阅读说明：本技术 具有表面涂层的制动垫块 (Brake pad with surface coating ) 是由 H·穆赫辛尼 M·菲普斯 于 2020-08-28 设计创作，主要内容包括：本发明涉及具有表面涂层的制动垫块。一种具有表面涂层的制动垫块,该表面涂层可操作以在正常操作期间增强磨合过程。表面涂层可以使用在制动垫块的摩擦衬片中存在的一种或多种材料来配制。表面涂层可以仅使用非金属材料配制。(The invention relates to a brake pad having a surface coating. A brake pad having a surface coating operable to enhance the break-in process during normal operation. The surface coating may be formulated using one or more materials present in the friction lining of the brake pad. The surface coating may be formulated using only non-metallic materials.)

1. A brake pad, comprising:

a back plate having a mounting surface;

a friction lining attached to the mounting surface and having a tribological surface parallel to the mounting surface within a certain tolerance; and

a surface coating adhered to a portion of the tribological surface with an adhesive and having a predetermined perimeter shape when viewed in a direction perpendicular to the tribological surface,

wherein the surface coating is a composite material comprising potassium titanate.

2. The brake pad of claim 1, wherein the composite material comprises at least two different potassium titanates.

3. The brake pad of claim 1, wherein the surface coating is visually distinct from the friction lining.

4. The brake pad of claim 1, wherein the adhesive has a cure time of no greater than 180 seconds within a specified tolerance.

5. The brake pad of claim 1, wherein the surface coating is adhered to the tribological surface using a stamping process.

6. The brake pad of claim 1, wherein the composite material comprises only non-metallic materials.

7. The brake pad of claim 1, wherein the composite material includes a material composition also present in the friction lining.

8. The brake pad of claim 1, wherein the composite material comprises at least two materials selected from the list consisting of inorganic resins, organic resins, sodium silicate, polycondensed sand-free grout, zirconia, zircon, barite, antimony trisulfide and magnetite.

9. The brake pad of claim 1, wherein the predetermined perimeter shape comprises a geometric shape.

10. The brake pad of claim 1, wherein the predetermined perimeter shape is located at a portion of the tribological surface that exhibits higher frequency contact with the brake disc during operation.

11. A brake pad, comprising:

a back plate having a mounting surface;

a friction lining attached to the mounting surface and having a tribological surface parallel to the mounting surface within a certain tolerance; and

a surface coating adhered to a portion of the tribological surface with an adhesive and having a predetermined perimeter shape when viewed in a direction perpendicular to the tribological surface,

wherein the surface coating is a composite material comprising only non-metallic materials.

12. The brake pad of claim 11, wherein the composite material comprises potassium titanate.

13. The brake pad of claim 12, wherein the composite material comprises at least two different potassium titanates.

14. The brake pad of claim 11, wherein the surface coating is visually distinct from the friction lining.

15. The brake pad of claim 11, wherein the adhesive has a specific cure time of no greater than 180 seconds within a specific tolerance.

16. The brake pad of claim 11, wherein the surface coating is adhered to the tribological surface using a stamping process.

17. The brake pad of claim 11, wherein the composite material includes a material composition also present in the friction lining.

18. The brake pad of claim 11, wherein the predetermined perimeter shape comprises a geometric shape.

19. The brake pad of claim 11, wherein the predetermined perimeter shape is located at a portion of the tribological surface that exhibits higher frequency contact with a brake disc during operation.

20. The brake pad of claim 11, wherein the composite material comprises at least two materials selected from the list comprising inorganic resins, organic resins, sodium silicate, polydoped non-sand grout, zirconia, zircon, barite, antimony trisulfide, magnetite and potassium titanate.

Technical Field

The present disclosure relates to brake pads and assemblies of brake pads.

Background

Brake pads used in motor vehicles undergo a "break-in" process involving the gradual deposition of friction material onto the surface of the brake disc. After the break-in process, the brake pads exhibit a more efficient and smoother delivery of braking power.

However, the break-in process is time consuming and may require slow and careful operation to make the newly installed brake most effective. Current braking systems can suffer from rapid heat build-up if the brakes are applied before or during the break-in process, which can lead to brake disc damage due to warping. If the brake pad is exposed to excessive heat buildup, it may itself suffer "burnishing" of the surface material, thereby reducing the efficiency of the brake and shortening the service life of the brake pad.

