CA2821897C - Metal and graphite laminate - Google Patents
Metal and graphite laminate Download PDFInfo
- Publication number
- CA2821897C CA2821897C CA2821897A CA2821897A CA2821897C CA 2821897 C CA2821897 C CA 2821897C CA 2821897 A CA2821897 A CA 2821897A CA 2821897 A CA2821897 A CA 2821897A CA 2821897 C CA2821897 C CA 2821897C
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- Canada
- Prior art keywords
- sheet
- shim
- graphite foil
- lamina
- noise damping
- Prior art date
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- 229910002804 graphite Inorganic materials 0.000 title claims abstract description 89
- 239000010439 graphite Substances 0.000 title claims abstract description 89
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 title claims abstract description 83
- 229910052751 metal Inorganic materials 0.000 title claims description 36
- 239000002184 metal Substances 0.000 title claims description 35
- 239000000463 material Substances 0.000 claims abstract description 81
- 239000011888 foil Substances 0.000 claims abstract description 79
- 238000000034 method Methods 0.000 claims description 22
- 238000013016 damping Methods 0.000 claims description 20
- 229910000831 Steel Inorganic materials 0.000 claims description 6
- 239000010959 steel Substances 0.000 claims description 6
- 238000005520 cutting process Methods 0.000 claims description 4
- 239000010410 layer Substances 0.000 description 24
- 239000011162 core material Substances 0.000 description 5
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- 238000005452 bending Methods 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000009977 dual effect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000002648 laminated material Substances 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 239000007770 graphite material Substances 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- -1 or "carrier" Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000012748 slip agent Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
- B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
- B32B9/007—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile comprising carbon, e.g. graphite, composite carbon
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/18—Layered products comprising a layer of metal comprising iron or steel
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/08—Interconnection of layers by mechanical means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
- B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B9/041—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of metal
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/0006—Noise or vibration control
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/02—Braking members; Mounting thereof
- F16D65/04—Bands, shoes or pads; Pivots or supporting members therefor
- F16D65/092—Bands, shoes or pads; Pivots or supporting members therefor for axially-engaging brakes, e.g. disc brakes
- F16D65/095—Pivots or supporting members therefor
- F16D65/097—Resilient means interposed between pads and supporting members or other brake parts
- F16D65/0971—Resilient means interposed between pads and supporting members or other brake parts transmitting brake actuation force, e.g. elements interposed between brake piston and pad
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16J—PISTONS; CYLINDERS; SEALINGS
- F16J15/00—Sealings
- F16J15/02—Sealings between relatively-stationary surfaces
- F16J15/06—Sealings between relatively-stationary surfaces with solid packing compressed between sealing surfaces
- F16J15/10—Sealings between relatively-stationary surfaces with solid packing compressed between sealing surfaces with non-metallic packing
- F16J15/12—Sealings between relatively-stationary surfaces with solid packing compressed between sealing surfaces with non-metallic packing with metal reinforcement or covering
- F16J15/121—Sealings between relatively-stationary surfaces with solid packing compressed between sealing surfaces with non-metallic packing with metal reinforcement or covering with metal reinforcement
- F16J15/122—Sealings between relatively-stationary surfaces with solid packing compressed between sealing surfaces with non-metallic packing with metal reinforcement or covering with metal reinforcement generally parallel to the surfaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/10—Properties of the layers or laminate having particular acoustical properties
- B32B2307/102—Insulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/536—Hardness
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/54—Yield strength; Tensile strength
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/56—Damping, energy absorption
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2475/00—Frictional elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D2200/00—Materials; Production methods therefor
- F16D2200/0004—Materials; Production methods therefor metallic
- F16D2200/0008—Ferro
- F16D2200/0021—Steel
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D2200/00—Materials; Production methods therefor
- F16D2200/0034—Materials; Production methods therefor non-metallic
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D2200/00—Materials; Production methods therefor
- F16D2200/0034—Materials; Production methods therefor non-metallic
- F16D2200/0052—Carbon
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
- Y10T428/24281—Struck out portion type
- Y10T428/24289—Embedded or interlocked
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
- Y10T428/24322—Composite web or sheet
- Y10T428/24331—Composite web or sheet including nonapertured component
- Y10T428/24339—Keyed
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24521—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness with component conforming to contour of nonplanar surface
- Y10T428/24529—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness with component conforming to contour of nonplanar surface and conforming component on an opposite nonplanar surface
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24521—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness with component conforming to contour of nonplanar surface
- Y10T428/24545—Containing metal or metal compound
Landscapes
- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Ceramic Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Laminated Bodies (AREA)
- Braking Arrangements (AREA)
- Gasket Seals (AREA)
Abstract
The present invention is a laminate sheet having two laminae. The first lamina is a relatively hard material having first and second surfaces. The first surface has a plurality of raised and generally pointed piercing structures, each structure having a tip. The second lamina is graphite foil material, which is mated to the relatively hard material, such that at least some of the piercing structures protrude into the graphite foil material. In one embodiment, the first lamina has no performations and is uniformly smooth. In another embodiment, the second surface also has a plurality of piercing strectures and a third lamina comprising graphite foil is mated to the second surface.
Description
METAL AND GRAPHITE LAMINATE
FIELD OF THE INVENTION
The present invention relates generally to laminated materials, and more particularly to laminated materials comprising at least one textured metal sheet layer bound to at least one graphite foil layer.
