阅读说明：本技术 制动衬片的阻尼材料和用于制造阻尼材料的方法 (Damping material for brake linings and method for producing a damping material ) 是由 G·米勒 M·拉科塔 H·本特 K·利布 于 2021-05-14 设计创作，主要内容包括：本发明涉及一种用于制动衬片的阻尼层或中间层的阻尼材料,所述阻尼材料至少具有橡胶分量和树脂分量。在所述阻尼材料10中形成多个宏观的、不均匀的分界的区域,所述区域包括：橡胶区域1,所述橡胶区域具有提高的、3％重量百分比至50％重量百分比的橡胶分量；和树脂区域2,所述树脂区域具有提高的、为至少5％重量百分比的树脂分量,其中,所述橡胶区域1不含树脂并且所述树脂区域2不含橡胶,或者所述橡胶区域1包括至多5％重量百分比的树脂。(The invention relates to a damping material for a damping layer or an intermediate layer of a brake lining, which damping material has at least a rubber component and a resin component. Forming a plurality of macroscopic, non-uniformly demarcated regions in the damping material 10, said regions comprising: a rubber region 1 having an increased rubber fraction of 3 to 50% by weight; and a resin region 2 having an increased resin content of at least 5% by weight, wherein the rubber region 1 is free of resin and the resin region 2 is free of rubber, or the rubber region 1 comprises at most 5% by weight of resin.)

1. Damping material for a damping layer or an intermediate layer of a brake lining, having at least a rubber component and a resin component, wherein a plurality of microscopic, non-uniformly delimited regions are formed in the damping material (10, 20, 30), said regions comprising: a rubber region (1) having an increased rubber fraction of 3 to 50% by weight and a fiber fraction of 20 to 90% by weight and a filler fraction of 0 to 50% by weight, the weight percentages being relative to the weight of the region 1, respectively; and a resin region (2) having an increased resin fraction of 5 to 50% by weight and a fiber fraction of 10 to 90% by weight and a filler fraction of 0 to 50% by weight, the weight percentages being relative to the weight of the region 2, respectively, wherein the rubber region (1) is free of resin and the resin region (2) is free of rubber, or the rubber region (1) has at most 5% by weight of resin,

the damping material can be obtained from a rubber premix and a resin mixture by a process comprising the process steps of:

(a) premixing rubber;

(i) providing a starting material for the rubber region (1), which starting material comprises rubber, fillers and/or fibers and, if appropriate, a resin or a resin mixture;

(ii) (ii) at least one plastication of the starting material of step (i);

(iii) (iii) grinding the mass obtained in step (ii) to a particle size of less than 4 mm;

(b) (iv) resin mixing and distributing the particles from step (iii) into the resin mixture;

(iv) providing a raw material of the resin area (2), wherein the raw material comprises a resin or a resin mixture, fibres and/or fillers;

(v) (iv) mixing the particles from step (iii) with the feedstock from step (iv); and

(vi) (vi) compacting the mass obtained in step (v) into the desired damping material (10, 20, 30).

2. Damping material according to claim 1, characterized in that the rubber zone (1) has a rubber fraction of 5-25% by weight, a fibre fraction of 30-60% by weight, a filler fraction of 15-40% by weight and a resin fraction of 0-5% by weight, the weight percentages being relative to the weight of the zone (1), respectively.

3. Damping material according to claim 1 or 2, characterized in that the resin area (2) has a resin component of 10-35% by weight, a fibre component of 10-70% by weight and a filler component of 15-40% by weight, the weight percentages being relative to the weight of the area 2, respectively.

4. Damping material according to any of claims 1-3, characterized in that the rubber area (1) forms a mesh in the damping material (10, 20, 30).

5. Damping material according to any of the preceding claims, characterized in that the resin area (2) forms a mesh in the damping material (10, 20, 30).

6. Damping material according to one of the preceding claims, characterized in that the rubber zone (1) comprises NBR rubber or rubber based on ethylene vinyl acetate as sole rubber or mixed with another rubber.

7. Damping material according to any of the preceding claims, characterized in that the resin area (2) embeds the rubber area (1) in the damping material (10, 20, 30).

