Brake Pad Under-Layer Composition for Low-Aramid NVH Damping
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Solution Overview
Problem
Conventional brake pad under-layers are costly due to high aramid fiber content and often require expensive mixing equipment, leading to inefficiencies in noise and vibration damping and thermal management.
Innovation Solution
A composition for the under-layer comprising a fiber pack with aramid fibers in a range of 0.1 wt% to 3 wt%, mixed with powdered rubber and a binder, using a Loedige mixer to reduce costs and maintain performance, allowing for better process control and flexibility in manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If high aramid fiber content is used in the under-layer, then noise and vibration damping performance is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent optimizes the aramid fiber content parameter to a specific range (0.1-3 wt%) rather than using high concentrations, achieving cost reduction while maintaining adequate NVH performance through parameter optimization
Solution Approach 2:
The patent creates a composite under-layer material combining aramid fibers with rubber powder and binders, where the synergistic interaction between different materials provides effective noise and vibration damping at lower aramid fiber concentrations
2Productivity
If conventional mixing equipment is used for the under-layer composition, then manufacturing process is simpler, but production efficiency and process control are reduced
Solution Approach 1:
The patent replaces conventional mechanical mixing equipment with a Loedige mixer that uses a specific mechanical action principle, achieving superior mixing efficiency and process control through a specialized mixing mechanism
3Strength
If high aramid fiber content is used in the under-layer, then bonding strength between back plate and friction material is improved, but thermal management performance deteriorates
Solution Approach 1:
The patent optimizes the aramid fiber content to a moderate range (0.1-3 wt%) rather than using high concentrations, achieving a balance between bonding strength and thermal management through parameter optimization
Solution Approach 2:
The patent uses a composite formulation combining aramid fibers with rubber powder and binders, where the rubber component provides thermal flexibility and heat dissipation while the aramid fibers provide bonding strength
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 achieves comparable shear strength and noise-vibration damping to traditional under-layers while reducing aramid fiber content and using less expensive mixing equipment, enhancing thermal management and compressibility, with improved flexibility in production.
Implementation Method 1
The fiber pack contains aramid fibers... improve the bonding between the backplate and the friction material... reduce the noise generated by the vibration of the friction material
Implementation Method 2
The under-layer also may be used to reduce the noise generated by the vibration of the friction material
Implementation Method 3
a powdered rubber... improve the bonding between the backplate and the friction material
Implementation Method 4
at least one binder... improve the bonding between the backplate and the friction material
Data Source
AI summary
Technologies are generally described for a composition for an under-layer of a brake pad of a brake disc rotor. The composition may include a fiber pack, a powdered rubber, at least one binder, and at least one filler, wherein the fiber pack includes aramid fibers up to about 3 wt %.