BACKGROUND OF THE INVENTION
There is a growing need for lighter, stiffer, cheaper structural materials, preferably with all three qualities, with which to make better products.
Stainless steel laminated with graphite foil is a widely used material that has properties that make it suitable for many purposes, such as making gaskets.
Such gaskets can provide high blowout resistance and so can be used in applications with high sealing stresses. Such material is permanently elastic over a wide temperature range, such as -200 C to 550 C. It does not age, is not brittle and provides long-term uniformity and resiliency independent of temperature so that is can withstand high compressive stresses.
It can also tolerate high pressure, such as up to 500 bar. The steel, or "carrier", layer is typically a 0.10 ¨ 0.12 mm thick sheet of "tanged" stainless steel. The laminate is then formed by pressing a sheet of graphite foil onto each surface of the metal sheet to create a laminate with a thickness typically of 1 to 4 mm. The use of tanged metal allows the layers to bind mechanically, without the need for any adhesive, as the tangs on each surface of the metal penetrate into the graphite foil pressed on each surface.
Such tanged metal sheeting is formed by a metal foil puncher, which employs needles that perforate the foil, causing tangs to extend from the side of the sheet opposite the side that the needle penetrates. As a result, the sheeting is weakened by the perforations. Also, if the metal sheet is only laminated on one side, the unlaminated metal surface is not smooth because of the perforations. Furthermore, the thickness of the metal layer is limited because it must be thin enough to allow the puncher needles to penetrate it. It would be desirable to provide a material having graphite foil laminated on at least one side that does not suffer from the disadvantages resulting from the use of such tanged metal.
In a disc brake caliper, a hydraulically actuated piston forces, by action and reaction, a pair of opposing brake pads to pinch a rotor attached to a vehicle wheel. Brake pads have a stiff backing plate with friction pads affixed to one side. Shims of a thin material are often used on the side of the plate contacted by the piston. The shim's function is to reduce the frequency of occurrence of a loud and annoying squeal noise from what are otherwise mechanically perfect brakes. At least some of the noise comes from the fact that, to prevent jamming, the plate has some freedom of radial movement within the caliper so that the rotor can be freed, while the piston has little freedom of movement. In braking, the rigid rotor is frictionally engaged by the hard brake pad (which is in turn supported by its hard backing plate). The brake pad can frictionally slide to some degree against the rigid piston and caliper. High frictional forces are generated during this sliding movement which can cause squeal. Like a stick of chalk forced at an angle across a rigid board, friction can lead to very severe vibrational noise. As well, these recurring forces can lead to fretting and chipping of the piston rim.
Brake squeal is a very expensive problem for car and brake manufacturers as customers invariably want the noise remedied under warranty even if the brakes are otherwise perfect.
A great many designs of shims using various materials have been tried over the years to fit between the piston and the plate to reduce such friction and resulting squeal.
None have been entirely satisfactory. While graphite sheeting has various properties that make it very suitable for noise reduction, it is unsuitable by itself for use as a shim because of its brittleness. Laminates using graphite foil and tanged metal are generally not suitable because such tanged metal is not strong enough to be well suited for use in brake pad shims. It would be desirable to provide a material with graphite on at least one side that is suitable for use as a shim.
SUMMARY OF THE INVENTION
According to some aspects, a laminate sheet having as a first lamina a relatively hard material with first and second surfaces is provided. The first surface has piercing
FIELD OF THE INVENTION
The present invention relates generally to laminated materials, and more particularly to laminated materials comprising at least one textured metal sheet layer bound to at least one graphite foil layer.
BACKGROUND OF THE INVENTION
There is a growing need for lighter, stiffer, cheaper structural materials, preferably with all three qualities, with which to make better products.
Stainless steel laminated with graphite foil is a widely used material that has properties that make it suitable for many purposes, such as making gaskets.
Such gaskets can provide high blowout resistance and so can be used in applications with high sealing stresses. Such material is permanently elastic over a wide temperature range, such as -200 C to 550 C. It does not age, is not brittle and provides long-term uniformity and resiliency independent of temperature so that is can withstand high compressive stresses.
It can also tolerate high pressure, such as up to 500 bar. The steel, or "carrier", layer is typically a 0.10 ¨ 0.12 mm thick sheet of "tanged" stainless steel. The laminate is then formed by pressing a sheet of graphite foil onto each surface of the metal sheet to create a laminate with a thickness typically of 1 to 4 mm. The use of tanged metal allows the layers to bind mechanically, without the need for any adhesive, as the tangs on each surface of the metal penetrate into the graphite foil pressed on each surface.
Such tanged metal sheeting is formed by a metal foil puncher, which employs needles that perforate the foil, causing tangs to extend from the side of the sheet opposite the side that the needle penetrates. As a result, the sheeting is weakened by the perforations. Also, if the metal sheet is only laminated on one side, the unlaminated metal surface is not smooth because of the perforations. Furthermore, the thickness of the metal layer is limited because it must be thin enough to allow the puncher needles to penetrate it. It would be desirable to provide a material having graphite foil laminated on at least one side that does not suffer from the disadvantages resulting from the use of such tanged metal.