8. Damping material according to one of the preceding claims, characterized in that the components of the resin region (2) and the components of the rubber region (1) are evenly distributed in the respective regions.

9. Damping material according to any of the preceding claims, characterized in that 50 to 90% by volume of the damping material (10, 20, 30) consists of the rubber area (1).

10. Damping material according to any of the preceding claims, characterized in that the rubber area (1) is free or substantially free of resin component.

11. Use of a damping material according to one of the preceding claims as a damping layer or intermediate layer of a brake lining, which is arranged between a brake lining carrier and a friction layer.

Technical Field

The invention relates to a damping material for a damping layer or an intermediate layer (also referred to as a transition layer) of a brake lining for improving the comfort properties of the brake lining or of the brake. The invention also relates to a brake lining having a damping layer or an intermediate layer made of a damping material and to a method for producing a damping material.

Background

In the brakes used today, the comfort characteristics of the brake are very important. This includes noise development of the brake and mechanical vibrations during the braking process. Both phenomena are linked to the occurrence of vibrations, which may occur at different frequencies depending on the type of braking system. In order to damp vibrations or damp vibrations and thus minimize both phenomena, an intermediate layer can be inserted between the friction layer and the carrier plate of the brake lining. In addition to comfort properties, the intermediate layer must also have a high mechanical strength.

Brake pads or brake linings known from the prior art have lining carriers and friction linings, and an intermediate layer arranged between the friction lining and the lining carrier serves as a damping element for avoiding squeak noises. The use of such an intermediate layer enables the damping of resonant vibrations occurring during braking. Damping layers of this type are known, for example, from EP 0621414 a1, US 5,407,034, DE 102013108159 a1, DE 4231549 a1 or EP 0849488B 1 and can consist of a plurality of materials or material mixtures. Furthermore, the application of damping plates in disc brake linings has also been described in the prior art for the above-mentioned purposes; see EP 1035345 a 2.

Additionally, there have been proposals in the prior art for friction linings or friction materials which themselves already have noise-reducing or damping properties, for example according to US 9,765,836B 2.

In addition, when using damping layers as intermediate layers between the actual friction lining and the lining carrier, in addition to high mechanical requirements, care should be taken that there is no layer separation or edge separation between the friction lining and the intermediate layer. Partial detachment of the intermediate layer from the lining carrier plate is referred to as edge detachment.

The results achieved to date still require improvement in the above-mentioned properties, in particular in the friction and brake linings used in the truck/passenger car industry.

Disclosure of Invention

The object of the present invention is therefore to provide a brake lining, in particular for a disc brake, in which an optimized comfort behavior, in particular with regard to a reduction in the development of noise and a reduction in the occurrence of mechanical vibrations during continuous operation, can be ensured while maintaining or improving the performance behavior.

This object is achieved by the damping material according to the invention for a damping layer or intermediate layer of a brake lining, and in particular by a brake lining having a damping layer or intermediate layer made of the damping material according to the invention, which is arranged between the actual friction lining and the lining carrier (lining carrier plate).

The desired minimization or suppression of vibrations at the brake linings during continuous operation is determined by damping measurements known and applied in the prior art. In the development of friction linings or brake linings, so-called natural frequency measurements are preferably used. In order to make the development work efficient, reference brake linings with a damping layer between the lining carrier and the friction lining are used.

The preferred minimum requirements according to the invention for such a brake lining according to the invention can be summarized in terms of the most important parameters as follows:

(1) shear strength>400N/cm²，

(2) Shear strength after temperature load>250N/cm²，

(3) In the measurement of the natural frequency, the damping should be at a value > 15% o,

(4) the compressibility should be at a value between 150 and 200 microns,

(5) no layer separation after thermal loading (crack formation rating ≧ 9),

(6) and did not peel from the carrier plate after mechanical loading (crack formation evaluation ≧ 9).

Shear strength (1) was determined according to ISO 6312.

Shear strength after loading (2): here, the test as in (1) was performed after high thermal stress. Here, the following conditions apply for the dynamic test, see table below:

n is the number of times of braking,

v_a: the speed at which the braking is initiated is,

v_e: the speed at the end of the braking is,

p: the pressure of the brake is controlled by the brake pressure,

deceleration in g, wherein 100% is 1g, and g is 9.81m/s²，

Ta: brake disc temperature at the start of braking.