Disclosure of Invention

One aspect of the present disclosure is directed to a brake pad that includes a backing plate having a mounting surface, a friction lining having a tribological surface, and a surface coating applied to a portion of the tribological surface. The tribological surface may be arranged parallel to the mounting surface. The surface coating may be attached to the tribological surface using an adhesive. The surface coating may have a predetermined design that produces a visual effect on the tribological surface. The surface coating may include a composite material formulated with one or more potassium titanates.

Another aspect of the disclosure is directed to a brake pad that includes a backing plate having a mounting surface, a friction lining having a tribological surface, and a surface coating applied to a portion of the tribological surface. The tribological surface may be arranged parallel to the mounting surface. The surface coating may be attached to the tribological surface using an adhesive. The surface coating may have a predetermined design that produces a visual effect on the tribological surface. The surface coating may comprise a composite material formulated using only non-metallic materials.

The above aspects and other aspects of the present disclosure will be explained in more detail below with reference to the attached drawings.

Drawings

FIG. 1 is an illustration of a brake pad having a surface coating.

FIG. 2 is an illustration of a brake pad having a surface coating applied in a predetermined design.

FIG. 3 is an illustration of a brake pad having a surface coating applied in a predetermined design.

FIG. 4 is an illustration of a brake pad having a surface coating applied in a predetermined design.

FIG. 5 is an illustration of a brake pad having a surface coating applied in a predetermined design.

FIG. 6 is an illustration of a brake pad having a surface coating applied in a predetermined design.

FIG. 7 is an illustration of a brake pad having a surface coating applied in a predetermined design.

FIG. 8 is an illustration of a brake pad having a surface coating applied in a predetermined design.

FIG. 9 is an illustration of a brake pad having a surface coating applied in a predetermined design.

FIG. 10 is an illustration of a brake pad having a surface coating applied in a predetermined design.

FIG. 11 is an illustration of a brake pad having a surface coating applied in a predetermined design.

Detailed Description

The illustrated embodiments are disclosed with reference to the accompanying drawings. However, it is to be understood that the disclosed embodiments are intended only as examples that may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. Specific structural and functional details disclosed are not to be interpreted as limiting, but as a representative basis for teaching one skilled in the art how to practice the disclosed concepts.

Fig. 1 illustrates a brake pad 100 according to one embodiment of the teachings herein. Brake pad 100 includes a backing plate 101 having a mounting surface 103. Mounting surface 103 may be adapted to provide a coupling surface between back plate 101 and friction lining 105. The friction linings 105 may be operable to apply a frictional force to the brake disc to generate a braking power of the vehicle. The friction of the friction lining 105 is transmitted via a tribological surface 107, which tribological surface 107 is substantially parallel to the mounting surface 103 within certain tolerances. The friction lining 105 formulation may be adapted for a particular vehicle type, actuator design, brake disc type, or any combination thereof without departing from the teachings disclosed herein.

During normal braking operation, the friction linings 105 wear and during the break-in period of operation, residual material may be left on the surface of the drum rotor. Such residual material is referred to as a "transfer layer," and a properly formed transfer layer can improve the efficiency of braking, the smoothness of the application of braking force, and the service life of the brake pads. Until break-in is complete, the brake can operate at sub-optimal performance.

The transfer layer also reduces heat build-up during braking, which may prevent damage to the brake disc or heat from adversely affecting the friction lining. However, because friction lining 105 is formulated to resist wear, the time taken to run-in may be longer than desired. To this end, the brake pad 100 includes a surface coating 109 applied to the tribological surface 107 of the friction lining 105.

Surface coating 109 may be advantageously formulated to readily produce a transfer layer having properties similar to those of friction lining 105, except that it forms faster under normal use. The transmission layer generated by surface coating 109 may exhibit friction characteristics similar to the transmission layer generated by friction lining 105 within certain tolerances, except that the transmission layer may be generated at a substantially lower heating level and substantially fewer braking cycles than friction lining 105 alone. Thus, the brake disc may be protected from heat-related warping, and the friction lining 105 may be protected from adverse conditions caused by heat build-up during running-in. In some previous designs, break-in may require 300 miles to 400 miles of operation, but the addition of the surface coating 109 may advantageously reduce the necessary operations to complete the break-in. The formulation of the surface coating 109 may be adapted for a particular vehicle type, brake design, brake disc type, friction lining formulation, or any combination thereof without departing from the teachings disclosed herein.

Based on the formulation of the friction lining 105 and the surface coating 109, the braking performance can be improved during running-in. In some embodiments, friction lining 105 may comprise a first composite material and surface coating 109 may comprise a second composite material having some of the same composition as friction lining 105. In some embodiments, the formulation of the surface coating 109 with some composition, such as friction lining 105, may improve the braking function or the useful life of the brake pad.