In a disc brake caliper, a hydraulically actuated piston forces, by action and reaction, a pair of opposing brake pads to pinch a rotor attached to a vehicle wheel. Brake pads have a stiff backing plate with friction pads affixed to one side. Shims of a thin material are often used on the side of the plate contacted by the piston. The shim's function is to reduce the frequency of occurrence of a loud and annoying squeal noise from what are otherwise mechanically perfect brakes. At least some of the noise comes from the fact that, to prevent jamming, the plate has some freedom of radial movement within the caliper so that the rotor can be freed, while the piston has little freedom of movement. In braking, the rigid rotor is frictionally engaged by the hard brake pad (which is in turn supported by its hard backing plate). The brake pad can frictionally slide to some degree against the rigid piston and caliper. High frictional forces are generated during this sliding movement which can cause squeal. Like a stick of chalk forced at an angle across a rigid board, friction can lead to very severe vibrational noise. As well, these recurring forces can lead to fretting and chipping of the piston rim.
Brake squeal is a very expensive problem for car and brake manufacturers as customers invariably want the noise remedied under warranty even if the brakes are otherwise perfect.
A great many designs of shims using various materials have been tried over the years to fit between the piston and the plate to reduce such friction and resulting squeal.
None have been entirely satisfactory. While graphite sheeting has various properties that make it very suitable for noise reduction, it is unsuitable by itself for use as a shim because of its brittleness. Laminates using graphite foil and tanged metal are generally not suitable because such tanged metal is not strong enough to be well suited for use in brake pad shims. It would be desirable to provide a material with graphite on at least one side that is suitable for use as a shim.
SUMMARY OF THE INVENTION
According to some aspects, a laminate sheet having as a first lamina a relatively hard material with first and second surfaces is provided. The first surface has piercing
2 structures extending therefrom which may be pointed. Each structure has an apex portion referred to as a tip. The second lamina is a graphite foil material that is mated to the relatively hard material. The mating is effected by some of the piercing structures protruding into the graphite foil material, piercing the inner surface of the graphite foil.
The relatively hard material is preferably not perforated and the second surface may be flat. At least some of the piercing structures may extend completely through the graphite foil material, protruding through the outer surface of the graphite foil to expose their tips. At least some of the exposed tips of the piercing structures may be clinched, meaning that they are turned over, onto or into the graphite foil material. In other embodiments, the piercing structures may not extend completely through the graphite foil material so that the outer surface of the foil remains uniformly smooth.
The relatively hard material is preferably metal, which preferably is steel.
It may have a thickness of at least 0.2 mm or may have a thickness of at least 5.0 mm, although the thickness may be less than or equal to 0.2 mm.
According to some aspects, a multi-layer laminate sheet having a first lamina that is a dual sided sheet of a relatively hard material with texturing on two surfaces thereof is provided. The surface texture is created by a plurality of raised and generally pointed piercing structures, with each structure having an apex portion referred to as a tip. The laminate includes two outer laminae of a graphite foil material, one layer being disposed on each surface of the dual sided sheet. The graphite foil material is mated to the relatively hard material by having some of the piercing structures of the relatively hard material protrude through the inner surface of the foil into the graphite foil material. The relatively hard material is preferably not perforated. At least some of the piercing structures may extend completely through one of the layers of graphite foil material, protruding through the outer surface of the foil, to expose their tips. At least some of the exposed tips of the piercing structures may be clinched by being turned over, onto or into the graphite foil material. In other embodiments, the piercing structures may not extend completely through the graphite foil material so that the outer surfaces of the foils remain uniformly smooth.
The relatively hard material is preferably not perforated and the second surface may be flat. At least some of the piercing structures may extend completely through the graphite foil material, protruding through the outer surface of the graphite foil to expose their tips. At least some of the exposed tips of the piercing structures may be clinched, meaning that they are turned over, onto or into the graphite foil material. In other embodiments, the piercing structures may not extend completely through the graphite foil material so that the outer surface of the foil remains uniformly smooth.
The relatively hard material is preferably metal, which preferably is steel.
It may have a thickness of at least 0.2 mm or may have a thickness of at least 5.0 mm, although the thickness may be less than or equal to 0.2 mm.
According to some aspects, a multi-layer laminate sheet having a first lamina that is a dual sided sheet of a relatively hard material with texturing on two surfaces thereof is provided. The surface texture is created by a plurality of raised and generally pointed piercing structures, with each structure having an apex portion referred to as a tip. The laminate includes two outer laminae of a graphite foil material, one layer being disposed on each surface of the dual sided sheet. The graphite foil material is mated to the relatively hard material by having some of the piercing structures of the relatively hard material protrude through the inner surface of the foil into the graphite foil material. The relatively hard material is preferably not perforated. At least some of the piercing structures may extend completely through one of the layers of graphite foil material, protruding through the outer surface of the foil, to expose their tips. At least some of the exposed tips of the piercing structures may be clinched by being turned over, onto or into the graphite foil material. In other embodiments, the piercing structures may not extend completely through the graphite foil material so that the outer surfaces of the foils remain uniformly smooth.
3 According to some aspects, a noise damping shim is provided. The shim has a first layer of a relatively hard material having first and second opposed surfaces. The first surface has a plurality of raised and generally pointed piercing structures. A
second layer of a graphite foil material is mated to the first layer such that at least some of the piercing structures pierce the graphite foil material. The shim may be configured to engage a brake pad so that it acts as an intemiediate element (or buffer) between the backing plate and piston of the braking system.
The noise damping shim may be a brake pad shim.
The first lamina may have a thickness of at least 0.3 mm, or of less than 0.3 mm.