(3) The natural frequency measurement is carried out according to the standard DIN ISO 6267. The damping is determined by a reduction of the first amplitude.

(4) Compressibility is determined according to ISO standard 6310. Here, compressibility is described in μm units. Typically, a tolerance of ± 15% is acceptable for this value. For a new system, this value must be within the tolerance value that also applies for the old system.

(5) Evaluation of layer separation and (6) delamination from the carrier plate: evaluation of the lining was performed after the load test for inspection (2). Here, the following scale is applied to the evaluation of the damage.

Only when classified by category 9 or 10 is the test considered to be passed. Here, a metal plate having a thickness of 50 μm is used for the case of classification into category 9. Only when the metal sheet cannot be pushed into the formed crack, the crack still meets the standard, graded into grade 9.

According to the invention, it has been shown that such a characteristic curve is caused only by the damping layer made of a special elastic material. It has also been shown that these elastomeric materials can be further reinforced by the use of resins and fibers to achieve the desired combination of high mechanical properties (e.g., high shear strength) and high damping properties.

Furthermore, an additional object of the invention is to provide materials having the above-mentioned properties at the lowest possible cost, which at the same time means that it is possible to use so-called low-cost standard materials and to dispense with expensive special components to the greatest possible extent. According to the invention, the elastomer standard material is a standard elastomer, preferably a standard rubber known as follows:

NBR is an acrylonitrile-butadiene rubber,

BR is a butadiene rubber, and the rubber is a butadiene rubber,

IIR is isobutene-isoprene rubber, and the rubber is prepared by mixing IIR with isobutene-isoprene rubber,

BIIR is the brominated butyl rubber, and the rubber,

CIIR chlorobutyl/chlorobutyl rubber,

EPM ethylene-propylene copolymer/ethylene-propylene rubber,

EPDM, ethylene-propylene-diene rubber,

NR is natural rubber, and the rubber is rubber,

SBR is styrene-butadiene rubber, wherein the styrene-butadiene rubber is styrene-butadiene rubber,

CM is the chlorinated polyethylene and the chlorinated polyethylene,

IR is the ratio of isoprene rubber to rubber,

AEM is acrylic acid-ethylene-polymethyl rubber,

EAM is ethylene-vinyl acetate rubber,

ACM is acrylate rubber.

These standard elastomers are, individually or also mixed with one another, the main constituent of the elastomer of the damping material according to the invention. Other elastomeric materials/components and/or various fillers and/or fibers may also be added to the elastomer body. The other elastomer component is preferably a rubber belonging to the standard rubber class. However, fluororubbers such as, for example, the type described in DE 102013108159A 1 may also be used here. For the purposes of the present invention, more precisely not only alone, but also in combination with other elastomers or rubbers mentioned here, particular preference is given to acrylate rubbers, such as those sold under the trademark Denka ER by Tokyo electric appliances Ltd (Denka Company Ltd), Tokyo (Japan). This is an ethylene-acetic acid-acrylate copolymer generally belonging to the plastic class EVAC. Such copolymers are available in different types by the general electric company ltd, which are distinguished in particular by different residues for the hardening (so-called hardening sites) of the polymers, for example epoxy resins and carboxyl groups. The elastomers mentioned are distinguished in particular by their resistance to temperature and oil.

According to the invention, the different fillers may also be present as a mixture of different fillers, these different fillers preferably being carbon black and/or silicates.

The fibers suitable according to the invention, which may also be present as a mixture of different fibers, are preferably mineral fibers, and/or aramid fibers, and/or metal fibers, wherein for the purposes of the present invention the term "metal fibers" also includes metal wool and metal chips.

Thus, the fillers and fibers that can be used according to the present invention are materials known in the art for making friction linings.

The use of fillers and especially fibers leads to a so-called reinforced rubber phase. Accordingly, such fillers are also referred to herein as active fillers. These fillers are characterized either by a particle size of less than 100 nm and by interaction with the rubber phase, or by a high aspect ratio, i.e. the ratio of the height or depth of the structure to its minimum width, (as fibers or platelets). In the case of fibres or exfoliated layers, for example separate layers of phyllosilicates, it is critical that the fibres or layers have a size of less than 500 micrometers in at least one dimension.

