Brake Pad Damping Interlayer With Rubber-Resin Phase Separation
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Solution Overview
Problem
Current brake linings face challenges in reducing noise and mechanical vibrations during braking, requiring improved damping materials that balance high mechanical strength with comfort properties without layer separation or edge detachment.
Innovation Solution
A damping material composed of special elastic materials reinforced with resins and fibers, specifically using standard elastomers like NBR and acrylate rubbers, combined with fillers and fibers, forming a two-phase system with a percolating network in Phase 1 and a stable matrix in Phase 2, to achieve high shear strength and damping properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If damping layers are used to suppress vibrations and noise, then comfort properties are improved, but mechanical strength and structural stability deteriorate
Solution Approach 1:
The patent applies composite materials by combining rubber particles (5-50 μm) with a binder matrix to create a damping layer that exhibits both high damping properties and mechanical strength. The composite structure allows the rubber particles to provide vibration suppression while the binder matrix maintains structural integrity and prevents layer separation.
Solution Approach 2:
The patent utilizes the viscoelastic properties of rubber particles and changes their physical state through temperature-dependent behavior. The damping layer's mechanical properties are optimized by controlling the rubber particle characteristics (size, content) and binder composition, allowing the material to exhibit enhanced damping at operating temperatures while maintaining structural stability.
2Object-affected harmful factors
If damping layers are used to improve comfort properties, then vibrations are suppressed, but layer separation and edge detachment occur
Solution Approach 1:
The patent introduces a binder as an intermediary material that bonds rubber particles together and to the friction lining and carrier plate. This binder matrix acts as a mediating phase that ensures strong adhesion between layers, preventing layer separation and edge detachment while allowing the rubber particles to maintain their damping function.
Solution Approach 2:
The composite structure of rubber particles embedded in a binder matrix creates a cohesive damping layer that resists delamination. The binder provides continuous phase that bonds to both the friction lining and carrier plate, ensuring reliable attachment and preventing edge detachment during brake operation.
3Ease of manufacture
If standard elastomers are used instead of special materials, then cost is reduced, but damping performance may be compromised
Solution Approach 1:
The patent optimizes the parameters of standard elastomers (NBR, SBR, BR) by controlling rubber particle size (5-50 μm), particle morphology, and concentration (30-70 wt%) to achieve high damping performance. By carefully adjusting these parameters, conventional materials exhibit superior damping characteristics comparable to or exceeding special-purpose materials.
Solution Approach 2:
The patent creates local quality variations by distributing rubber particles of specific size ranges throughout the binder matrix. The localized concentration and size distribution of rubber particles optimize damping in specific regions while maintaining overall cost efficiency through the use of standard materials throughout the structure.
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 effectively suppresses vibrations and noise while maintaining mechanical stability, ensuring no layer separation or detachment, and is cost-efficient by utilizing inexpensive standard materials.
Implementation Method 1
a damping material for a damping layer or interlayer for brake linings in order to enhance the comfort properties of brake linings or brakes... to suppress the vibrations or to damp them, thus minimizing both phenomena
Implementation Method 2
A damping material composed of special elastic materials reinforced with resins and fibers, specifically using standard elastomers like NBR and acrylate rubbers
Data Source
AI summary
A damping material 10 for a damping layer or interlayer of a brake lining has at least one rubber content and one resin content. A plurality of macroscopic, heterogeneously delimited areas are formed in the damping material 10, areas comprising rubber areas 1 with a high rubber content of at least 3% to maximally 50% by weight, and resin areas 2 with a high resin content of at least 5% by weight, wherein the rubber areas 1 are free of resin or have a resin content ≤5% by weight, and the resin areas 2 are free of rubber.