The piercing structures may comprise tips that protrude through the second layer.
tips are clinched. The tips may be clinched.
The relatively hard material may be a metal. The relatively hard material may be steel.
The first layer may not be perforated.
According to some aspects, a method for making a noise damping shim comprises a) forcing together a sheet of graphite foil material and a first surface of a sheet of a relatively hard material. The first surface comprises a plurality of piercing structures that pierce the sheet of graphite foil material when forced together therewith, to form a laminate sheet. The method further comprises b) cutting the laminate sheet to a shape of a noise damping shim.
The method may further comprise, between steps a) and c), collecting the laminate sheet on a take-up reel.
Step a) may comprise feeding the sheet of graphite foil material and the sheet of relatively hard material between rollers.
Step a) may comprise allowing tips of the piercing structures to penetrate through the graphite foil material. Step a) may further comprise clinching the tips.
Clinching the
second layer of a graphite foil material is mated to the first layer such that at least some of the piercing structures pierce the graphite foil material. The shim may be configured to engage a brake pad so that it acts as an intemiediate element (or buffer) between the backing plate and piston of the braking system.
The noise damping shim may be a brake pad shim.
The first lamina may have a thickness of at least 0.3 mm, or of less than 0.3 mm.
The piercing structures may comprise tips that protrude through the second layer.
tips are clinched. The tips may be clinched.
The relatively hard material may be a metal. The relatively hard material may be steel.
The first layer may not be perforated.
According to some aspects, a method for making a noise damping shim comprises a) forcing together a sheet of graphite foil material and a first surface of a sheet of a relatively hard material. The first surface comprises a plurality of piercing structures that pierce the sheet of graphite foil material when forced together therewith, to form a laminate sheet. The method further comprises b) cutting the laminate sheet to a shape of a noise damping shim.
The method may further comprise, between steps a) and c), collecting the laminate sheet on a take-up reel.
Step a) may comprise feeding the sheet of graphite foil material and the sheet of relatively hard material between rollers.
Step a) may comprise allowing tips of the piercing structures to penetrate through the graphite foil material. Step a) may further comprise clinching the tips.
Clinching the
4 tips may comprise passing the sheet of graphite foil material and the sheet of relatively hard material between a second set of rollers.
Step b) may comprise cutting the laminate sheet to the shape of a brake pad shim.
The sheet of relatively hard material may be non-perforated.
According to another aspect, a method for damping brake noise comprises: a) installing a metal-graphite laminate brake pad shim between a brake piston and a brake pad packing plate.
The metal graphite laminate brake pad shim may comprise a first lamina of a metal and a second lamina of a graphite foil material, and the first lamina may be non-perforated.
The metal graphite laminate brake pad shim may comprise a first lamina of a metal and a second lamina of a graphite foil material, and the first lamina may comprise a plurality of piercing structures extending therefrom and piercing the second lamina.
BRIEF DESCRIPTION OF THE DRAWINGS
1 5 Figure 1 shows a continuous process of producing a laminate sheet from two supply coils, the lower lamina having piercing structures and the upper lamina being made of a graphite foil material.
Figure 2 shows detail of a textured lamina sheet of relatively hard material with piercing structures that have a tapered cross-section ending in a pointed tip, populating the surface.
Figure 3 shows an embodiment where the structures have pierced through the graphite foil material and where the pointed tips are above its surface.
Figure 4 shows an embodiment of a textured lamina sheet of relatively hard material with both faces textured with piercing structures.
Figure 5 shows another embodiment of three layer laminate where the central textured lamina sheet of relatively hard material has both faces textured with piercing structures and the outer graphite foil laminae have been pierced by the pointed tips of the piercing structures.
Figure 6 shows detail of clinching where the tips are sequentially rolled down to the final clinched position on the upper face of the pierceable graphite foil lamina.
=
Figure 7 shows detail of a single piercing structure embedded in a graphite foil lamina, which may be too thick to pierce through.
Figure 8 shows another embodiment where the core material is the harder piercing lamina textured on both faces and the outer lamina are pierceable graphite foil material and are forced onto the harder core.
Figure 9 shows the graphite foil side of a two-layer metal-graphite laminate in the form of a brake bad shim.
DETAILED DESCRIPTION OF THE INVENTION
In the following description the word "clinch" (clinching, clinchable, clinched), is used to describe the act of bending over the exposed apex portion or "tip" of a pin- or nail-like structure that has pierced through two or more layers and extends therefrom.
Clinching is common practice in the wood construction trade. Clinching is analogous to riveting in metal work, or to any other deformation of a fastener to prevent its easy withdrawal. The purpose of clinching is to impart greater cohesion between the two laminate layers that are so joined.
The terms "pointed structure" and "piercing structure" are used synonymously herein as a general term to describe any type of nail- or pin-like structure (or hooked or barbed structure) raised on the surface of a material (for embedding or piercing) that are capable of piercing and then penetrating the surface of a graphite foil. An appropriate choice of hardness of the material and shape and configuration of the piercing structures is selected to ensure such piercing capability.
In the instant invention, piercing structures have been raised from a surface of a lamina consisting of relatively hard material, such as a sheet of stainless steel. They can pierce into the inner surface of an adjacent graphite foil lamina and, if longer than the graphite foil's thickness, can protrude through the outer surface of the foil.
