Layered Brake Shim Structure With Calendered and Liquid Elastomer Layers
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Solution Overview
Problem
Existing methods for manufacturing brake shims and gaskets face challenges in ensuring that all layers are equally well-suited for their purposes, particularly due to the dynamic forces involved in disc brakes and the need for precise elastomer characteristics.
Innovation Solution
A method of manufacturing a layered product involving a base sheet with a first elastomer layer applied through calendering and a second elastomer layer applied as a liquid, allowing for optimized properties in each layer based on their respective manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single manufacturing process is used for both elastomer layers, then the manufacturing process is simple, but neither layer can be optimized for its specific purpose
Solution Approach 1:
The manufacturing process is segmented into two distinct methods: calendering for the first elastomer layer and liquid coating for the second elastomer layer. This segmentation allows each layer to be manufactured with process-specific optimizations - calendering provides uniform thickness and mechanical properties for the first layer, while liquid coating enables precise control of thickness and composition for the second layer, thereby resolving the contradiction between process simplicity and layer optimization.
Solution Approach 2:
Different manufacturing processes are applied to different layers based on their specific functional requirements. The first layer (facing the brake piston) uses calendering to achieve uniform density and mechanical strength for withstanding high pressure, while the second layer (facing the brake pad) uses liquid coating to achieve specific thickness and compositional properties for optimal friction and noise reduction. This local quality approach allows each layer to have tailored properties suited to its specific purpose.
2Productivity
If calendering is used for both layers, then manufacturing efficiency is high, but the second layer cannot achieve optimal sealing properties
Solution Approach 1:
The process segments the manufacturing approach by using calendering only for the first layer where high productivity is needed, and liquid coating for the second layer where superior sealing properties are critical. This segmentation maintains high overall manufacturing efficiency while ensuring the second layer achieves optimal sealing performance through the liquid coating process, which allows for better wetting and adhesion to the substrate.
Solution Approach 2:
The invention changes the manufacturing parameter (process type) for the second layer from calendering to liquid coating. Liquid coating allows for precise control of thickness, composition, and surface properties, which are critical parameters for achieving optimal sealing properties. This parameter change enables the second layer to achieve superior sealing performance while the first layer maintains high productivity through calendering.
3Manufacturing precision
If liquid coating is used for both layers, then each layer can be precisely controlled, but manufacturing time and cost increase
Solution Approach 1:
The manufacturing process is segmented to apply liquid coating only to the second layer where precise control is most critical for sealing performance, while the first layer uses faster calendering. This segmentation reduces overall manufacturing time and cost compared to using liquid coating for both layers, while still achieving the necessary precision for the second layer's sealing function.
Solution Approach 2:
Different levels of manufacturing precision are applied locally to different layers based on their functional requirements. The first layer uses calendering which provides sufficient uniformity and speed for structural support, while the second layer uses liquid coating which provides superior precision for sealing. This local quality approach optimizes the balance between manufacturing precision and time efficiency.
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 method results in layered products with improved vibration insulation and sealing properties, better suited for their intended applications due to the tailored characteristics of each layer.
Implementation Method 1
a first layer of elastomeric material, a thickness of which being obtained through calendering before being applied to the one surface of the base sheet
Implementation Method 2
applying a second layer of elastomeric material to another surface of the base sheet, said second layer being fabricated by liquid coating performed by a liquid material being passed from a vessel containing the liquid material
Data Source
AI summary
A method for manufacturing a layered product providing a base sheet (1) with one surface (4) and another, opposite surface (5), applying a first layer (2) of elastomeric material to the one surface (4) of the base sheet (1), said first layer (2) being a premanufactured foil of elastomeric material manufactured by being calendered, and applying a second layer (3) of elastomeric material to the other surface (5) of the base sheet (1), said second layer (3) being fabricated by liquid coating performed by a liquid material being passed from a vessel (14) containing the liquid material directly to the base sheet (1), or indirectly to the base sheet (1) via a liner (19). The disclosure also relates to a brake shim and to a gasket, each of which constituting a layered product according to the disclosure and being manufactured by the method according to the disclosure.