Brake Pad Composite Coating for NVH Damping
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Solution Overview
Problem
Existing damping elements for automotive brake pads are susceptible to corrosion, migration, and delamination, requiring additional protective measures and machining, which are not adaptable to various shapes and sizes, and do not effectively reduce noise, vibration, and harshness (NVH) to an acceptable level.
Innovation Solution
A coating comprising a pair of epoxy bonding layers and a composite layer with a mixture of rubber material and secondary particles, such as steel fibers or graphite flakes, applied to the back side of the brake pad without structural fixing elements, providing adhesion and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional damping elements (shims) are used with brake pads, then vibration damping is provided, but the damping elements are susceptible to corrosion, migration, and delamination, requiring additional protective measures and machining
Solution Approach 1:
The patent combines the damping function and protective function into a single integrated coating layer applied directly to the brake pad. The coating includes damping materials (rubber particles, steel fibers, graphite flakes) mixed with adhesive materials, eliminating the need for separate damping shims and protective coatings. This merging resolves the contradiction by providing both vibration damping and corrosion/migration resistance in one component, reducing overall device complexity.
Solution Approach 2:
The patent uses composite materials in the coating formulation, combining adhesive materials with damping materials (rubber particles, steel fibers, graphite flakes) to create a multi-functional coating. This composite approach allows the single coating layer to simultaneously provide adhesion, vibration damping, and corrosion resistance, eliminating the need for multiple separate components and their associated mounting and protection systems.
2Reliability
If damping elements are protected from migration using additional adhesive material or structural features, then damping element stability improves, but the brake pad requires additional machining or assembly
Solution Approach 1:
The adhesive material is merged into the coating formulation itself rather than being applied as a separate layer. The coating comprises adhesive materials combined with damping materials, creating a unified composition that adheres to the brake pad while providing damping functionality. This eliminates the need for separate adhesive application steps and structural fixing elements, simplifying manufacturing.
Solution Approach 2:
The patent changes the physical and chemical parameters of the coating by incorporating specific adhesive materials and controlling the composition ratios of adhesive to damping materials. This parameter optimization ensures strong adhesion to the brake pad surface without requiring additional mechanical fixing features, thereby simplifying the manufacturing process while maintaining reliability.
3Reliability
If damping elements are protected from corrosion using additional protective material, then damping element durability improves, but the brake pad requires additional machining or assembly
Solution Approach 1:
The protective function is merged into the coating formulation by incorporating corrosion-resistant adhesive materials and damping materials that inherently resist corrosion. The single coating layer provides both damping and corrosion protection, eliminating the need for separate protective coatings or material layers, thereby simplifying manufacturing while improving durability.
Solution Approach 2:
The use of composite materials in the coating, particularly the combination of adhesive materials with corrosion-resistant damping materials (steel fibers, graphite flakes), provides inherent corrosion resistance. This composite approach integrates protective functionality into the structural damping layer, avoiding the need for additional protective material layers and their associated manufacturing complexity.
4Object-generated harmful factors
If friction materials are shaped onto brake pad to reduce NVH, then vibration damping is provided, but the techniques alone are insufficient to reduce NVH to an acceptable level
Solution Approach 1:
The patent employs composite materials in the coating formulation, combining adhesive materials with damping materials (rubber particles, steel fibers, graphite flakes) to create a multi-functional coating that provides both adhesion and superior vibration damping. This composite approach delivers enhanced NVH reduction effectiveness that friction material shaping alone cannot achieve.
Solution Approach 2:
The patent optimizes the parameters of the coating by controlling the composition ratios, particle sizes, and material properties of the adhesive and damping components. This parameter optimization enables the coating to effectively dampen vibrations and reduce noise, achieving NVH reduction levels that exceed what can be obtained through friction material shaping techniques alone.
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 coating effectively reduces noise and vibration, inhibits corrosion, and maintains adhesion to the brake pad surface, improving NVH ratings and durability without additional machining or structural features, and can be applied to various brake pad sizes and shapes.
Implementation Method 1
Each of the bonding layers includes an epoxy material
Implementation Method 2
The composite layer is disposed between the pair of bonding layers, and includes a mixture of a rubber material and particles of a secondary material
Implementation Method 3
configured to coat at least one surface of a brake pad and at least one of reduce a noise resulting from operation of a coated brake pad, dampen a vibration resulting from operation of the coated brake pad
Implementation Method 4
configured to inhibit a corrosion of the at least one surface of the brake pad
Data Source
AI summary
A coating, in particular a coating for a back side of a brake pad opposite a braking side, includes a pair of bonding layers and a composite layer. Each of the bonding layers includes an epoxy material. The composite layer is disposed between the pair of bonding layers, and includes a mixture of a rubber material and particles of a secondary material. A method for forming the coating includes coating a layer of epoxy onto the surface to be coated to form a first bonding layer, coating the mixture of the rubber material and particles of a secondary material onto the first bonding layer to form a composite layer, coating a layer of epoxy to the composite layer to form a second bonding layer, and then curing the coating via a curing process.