The protruding tips may be bent over or clinched to create the "locked-laminate"
embodiment of the instant invention. In a laminate, where a first lamina is mated with only one other lamina, the surface, or face, of the first lamina that is mated to the other lamina is referred
Step b) may comprise cutting the laminate sheet to the shape of a brake pad shim.
The sheet of relatively hard material may be non-perforated.
According to another aspect, a method for damping brake noise comprises: a) installing a metal-graphite laminate brake pad shim between a brake piston and a brake pad packing plate.
The metal graphite laminate brake pad shim may comprise a first lamina of a metal and a second lamina of a graphite foil material, and the first lamina may be non-perforated.
The metal graphite laminate brake pad shim may comprise a first lamina of a metal and a second lamina of a graphite foil material, and the first lamina may comprise a plurality of piercing structures extending therefrom and piercing the second lamina.
BRIEF DESCRIPTION OF THE DRAWINGS
1 5 Figure 1 shows a continuous process of producing a laminate sheet from two supply coils, the lower lamina having piercing structures and the upper lamina being made of a graphite foil material.
Figure 2 shows detail of a textured lamina sheet of relatively hard material with piercing structures that have a tapered cross-section ending in a pointed tip, populating the surface.
Figure 3 shows an embodiment where the structures have pierced through the graphite foil material and where the pointed tips are above its surface.
Figure 4 shows an embodiment of a textured lamina sheet of relatively hard material with both faces textured with piercing structures.
Figure 5 shows another embodiment of three layer laminate where the central textured lamina sheet of relatively hard material has both faces textured with piercing structures and the outer graphite foil laminae have been pierced by the pointed tips of the piercing structures.
Figure 6 shows detail of clinching where the tips are sequentially rolled down to the final clinched position on the upper face of the pierceable graphite foil lamina.
=
Figure 7 shows detail of a single piercing structure embedded in a graphite foil lamina, which may be too thick to pierce through.
Figure 8 shows another embodiment where the core material is the harder piercing lamina textured on both faces and the outer lamina are pierceable graphite foil material and are forced onto the harder core.
Figure 9 shows the graphite foil side of a two-layer metal-graphite laminate in the form of a brake bad shim.
DETAILED DESCRIPTION OF THE INVENTION
In the following description the word "clinch" (clinching, clinchable, clinched), is used to describe the act of bending over the exposed apex portion or "tip" of a pin- or nail-like structure that has pierced through two or more layers and extends therefrom.
Clinching is common practice in the wood construction trade. Clinching is analogous to riveting in metal work, or to any other deformation of a fastener to prevent its easy withdrawal. The purpose of clinching is to impart greater cohesion between the two laminate layers that are so joined.
The terms "pointed structure" and "piercing structure" are used synonymously herein as a general term to describe any type of nail- or pin-like structure (or hooked or barbed structure) raised on the surface of a material (for embedding or piercing) that are capable of piercing and then penetrating the surface of a graphite foil. An appropriate choice of hardness of the material and shape and configuration of the piercing structures is selected to ensure such piercing capability.
In the instant invention, piercing structures have been raised from a surface of a lamina consisting of relatively hard material, such as a sheet of stainless steel. They can pierce into the inner surface of an adjacent graphite foil lamina and, if longer than the graphite foil's thickness, can protrude through the outer surface of the foil.
The protruding tips may be bent over or clinched to create the "locked-laminate"
embodiment of the instant invention. In a laminate, where a first lamina is mated with only one other lamina, the surface, or face, of the first lamina that is mated to the other lamina is referred
5 to as the inner surface, and the other surface, which is not mated with another lamina, is referred to as the outer surface.
Figure 1 shows a process for making a continuous laminated metal and graphite material. Coil 101 supplies the first lamina of textured metal 104 having one face textured with piercing structures 105 having pointed tips 106. Coil 102 supplies the second lamina of graphite foil 103. The two lamina layers are fed between pressure rolls 100, 100a. Under pressure from rolls 100, 100a, the inner surfaces of the two laminae are forced together so that some, or preferably most or all of the piercing structures of the textured metal sheet 104 penetrate through the lower surface of the graphite foil 103.
They may not pierce the upper surface of the graphite foil 103, as in Figure 1.
Alternatively, the piercing structures of the textured metal sheet 104 may penetrate through the upper surface of the graphite foil 103, so that their apex portions or "tips" are exposed (as shown in Figure 3), and then be clinched by a second roll set (not shown) or other means.
The first lamina may be formed from any suitable relatively hard material but is preferably made of a ductile material such as sheet steel. Various materials may be used.
In one preferred embodiment, the first material has a Brinell hardness of more than about 80. The side (outer surface) of the first lamina, which is not textured, is preferably flat and uniformly smooth, with no holes or perforations therethrough.
The two laminae are thereby continuously locked together as a laminate 108 which can then be severed into individual sheets 107 of laminate.
Alternatively, the laminate 108 may be collected as a bulk product on a take-up reel (not shown) (thus, the process may be a coil-to-coil process). The bulk product may be further cut or shaped for specific applications, including cut-to-measure applications on a job site.
Rolls 100, 100a can press against the entire width of the material "sandwich"
or just in localized areas (e.g. edges).
