Brake Pad Damping Material With Rubber-Resin Phase Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current brake pad technologies fail to adequately reduce noise and mechanical vibrations during braking while maintaining performance, with existing damping layers lacking sufficient mechanical strength and stability, particularly in disc brake applications.
Innovation Solution
A damping material composed of a two-phase system, where Phase 1 consists of reinforced rubber with a particulate structure and Phase 2 is a resin matrix, providing high shear strength, damping properties, and resistance to thermal and mechanical stress, with specific composition and manufacturing processes ensuring optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an intermediate layer is inserted between the friction layer and the carrier plate to suppress vibrations and noise, then the comfort properties of the brake pad are improved, but the mechanical strength and stability of the brake pad structure deteriorates
Solution Approach 1:
The damping material is formulated as a composite consisting of rubber components (providing damping), resin components (providing binding and structural support), and reinforcing fibers (providing mechanical strength). This composite structure enables the intermediate layer to simultaneously achieve vibration suppression and maintain structural integrity.
Solution Approach 2:
The invention specifies precise compositional parameters including rubber content (10-40 wt%), resin content (30-60 wt%), and fiber content (10-30 wt%), along with specific shear strength requirements (>400 N/cm²) and damping values (>15‰). By controlling these parameters, the material achieves both damping performance and mechanical strength.
2Object-affected harmful factors
If the damping layer is made with high rubber content to improve damping properties, then the vibration suppression is enhanced, but the mechanical strength and thermal stability deteriorates
Solution Approach 1:
The invention optimizes the rubber content to 10-40 wt%, preventing excessive rubber content that would compromise thermal stability. The resin content is set at 30-60 wt% to provide thermal resistance and structural support, while fibers (10-30 wt%) enhance both mechanical strength and thermal stability. This balanced composition achieves vibration suppression without sacrificing reliability.
Solution Approach 2:
The composite structure combines rubber (for damping), resin (for thermal stability and binding), and fibers (for mechanical reinforcement). This multi-material composition allows the damping layer to achieve vibration suppression while maintaining thermal stability and mechanical strength simultaneously.
3Object-affected harmful factors
If a complex multi-material damping structure is used to achieve high damping performance, then the vibration suppression is improved, but the manufacturing complexity and cost increases
Solution Approach 1:
The invention uses a composite of rubber, resin, and fibers in specific proportions to achieve high damping performance. While this is a multi-material system, the components are standard industrial materials that can be procured and processed using conventional manufacturing techniques, balancing performance with manufacturability.
Solution Approach 2:
The invention specifies clear compositional ranges (rubber: 10-40 wt%, resin: 30-60 wt%, fibers: 10-30 wt%) and performance targets (shear strength >400 N/cm², damping >15‰). These defined parameters provide manufacturing guidance that simplifies the production process despite the multi-material nature of the damping layer.
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 damping material effectively suppresses vibrations and noise, maintaining performance while ensuring high mechanical stability and cost-effectiveness through the use of standard elastomeric materials and fibers, achieving superior damping properties and structural integrity.
Implementation Method 1
a damping material for a damping or intermediate layer for brake pads... consist of a lining carrier and a friction lining, as well as an intermediate layer arranged between the friction lining and the lining carrier as a damping element to avoid friction squeaking
Implementation Method 2
an intermediate layer can be inserted between the friction layer and the carrier plate of a brake pad... suppress the vibrations or to dampen the vibrations and thus minimize both phenomena
Implementation Method 3
The shear strength (1) is determined based on ISO 6312. Shear strength (2) after loading: Here the test is carried out as in (1) after high thermal stress
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a damping material 10 for a damping or intermediate layer of a brake pad, which comprises at least a rubber component and a resin component. The damping material 10 has a plurality of macroscopically, heterogeneously defined regions, comprising rubber regions 1 with an increased rubber content of at least 3 wt.% to a maximum of 50 wt.% and resin regions 2 with an increased resin content of at least 5 wt.%, wherein the rubber regions 1 are free of resin and the resin regions 2 are free of rubber, or the rubber regions 1 comprise resin of less than or equal to 5 wt.%.