In addition to the above fillers, further fillers are also used in the formulation which do not lead to a targeted improvement in the properties. These additional fillers may be a variety of different natural materials. These natural materials are generally characterized by their granular structure. The natural material either does not interact strongly with the remaining constituents of the mixture or has a particle size of more than 100 nm, so that the specific surface area of the natural material is so small that the amount of interaction with the constituents of the mixture is also low.

Suitable fillers are, for example, carbon black particles and/or composites composed of silicate and silane, in particular silane-coated silicate fibers or silane-coated sheet silicates. For example, BaSO₄、 CaCO₃Zn and/or graphite are also suitable fillers.

In summary, phase 1 (comprising rubber) has, for example, the following composition, see the following table:

it has surprisingly been shown that excellent results with respect to damping properties are achieved in terms of damping brake noise and mechanical vibrations if the damping material is manufactured in the form of a so-called two-phase system (phase 1/phase 2). The first phase (phase 1) contains the rubber particles according to the invention and has a particle structure with a particle size of preferably less than 4 mm.

The particles of phase 1 may form a network with each other in the damping material, in particular a percolation network (perkoliertendes Netzwerk). For this reason, a volume fraction of the damping material of more than 50% is particularly advantageous. In the above-described mesh, a plurality of particles of phase 1 material in the damping material may be stacked or abutted against one another and constitute strands or irregular associative structures composed of phase 1 in the damping material. Advantageously, the mesh has improved damping characteristics compared to the same amount of separated particles.

The particle size is derived from the method of making the phase 1 particles. These particles are produced by a milling process. Here, a perforated plate having a diameter of 4mm is preferably used. This means that all particles transported from the grinding chamber into the collection container can only have a maximum diameter of 4 mm.

The rubber fraction in phase 1 is preferably from 3 to 50% by weight, in particular from 5 to 25% by weight, and particularly preferably 15% by weight, relative to the weight of phase 1.

The filler/filler mixture and/or the fiber/fiber mixture contained in phase 1 (reinforced rubber phase) preferably has a particle size of 4 to 200 nm for the filler and 0.75 to 1.2 mm (fiber length) for the fiber.

Phase 2 (matrix phase) comprises a resin or resin mixture and, if appropriate, further fillers or filler mixtures and, if appropriate, further fibers or fiber mixtures. In summary, phase 2 has, for example, the following composition, see the table below:

the resin used in phase 2 preferably constitutes from 5 to 50% by weight of this phase. In principle, all resins, resin mixtures or adhesives known for use in friction linings are suitable according to the invention, for example phenol-formaldehyde resins or polyacrylonitriles. This applies not only to phase 2 but also to phase 1.

The fibres here preferably constitute a proportion of 10 to 90% by weight. Preferred fibers here are metal fibers. In particular, these metal fibers represent a fraction of 32% by weight. The aramid fibers are preferably present in a proportion of 1 to 6% by weight. All weight percent data are relative to the total weight of phase 2.

The volume ratio of phase 1 and phase 2 used to make the damping material is preferably from 50/50 to 70/30 up to 90/10 and all possible intermediate values (data in volume percent). The component of phase 1 is therefore advantageously selected to be so high that the above-described net or associated structure consisting only of phase 1 is formed in the damping material or brake lining. This includes in particular the percolation network consisting of phase 1. Theoretically, such a network would be formed from a volume fraction of more than 74% by volume with approximately the same size of the particles. In the case of different particle sizes, the larger the particle diameter distribution, the higher the value. At the same time, phase 2 should advantageously also be able to constitute a stable matrix, ensuring a high strength of the damping material. This is particularly good in the case of these volumetric quantities.

Phase 2 preferably also contains a filler, which in turn is preferably present in phase 2 in a weight percentage of from 0 to 50%. Data of the percentages by weight of the constituents of phase 2 relative to the total weight of phase 2, respectively

The preferred fillers and/or fibers are the same for phase 1 and phase 2, with the addition of rubber and typical, rubber-reinforcing particles and reactive fillers preferably being added only to phase 1 and the addition of the resin system only to phase 2. In another preferred embodiment, phase 1 may also contain up to 5 weight percent of a resin or resin mixture. The resin fraction in phase 1 is always smaller than the resin fraction in phase 2 (resin phase). In a preferred embodiment, phase 1 (the rubber phase) (as defined below) is free or substantially free of resin content.