Figure 2 shows the textured face 201 and plain face 200 of textured metal sheet 104, which faces may be the same or of different materials such as steel-steel or steel-
Figure 1 shows a process for making a continuous laminated metal and graphite material. Coil 101 supplies the first lamina of textured metal 104 having one face textured with piercing structures 105 having pointed tips 106. Coil 102 supplies the second lamina of graphite foil 103. The two lamina layers are fed between pressure rolls 100, 100a. Under pressure from rolls 100, 100a, the inner surfaces of the two laminae are forced together so that some, or preferably most or all of the piercing structures of the textured metal sheet 104 penetrate through the lower surface of the graphite foil 103.
They may not pierce the upper surface of the graphite foil 103, as in Figure 1.
Alternatively, the piercing structures of the textured metal sheet 104 may penetrate through the upper surface of the graphite foil 103, so that their apex portions or "tips" are exposed (as shown in Figure 3), and then be clinched by a second roll set (not shown) or other means.
The first lamina may be formed from any suitable relatively hard material but is preferably made of a ductile material such as sheet steel. Various materials may be used.
In one preferred embodiment, the first material has a Brinell hardness of more than about 80. The side (outer surface) of the first lamina, which is not textured, is preferably flat and uniformly smooth, with no holes or perforations therethrough.
The two laminae are thereby continuously locked together as a laminate 108 which can then be severed into individual sheets 107 of laminate.
Alternatively, the laminate 108 may be collected as a bulk product on a take-up reel (not shown) (thus, the process may be a coil-to-coil process). The bulk product may be further cut or shaped for specific applications, including cut-to-measure applications on a job site.
Rolls 100, 100a can press against the entire width of the material "sandwich"
or just in localized areas (e.g. edges).
Figure 2 shows the textured face 201 and plain face 200 of textured metal sheet 104, which faces may be the same or of different materials such as steel-steel or steel-
6 aluminum. Piercing structures 105 have piercing, pointed tips 106. In Figure 3, the tips 106 are shown to pierce through the outer surface of the graphite foil 103 and extend thereabove. For example, curved or hook-shaped piercing structures 105 may be inherently formed in the initial process to prepare the textured metal sheet 104 (for example, using the process described in the application "Bulk Textured Material Sheeting", Canadian Patent Application No. 2,778,455, of the same applicants, filed in Canada on May 29, 2012, or the process described for example in any of Canadian Patent Nos. 1,330, 521, 1,337,622, or 2,127,339. Alternatively, more straight upright (e.g. nail-like) structures may be employed. These may be pre-bent into more hook-shape structures. Such pre-bending can be done using rollers or a press arrangement between flat platens so as to bend the thinner tips over into hooks.
Figure 4 shows a metal sheet 400 with both faces textured with piercing structures 105 so that that it can form the core between two graphite foil layers 103, 103a. In Figure the same double textured metal sheet 400 is shown as a first (core) lamina with a graphite foil layer 103, 103a on either side, creating a three layer laminate.
Figure 6 shows a laminate 108 with the tips 106 being clinched, while passing between rollers, to a fully clinched position 600 by being pressed together against a hard third surface such as an anvil. Also shown in Figure 6 are examples of how the tips 106 may be reverted 601 so as to be pointing pack into the graphite foil, or crushed 602, where the effect is akin to riveting.
Figure 7 shows detail of one piercing structure 700 on the textured face 201 of textured metal sheet 104. The piercing structure 700 has a tapered cross-section ending in a pointed tip. The inner surface of the graphite foil 103 is pierced by the piercing structure 700, but the piercing structure 700 does not pierce the outer surface of the graphite foil 103 and so the piercing structure 700 is fully embedded in the graphite foil 103. This of course applies to all piercing structures in such a lamination process.
Figure 8 shows the rolling lamination process applied to a core of double-textured metal sheet 800 with outer laminae both being graphite foil 103, 103a which are fed from
Figure 4 shows a metal sheet 400 with both faces textured with piercing structures 105 so that that it can form the core between two graphite foil layers 103, 103a. In Figure the same double textured metal sheet 400 is shown as a first (core) lamina with a graphite foil layer 103, 103a on either side, creating a three layer laminate.
Figure 6 shows a laminate 108 with the tips 106 being clinched, while passing between rollers, to a fully clinched position 600 by being pressed together against a hard third surface such as an anvil. Also shown in Figure 6 are examples of how the tips 106 may be reverted 601 so as to be pointing pack into the graphite foil, or crushed 602, where the effect is akin to riveting.
Figure 7 shows detail of one piercing structure 700 on the textured face 201 of textured metal sheet 104. The piercing structure 700 has a tapered cross-section ending in a pointed tip. The inner surface of the graphite foil 103 is pierced by the piercing structure 700, but the piercing structure 700 does not pierce the outer surface of the graphite foil 103 and so the piercing structure 700 is fully embedded in the graphite foil 103. This of course applies to all piercing structures in such a lamination process.
