. This composite approach optimizes damping performance by combining materials with different acoustic properties. The third layer may be made of the first material or a third material, creating a multi-material composite structure that enhances noise reduction while maintaining manufacturability through standardized material selection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly reduces brake noise through efficient damping of airborne sound, achieving effective noise attenuation without the high costs associated with previous methods, by leveraging the unique configuration of the dust sheet layers and their positioning relative to the brake components.
Implementation Method 1
The two or more layers represent a functional arrangement for attenuating airborne sound emerging from the vehicle brake. The layers may be tuned and configured to optimize damping.
Implementation Method 2
The layers may be tuned and configured to optimize damping... the number of layers and/or their material(s) and/or their distance from another and/or their thicknesses may be tuned for efficient damping.
Data Source
AI summary
The invention relates to a dust sheet for a vehicle brake configured for reducing brake noise, to a disk brake system comprising a dust sheet and to a method for making a dust sheet, wherein the dust sheet comprises, at least in a section, two or more layers.