Brake Pad Guide Surface Anti-Noise Coating
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Solution Overview
Problem
Vehicle disc brake units experience operating noise due to vibrations and slipping between brake pads and caliper components, with existing solutions like rubber coatings being expensive and prone to jamming, and alternative coatings not effectively addressing the issue in mass production.
Innovation Solution
A brake caliper unit with guide surfaces coated in a crosslinked polymeric resin containing spherical glass particles, applied using methods like spraying or immersion, and cured at low temperatures, providing an anti-noise layer comparable to elastomeric coatings without the drawbacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If rubber or elastomer coatings are applied to sliding springs for noise reduction, then noise is effectively reduced, but the friction between the sliding spring and guide support increases causing jamming
Solution Approach 1:
The invention uses a composite coating material consisting of PTFE (polytetrafluoroethylene) as the base polymer combined with solid lubricant particles (graphite and/or molybdenum disulphide) and filler materials. This composite structure provides both noise reduction through vibration damping and maintains low friction through the lubricating properties of PTFE and solid lubricants, preventing jamming while achieving the desired noise reduction effect.
Solution Approach 2:
The invention modifies the surface properties of the sliding spring by applying a coating with specific friction and damping characteristics. The coating changes the coefficient of friction and vibration absorption parameters of the surface, enabling noise reduction without the excessive friction increase that occurs with pure rubber or elastomer coatings.
2Reliability
If powder coating with phenolic resins, graphite and molybdenum disulphide is applied, then friction is reduced, but the manufacturing process becomes expensive and difficult for mass production
Solution Approach 1:
The invention simplifies the manufacturing process by using a coating composition that can be applied at lower temperatures and with simpler equipment compared to high-temperature powder coating processes. The PTFE-based coating can be applied using conventional coating methods and cured at lower temperatures, making it more suitable for mass production while maintaining friction reduction properties.
Solution Approach 2:
The invention employs a coating formulation that uses readily available, cost-effective materials (PTFE, graphite, molybdenum disulphide) that can be processed economically. The coating is designed to be applied in a single layer without requiring complex multi-step processes, reducing manufacturing costs and complexity for mass production.
3Ease of manufacture
If PTFE dispersed in organic binder and solvent is sprayed onto surfaces, then application becomes simpler, but noise reduction effectiveness is insufficient
Solution Approach 1:
The invention enhances the noise reduction capability of the sprayed PTFE coating by incorporating solid lubricant particles (graphite and/or molybdenum disulphide) and filler materials into the coating composition. This composite formulation provides both the ease of application from sprayable PTFE suspension and improved noise reduction through vibration damping from the particulate fillers, achieving effectiveness comparable to elastomeric coatings.
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 anti-noise coating significantly reduces operating noise in vehicle braking units, achieving results comparable to rubber or elastomer coatings without the associated costs or production issues, as demonstrated by NVH test results.
Implementation Method 1
an anti-noise coating or layer consisting of a layer of a crosslinked polymeric resin with glass particles, preferably spherical shaped, with size not larger than 50 micron and preferably not smaller than 10 micron being dispersed therein
Implementation Method 2
without the friction between the sliding spring and the guide support increases, which in use can produce jamming
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Vehicle braking unit (3) including a support (5), at least one braking element (6) that is carried in a movable way by the support and first and second guide surfaces (8,9) which are integral, respectively, to the braking element and to the support and cooperating with each other to guide and support the braking element when it is displaced by the activation of actuating elements; the first and/or the second guide surfaces (8,9) are covered by an anti-noise coating (16) consisting of: a layer of a polymeric resin; and glass particles with a rounded shape, preferably spheres, dispersed in the polymeric resin layer.