Figure 8 shows the rolling lamination process applied to a core of double-textured metal sheet 800 with outer laminae both being graphite foil 103, 103a which are fed from
7 upper and lower coils 102, 102a. The rollers 100, 100a, press the upper sheet of graphite foil 103 against the textured upper surface of the metal sheet 800 so that the piecing structures on the top surface of the metal sheet 800 penetrate through the lower surface of the upper graphite sheet and become embedded in the graphite foil 103 to mate the layers in the laminate 800. Similarly, the rollers 100, 100a, press the lower sheet of graphite foil 103 against the textured lower surface of the metal sheet 800 so that the piecing structures on the lower surface of the metal sheet 800 penetrate through the upper surface of the lower graphite sheet and become embedded in the graphite foil 103 to mate the layers in the laminate 800. The resulting laminate 801 may be severed into individual sheets of laminate 802 Unlike the prior art, the first lamina of relatively hard material may be formed from any desired thickness of material that can be suitably textured. For example, the thickness of the first lamina may be greater than or equal to 0.3 mm, 1.0 mm, 5.0 mm or 10.0 mm, although for some applications the thickness may be less than 0.3 mm, 0.2 mm or 0.1 mm. The texturing may be performed so as to ensure that the vertical (i.e.
perpendicular to the surface of the lamina) heights of the piercing structures do not exceed the thickness of the graphite foil lamina(e) to be used, in which case the piercing structures will not penetrate through the outer surface(s) of the foil(s) in the laminate so that the outer surfaces of the laminate are uniformly smooth. Alternatively, the piercing structures may have a vertical height sufficiently greater than (e.g., 1.3 to 1.5 times greater than) the thickness of the graphite foil to be used to form the laminate so that the tips of some, most or all of the piercing structures protrude through the outer surface of the graphite foil and are exposed. As discussed above, the exposed tips of the piercing structures may then be clinched.
A shim is a noise-reducing inter-layer piece of material of any shape or outline.
As discussed above, shims are widely employed between brake pistons and brake pad backing plates to reduce noise, such as squealing, which may occur when the piston engages the backing plate during braking.
perpendicular to the surface of the lamina) heights of the piercing structures do not exceed the thickness of the graphite foil lamina(e) to be used, in which case the piercing structures will not penetrate through the outer surface(s) of the foil(s) in the laminate so that the outer surfaces of the laminate are uniformly smooth. Alternatively, the piercing structures may have a vertical height sufficiently greater than (e.g., 1.3 to 1.5 times greater than) the thickness of the graphite foil to be used to form the laminate so that the tips of some, most or all of the piercing structures protrude through the outer surface of the graphite foil and are exposed. As discussed above, the exposed tips of the piercing structures may then be clinched.
A shim is a noise-reducing inter-layer piece of material of any shape or outline.
As discussed above, shims are widely employed between brake pistons and brake pad backing plates to reduce noise, such as squealing, which may occur when the piston engages the backing plate during braking.
8 Graphite has noise-reducing properties that make it well suited for use as a noise insulator. However, by itself, it is too brittle to be used as a shim. The metal-graphite laminate described herein though is well suited for use as a shim, such as a braking pad shim. The laminate is an effective noise damping medium. With its lubricating properties, graphite modulates the braking effect of friction linings and contributes to braking comfort and to noise reduction. The excellent thermal conductivity properties of graphite also play an important role in the use of the laminate in applications where there are large temperature variations, such as in automotive brakes. Graphite has a much lower friction coefficient than materials typically used to produce shims so that the laminate acts as a slip agent, which contributes to its noise-reducing ability. Graphite is also resistant to oxidation.
In embodiments where the piercing structures protrude through the outer surface, and are optionally clinched, the resulting outer surface of the graphite foil becomes "bubbled", as shown in Figure 9. Figure 9 shows the graphite foil side of a two-layer metal-graphite laminate in the form of a brake bad shim. Each exposed tip 900 appears as a bubble on the surface of the foil. As long as the exposed tips are either clinched, or are sized so that only a small amount of the tip is exposed, the resulting bubbled surface remains relatively smooth to the touch.
It should be understood that the above-described embodiments of the present invention, particularly, any "preferred" embodiments, are only examples of implementations, merely set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiment(s) of the invention as will be evident to those skilled in the art.
Where, in this document, a list of one or more items is prefaced by the expression "such as" or "including", is followed by the abbreviation "etc.", or is prefaced or followed by the expression "for example", or "e.g.", this is done to expressly convey and emphasize that the list is not exhaustive, irrespective of the length of the list. The absence of such an expression, or another similar expression, is in no way intended to imply that a list is exhaustive. Unless otherwise expressly stated or clearly implied, such lists shall be
In embodiments where the piercing structures protrude through the outer surface, and are optionally clinched, the resulting outer surface of the graphite foil becomes "bubbled", as shown in Figure 9. Figure 9 shows the graphite foil side of a two-layer metal-graphite laminate in the form of a brake bad shim. Each exposed tip 900 appears as a bubble on the surface of the foil. As long as the exposed tips are either clinched, or are sized so that only a small amount of the tip is exposed, the resulting bubbled surface remains relatively smooth to the touch.
It should be understood that the above-described embodiments of the present invention, particularly, any "preferred" embodiments, are only examples of implementations, merely set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiment(s) of the invention as will be evident to those skilled in the art.
Where, in this document, a list of one or more items is prefaced by the expression "such as" or "including", is followed by the abbreviation "etc.", or is prefaced or followed by the expression "for example", or "e.g.", this is done to expressly convey and emphasize that the list is not exhaustive, irrespective of the length of the list. The absence of such an expression, or another similar expression, is in no way intended to imply that a list is exhaustive. Unless otherwise expressly stated or clearly implied, such lists shall be
9 read to include all comparable or equivalent variations of the listed item(s), and alternatives to the item(s), in the list that a skilled person would understand would be suitable for the purpose that the one or more items are listed.