Phase 2 preferably surrounds phase 1, i.e. the particles of phase 1, in such a way that these particles are embedded in the matrix composed of phase 2. However, the degree of encapsulation is preferably mostly less than 100%, so that the particles of phase 1 are still in contact with one another. The structure of the dual-phase damping material according to the present invention is recognizable with an optical microscope, but also with the naked eye.

The phase 2 may constitute a mesh or matrix in the damping material. Advantageously, this net is complementary to the previous net consisting of phase 1.

The dominant damping characteristic is mainly based on phase 1, while the required high mechanical stability is caused by phase 2.

In order to ensure the dominating properties of the damping material or damping layer according to the invention, it is necessary to comply with the manufacturing process according to the invention. The resulting damping material is characterized by the manufacturing process; the so-called process method defines the product characteristics.

To produce the phase 1 (rubber phase, in particular reinforced), fillers and/or fibers are mixed or masticated into the rubber and, if appropriate, into the resin, for example in a masticator (Kneter). The plasticator or produces not only a dispersion of the filler and/or the fibers but also a homogeneous distribution of the components.

A distinction can be made between active fillers and inactive fillers. Fillers which are active or which reinforce the rubber phase include, for example, carbon black particles and in particular also silicate/silane systems. Other active fillers are, for example, silicate fibers coated with silanes or layer silicates coated with silanes.

Non-reactive fillers are, for example, BaSO₄、CaCO₃Zn or graphite.

The plasticating process differs from the mixing process in nature. During the plastication process, the constituents are treated above the glass transition temperature of the rubber in such a way that not only dispersion but also distribution of the filler is achieved. This cannot be achieved in a hybrid process. The "grinding step" is carried out after at least one plastication step or plastication has been carried out.

The particles of phase 1 are produced by a milling process carried out after mastication. Here, the preferred particle size for all the constituents of phase 1 is less than 4 mm. The milling may comprise pre-comminution with knife milling, for example with a 16 mm perforated screen at 650 revolutions per minute. The preliminary comminution may be followed by a fine comminution using a cross mill (Schlagkreuzmuhle), for example at 4000 rpm with a 4mm square-hole sieve. Phase 1 was in the granular form by milling.

A mixing process for phases 1 and 2 follows, in which the phase 1 particles are distributed in a matrix consisting of phase 2, in particular a resin. Here, the particles manufactured by the milling process substantially maintain their size. At the beginning of the mixing process, the starting material of phase 2 has not yet constituted a homogeneous phase. All raw materials are still present as powder or fiber bundles. A hybrid (Gemenge) consisting of different raw materials of phase 2 and particles of phase 1 is produced by the mixing process. During the mixing phase, the fiber bundle is mainly also disintegrated (aufschlie β en).

The mixture can be produced by an Alisik Mixer (Alisik intensive mixer) from Alisik corporation (Firma Eirich), for example at a mixing temperature of from room temperature to 50 ℃, a swirler speed of from 5 to 40 m/s, a slot speed of 1 or 2 stages and a mixing time of from 1 minute to 30 minutes.

The essential distinction between the mastication process and the mixing process is important here. In the mastication process, the processing is carried out with an increase in pressure and an increase in temperature (T >100 ℃). This results in a phase in which the filler to be dispersed has been incorporated into the rubber and is encapsulated by the rubber. The pressure is absent in the pure mixing process. Usually, the mixing is performed even at room temperature. Although the constituents are distributed, embedding of the filler into the rubber phase has not yet taken place. Thus, the mixture exists as a hybrid after the mixing process. The result after the mastication process can be understood as a dispersion.

The phases 1 and 2 interact with each other in the subsequent pressing process for producing the damping material (in the form of a material layer or film). During the pressing process, the resin consisting of phase 2 liquefies and encapsulates the remaining particles of phase 2 and large particles of phase 1 up to 4 mm. The degree of encapsulation is preferably predominantly less than 100% in this case, so that the particles of phase 1 can still be in contact with one another.