The topcoat layer 109 may be formulated using a variety of materials. In some embodiments, the surface coating 109 may comprise a composite of non-metallic materials. In some embodiments, the surface coating 109 may include a composite of materials such as titanates, lubricants, abrasives, fillers, fibers, binders, or pH adjusters. By way of example and not limitation, titanates in the composite material may include potassium titanate, sodium titanate, and potassium magnesium. By way of example and not limitation, the lubricant in the composite material may include antimony trisulfide (antimony trisulfide), tin sulfide, or zinc sulfide. By way of example and not limitation, the abrasive in the composite material may include zircon, zirconia, alumina, magnetite, or mullite. By way of example and not limitation, the filler in the composite material may include barite, mica, ceramic pellets, or mineral pellets. By way of example and not limitation, the fibers in the composite material may include ceramic fibers, mineral fibers, or basalt fibers. By way of example and not limitation, the binder in the composite material may include an inorganic resin, an organic resin, sodium silicate, or a poly-blend non-sanded grout. By way of example and not limitation, the pH adjusting agent in the composite material may include lime or methyl alkali. One or more classes of other materials may be used without departing from the teachings disclosed herein.

In some embodiments, different forms of materials, such as two or more different potassium titanates, may be utilized without departing from the teachings disclosed herein. The composition of the top coat 109 may vary slightly in their respective ingredient content without departing from the teachings disclosed herein. For example, one composition may include 70-80% by weight resin, 10-20% zirconia, 2.5-12.5% potassium titanate, and 0-5% antimony trisulfide. In another exemplary embodiment, the composition may include 47-57% sodium silicate, 16-26% zirconia, 16-26% barite, 0-5% antimony trisulfide, and 0-5% magnetite. In yet another exemplary embodiment, the composition may include 20-30% multi-doped non-sand grout, 15-25% zirconia, 15-20% barite, 0-5% antimony trisulfide, 05% magnetite and up to 30% water.

Some embodiments may include a composite material having up to 40% zirconia, up to 20% zircon, up to 10% potassium titanate, up to 20% barite, and,Up to 5% ceramic fibres, up to 5% Sb₂S₃Up to 5% SnS₂Up to 5% mica, or some combination of the above listed amounts of the raw materials without departing from the teachings disclosed herein. In some embodiments, the resin may be utilized to balance the composition if the other raw materials do not produce a 100% mixture without departing from the teachings disclosed herein. Other embodiments may include other compositions without departing from the teachings disclosed herein.

The surface coating 109 may be applied to the friction lining 105 using an adhesive. The adhesive may be formulated for a specific cure time that is reasonably long for complete application, but short enough that the addition of the surface coating to the brake pad 100 has minimal impact on manufacturing and production time. In some embodiments, the cure time may be 180 seconds or less. In some embodiments, the cure time may be 60 seconds or less. In some embodiments, commercial adhesives may be utilized, such as flash dry formulations. In some embodiments, the adhesive may include an aliphatic resin or polyvinyl acetate. Other embodiments may include other formulations without departing from the teachings disclosed herein.

FIG. 1 provides an illustration of a brake pad 100 having a surface coating 109 that is uniformly applied to the entire area of the tribological surface 107 of the friction lining 105. Other embodiments may include different applications that may be advantageously used to accommodate different vehicle specifications. The application of the surface coating 109 may be applied using a stamping operation operable to accommodate a wide variety of application designs. The stamping operation may advantageously allow any arbitrary design desired to be utilized during manufacturing.

In the depicted embodiment, the surface coating 109 provides a different visual appearance to the friction lining 105 such that the applied design is visually identifiable. This visual difference may advantageously allow the surface coating 109 to be applied to the friction lining 105 in a manner that allows branding beyond operational advantages. The application of the surface coating 109 may utilize any design without departing from the teachings disclosed herein. For example, the design may be sold with a particular aesthetic or trademark design to identify the brake pad as having been manufactured by a particular manufacturer.

FIG. 1 depicts an embodiment wherein the surface coating 109 provides complete coverage of the tribological surface 107 of the friction lining 105. Other embodiments may include other configurations of the surface coating 109. By way of example and not limitation, some embodiments may concentrate the surface coating 109 in portions of the tribological surface 107 that are intended to make more frequent contact with the brake disc during operation. In some embodiments, the portion of the tribological surface 107 that is specified to experience more frictional forces during operation may be characterized by a concentration of the surface coating 109. Other embodiments may include other configurations without departing from the teachings disclosed herein.