The production process of the brake lining according to the invention can be carried out on a continuously operating press. Here, the friction lining compound and the damping layer made of the damping material described above are introduced into the pressing tool, for example, in two stations. Here, for example, the pressing temperature may be 100 ℃ to 200 ℃, the pressing time may be 60 seconds to 420 seconds, and the pressing pressure is 3bar to 200 bar. Here, the ratio of friction material to interlayer material is preferably 30:1 (weight percent: weight percent) up to 2: 1 (weight percent: weight percent).

Next, a lining carrier plate is placed over the cavity. The mirror plate, the stamp and the profiled plate which are assigned to them preferably have a temperature of between 130 ℃ and 190 ℃. Preferably, the pressing time is between 1 minute and 6 minutes. The pressure being, for example, 6N/mm²To 145N/mm²In the meantime.

Next, the lining is also hardened. The process may be carried out stationary in a furnace. For example, the hardening temperature may be room temperature to 300 ℃ and the hardening time may be 30 minutes to 24 hours.

The lining can also be hardened by a continuous process, for example at a hardening temperature from room temperature up to 700 ℃; and a hardening time of from 5 minutes to 30 minutes.

In summary, preferred features of the damping material formulation according to the invention are determined as follows:

1) preferably no resin is included in the rubber phase (phase 1), or the amount of resin in the rubber phase is less than/equal to 5% by weight;

2) no other organic crosslinking chemicals in the rubber phase, which cause covalent crosslinking of the rubber;

3) no constituent component having a decomposition temperature of less than 130 ℃ is contained in the entire mixture except for the rubber;

4) a filler for reinforcement is mixed into the rubber phase. These fillers must be dispersed and distributed during the mastication process.

In the matrix (phase 2), there are basically active fillers and/or fibers and inactive fillers and/or fibers in addition to the resin constituting the matrix.

In addition, the phase 1 component is important. It is preferred here to use a component of more than 50% by weight, in particular 60-70% by weight, relative to the weight of the finished damping material.

It has been shown that particularly advantageous results of the damping layer according to the invention with acrylonitrile-butadiene rubber (NBR rubber) and the above-mentioned acrylate rubber can be achieved. The rubber suitable according to the invention can in most cases be a standard rubber, and the damping material according to the invention also has a significant cost advantage over solutions using, for example, special polymers.

The intermediate layer or damping layer according to the invention can be embodied as a single layer or as a multilayer. The intermediate or damping layer is preferably single-layered. The thickness of the intermediate or damping layer varies depending on the configuration of the lining support and the friction lining. However, the intermediate or damping layer is typically about 2 to 4 mm.

The damping layer is preferably connected to the lining carrier plate by means of an adhesive layer and/or by means of screws.

The damping layer is connected with the friction layer through good adhesive force between the damping layer and the friction layer. The resin of the damping layer and the resin of the friction lining layer have not reacted before the final pressing process. Thus, the two layers may form a diffusion layer. Then, in this diffusion layer, a covalent bond contributing to overall strong bonding is formed by the reaction of the resin. Likewise, the layers are preferably not flat packed into the press mold. The mutual contact area between the phases is increased by the rough, matte surface structure. This also increases the attachment of the phases to each other (bindung). That is, the mixture of damping material and the mixture of friction material are preferably stacked and then compacted together in one process as described.

The following is a summary of the most important and preferred contents, features and aspects of the present invention:

the invention particularly preferably comprises a damping material for a damping layer or an intermediate layer of a brake lining, which damping material has at least a rubber component and a resin component, wherein a plurality of macroscopic, nonuniformly delimited regions (phases 1) are formed in the damping material, which regions comprise: a rubber region having an increased rubber fraction of at least 3% by weight up to a maximum of 50% by weight; and comprises a resin region (phase 2) with an increased resin content of at least 5% by weight, and wherein the rubber region is preferably free of resin or has a resin content of less than/equal to 5% by weight, and the resin region is free of rubber.

A "nonuniformly delimited region" is to be understood in particular to mean a region having an irregular contour or an irregular outer boundary. In this case, the contours or outer boundaries of the individual regions preferably differ from one another to the greatest possible extent.

In the sense of the present invention, when rubber or resin is not present or cannot be verified in the respective other region, or when rubber or resin cannot be verified in the respective other region with the naked eye or an optical microscope, then the rubber region (phase 1) is free of resin and the resin region (phase 2) is free of rubber, which is shown, for example, by the sharp (clear) region boundaries or phase boundaries as shown in fig. 1 to 3.

Another possible name for this meaning according to the invention of the term "free" is that the respective region/phase "free or essentially free" corresponds to the other component. This is the case, for example, if the other component enters only in very small amounts, for example by diffusion, into the other region. For example, it is a small amount when the resin or rubber is less than 1% by weight in the corresponding other region.

In a cross-sectional view of the damping material, at least one of the rubber regions may extend for a length of at least 4 millimeters.

At least one of the resin regions may extend for a length of at least 1 millimeter in a cross-sectional view of the damping material.

Preferably, the rubber region (phase 1) of the damping material has a rubber component of 5-25% by weight.

Preferably, the rubber zone of the damping material comprises NBR rubber or EVAC rubber as mentioned, either as sole rubber or mixed with other rubbers.

Preferably, the rubber region of the damping material has a fiber fraction of 30 to 60% by weight and/or a filler fraction of 15 to 40% by mass.

The resin region (phase 2) of the damping material preferably has a resin component of 10 to 35% by weight and/or a fiber component of 10 to 70% by weight.

Preferably, the resin region enables the rubber region to be embedded in the damping material.

The composition of the resin region and the composition of the rubber region are preferably uniformly distributed in the respective regions.

50-70% by weight of the damping material may consist of rubber regions.

Preferably, 50 to 90% by volume of the damping material consists of rubber regions.

Particularly preferably, 65 to 80% by volume of the damping material consists of rubber regions.

The invention furthermore comprises a brake lining having a lining carrier and a friction layer, wherein a damping layer or intermediate layer is arranged between the lining carrier and the friction layer, which damping layer or intermediate layer is composed of a damping material according to the preceding description.

Finally, the invention also relates to a manufacturing method for the damping material described above, comprising the following method steps:

(a) premixing rubber;

(i) providing a starting material for the rubber region, which starting material comprises rubber, fillers and/or fibers and, if appropriate, a resin or a resin mixture.

(ii) (ii) plasticating the starting material of step (i) at least once;

(iii) (iii) grinding the mass obtained in step (ii) to a particle size of less than 4 mm;

(b) (iv) resin mixing and distributing the particles in step (iii) in the resin mixture;

(iv) providing a feedstock for a resin zone, the feedstock comprising a resin or a resin mixture;

(v) (iv) mixing the particles of step (iii) with the feedstock of step (iv); and

(vi) (vi) compacting the mass obtained in step (v) into the desired damping material.

In the context of the production of linings, the substance obtained in step (v) can be used directly for producing a damping layer on the friction layer. In this case, the substance and the mixture for the friction layer are stacked as described and pressed together.

Drawings

Fig. 1-3 show preferred embodiments of the invention in which the rubber phase 1 is free or substantially free of resin constituents in the sense of the invention.

Detailed Description

Fig. 1 shows a schematic, enlarged representation of the macroscopic structure (surface) of a damping material 10 according to the invention, as it can be seen with the naked eye or with an optical microscope. Here, phase 1, the reinforced rubber phase, is shown in black (1), while the matrix phase 2 (consisting of resin and further fibres and fillers), into which phase 1 is embedded, is shown in clear (2);

fig. 2 shows the structure of a damping material 20 according to the invention after a shear test according to a first embodiment. Here, 70% by volume of the material consists of a black reinforced rubber phase 1 and 30% of the material consists of a matrix phase 2 (shown without colour) in which the rubber phase 1 is embedded. The rubber phase 1 shows a clear regional boundary with the matrix phase 2;

fig. 3 corresponds in terms of illustration and description to fig. 2, wherein the damping material 30 according to the second embodiment in this case consists of 50% by volume of the rubber phase 1 and 50% by volume of the matrix or resin phase 2. Here, the range boundary or the phase boundary is also clearly defined.

List of reference numerals

1 phase

2 phase of parent body

10 damping material

20 damping material

30 damping material