FIG. 2 is an illustration of a brake pad 200 that utilizes the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but the application of top coat 109 forms a pair of spaced apart circles. Other embodiments may include a different number of circles without departing from the teachings disclosed herein. Other embodiments may include multiple circles having different sizes or positions relative to friction lining 105 without departing from the teachings disclosed herein. Other embodiments may include a plurality of elliptical shapes other than circular without departing from the teachings disclosed herein.

FIG. 3 is an illustration of a brake pad 300 that utilizes the same formulation of backing plate 101, friction lining 105, and surface coating 109 as brake pad 100, but the application of surface coating 109 forms a pair of spaced apart rings. Other embodiments may include a different number of rings without departing from the teachings disclosed herein. Other embodiments may include multiple rings having different sizes or positions relative to friction lining 105 without departing from the teachings disclosed herein.

FIG. 4 is an illustration of a brake pad 400, the brake pad 400 utilizing the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but with the application of top coat 109 forming a pair of spaced apart strips. Other embodiments may include a different number of strips without departing from the teachings disclosed herein. Other embodiments may include a plurality of strips having different sizes or positions relative to friction lining 105 without departing from the teachings disclosed herein.

FIG. 5 is an illustration of a brake pad 500, the brake pad 500 utilizing the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but with the application of top coat 109 forming three spaced-apart strips. Other embodiments may include a different number of strips without departing from the teachings disclosed herein. Other embodiments may include a plurality of strips having different sizes or positions relative to friction lining 105 without departing from the teachings disclosed herein.

FIG. 6 is an illustration of a brake pad 600 that utilizes the same formulation of backing plate 101, friction lining 105, and top coating 109 as brake pad 100, but the application of top coating 109 forms a pair of angled strips. Other embodiments may include a different number of strips without departing from the teachings disclosed herein. Other embodiments may include a plurality of strips having different sizes or positions relative to friction lining 105 without departing from the teachings disclosed herein.

FIG. 7 is an illustration of a brake pad 700 that utilizes the same formulation of backing plate 101, friction lining 105, and surface coating 109 as brake pad 100, but the application of surface coating 109 forms a pair of angled strips. Other embodiments may include a different number of strips without departing from the teachings disclosed herein. Other embodiments may include a plurality of strips having different sizes or positions relative to friction lining 105 without departing from the teachings disclosed herein.

FIG. 8 is an illustration of a brake pad 800, the brake pad 800 utilizing the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but with the application of top coat 109 forming a strip. Other embodiments may include a different number of strips without departing from the teachings disclosed herein. Other embodiments may include a plurality of strips having different sizes or positions relative to friction lining 105 without departing from the teachings disclosed herein.

FIG. 9 is an illustration of a brake pad 900, the brake pad 900 utilizing the same formulation of backing plate 101, friction lining 105, and surface coating 109 as brake pad 100, but with the application of surface coating 109 being asymmetrically applied to the tribological surface of friction lining 105. In particular, the surface coating 109 varies with respect to position along the length x of the friction lining 105. In the depicted embodiment, the applied variation varies along the length x relative to the width y of the friction lining 105. At the proximal end x1 of the length x, all associated widths y are covered by the surface coating 109. At the distal end x2 of length x, at any point along width y, no friction lining 105 is covered by surface coating 109. The coverage of the surface coating 109 relative to the width y is gradually reduced between the proximal end x1 and the distal end x 2. In the depicted embodiment, the coverage of the surface coating 109 tapers linearly, but other embodiments may include other arrangements without departing from the teachings disclosed herein. In some embodiments, the brake pad 900 may be most effectively used in a particular brake location within a vehicle. In such embodiments, the brake pads may be utilized in series to provide effective braking on all wheels of the vehicle, wherein each brake pad, when installed in the vehicle, has a specific design adapted to its particular location without departing from the teachings disclosed herein.

In some embodiments, the application of the surface coating 109 may provide a geometric pattern. FIG. 10 is an illustration of a brake pad 1000 that utilizes the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but the application of top coat 109 forms a geometric pattern that includes a hexagonal grid. FIG. 11 is an illustration of a brake pad 1100, the brake pad 1100 utilizing the same formulation of backing plate 101, friction lining 105, and top coat 109 as brake pad 100, but the application of top coat 109 forms a geometric pattern comprising a hexagonal repeating pattern. Other embodiments may have other designs or other embodiments without departing from the teachings disclosed herein.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the disclosed apparatus and methods. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure as claimed. Features of the various embodiment can be combined to form additional embodiments of the disclosed concept.