The words "comprises" and "comprising", when used in this specification and the claims, are to used to specify the presence of stated features, elements, integers, steps or components, and do not preclude, nor imply the necessity for, the presence or addition of one or more other features, elements, integers, steps, components or groups thereof.
The scope of the claims that follow is not limited by the embodiments set forth in the description. The claims should be given the broadest purposive construction consistent with the description as a whole.
The words "comprises" and "comprising", when used in this specification and the claims, are to used to specify the presence of stated features, elements, integers, steps or components, and do not preclude, nor imply the necessity for, the presence or addition of one or more other features, elements, integers, steps, components or groups thereof.
The scope of the claims that follow is not limited by the embodiments set forth in the description. The claims should be given the broadest purposive construction consistent with the description as a whole.
Claims (20)
1. A noise damping shim comprising:
a first layer of a relatively hard material having first and second opposed surfaces, the first surface having a plurality of piercing structures, and a second layer of a graphite foil material mated to the first layer such that at least some of the piercing structures pierce the graphite foil material.
a first layer of a relatively hard material having first and second opposed surfaces, the first surface having a plurality of piercing structures, and a second layer of a graphite foil material mated to the first layer such that at least some of the piercing structures pierce the graphite foil material.
2. The noise damping shim of claim 1, wherein the noise damping shim is a brake pad shim.
3. The noise damping shim of claim 1, wherein the first layer has a thickness of at least 0.3 mm.
4. The noise damping shim of claim 1, wherein the first layer has a thickness of less than 0.3 mm.
5. The noise damping shim of claim 1, wherein the piercing structures comprise tips that protrude through the second layer.
6. The noise damping shim of claim 5, wherein the tips are clinched.
7. The noise damping shim of claim 1, wherein the relatively hard material is a metal.
8. The noise damping shim of claim 1, wherein the relatively hard material is steel.
9. The noise damping shim of claim 1, wherein the first layer is not perforated.
10. The noise damping shim of claim 1 for use in a braking system having a brake pad with a backing plate and having a piston, the shim being configured to act as an intermediate element between the backing plate and the piston.
11. A method for making a noise damping shim, comprising:
a) forcing together a sheet of graphite foil material and a first surface of a sheet of a relatively hard material, the first surface comprising a plurality of piercing structures that pierce the sheet of graphite foil material when forced together therewith, to form a laminate sheet; and b) cutting the laminate sheet to a shape of a noise damping shim.
a) forcing together a sheet of graphite foil material and a first surface of a sheet of a relatively hard material, the first surface comprising a plurality of piercing structures that pierce the sheet of graphite foil material when forced together therewith, to form a laminate sheet; and b) cutting the laminate sheet to a shape of a noise damping shim.
12. The method of claim 11, further comprising, between steps a) and c), collecting the laminate sheet on a take-up reel.
13. The method of claim 11, wherein step a) comprises feeding the sheet of graphite foil material and the sheet of relatively hard material between rollers.
14. The method of claim 13, wherein step a) comprises allowing tips of the piercing structures to penetrate through the graphite foil material.
15. The method of claim 14, wherein step a) further comprises clinching the tips.
16. The method of claim 15, wherein clinching the tips comprises passing the sheet of graphite foil material and the sheet of relatively hard material between a second set of rollers.
17. The method of claim 11, wherein step b) comprises cutting the laminate sheet to the shape of a brake pad shim.
18. The method of claim 11, wherein the sheet of relatively hard material is non-perforated.
19. A method for damping brake noise, comprising:
a) installing a metal-graphite laminate brake pad shim between a brake piston and a brake pad backing plate, wherein the metal-graphite laminate brake pad shim comprises a first lamina of a metal and a second lamina of a graphite foil material, the first lamina comprising a plurality of piercing structures extending therefrom and piercing the second lamina.
a) installing a metal-graphite laminate brake pad shim between a brake piston and a brake pad backing plate, wherein the metal-graphite laminate brake pad shim comprises a first lamina of a metal and a second lamina of a graphite foil material, the first lamina comprising a plurality of piercing structures extending therefrom and piercing the second lamina.
20. The method of claim 19, wherein the first lamina is non-perforated.
Priority Applications (11)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA2821897A CA2821897C (en) | 2013-07-26 | 2013-07-26 | Metal and graphite laminate |
RU2016105107/05A RU2604226C1 (en) | 2013-07-26 | 2014-07-21 | Denoising gasket |
EP14828679.2A EP3024648B1 (en) | 2013-07-26 | 2014-07-21 | Metal and graphite laminate |
JP2016516018A JP6208336B2 (en) | 2013-07-26 | 2014-07-21 | Laminate of metal and graphite |
CN201711362935.4A CN108162510A (en) | 2013-07-26 | 2014-07-21 | Metal and graphite laminate |
US14/907,350 US20160167341A1 (en) | 2013-07-26 | 2014-07-21 | Metal and graphite laminate |
PCT/CA2014/000579 WO2015010183A1 (en) | 2013-07-26 | 2014-07-21 | Metal and graphite laminate |
CN201480052555.9A CN105593011B (en) | 2013-07-26 | 2014-07-21 | metal and graphite laminate |
US14/674,058 US20150204400A1 (en) | 2013-07-26 | 2015-03-31 | Metal and graphite laminate |
JP2017171512A JP2018027693A (en) | 2013-07-26 | 2017-09-06 | Metal and graphite laminate |
US16/011,596 US11059267B2 (en) | 2013-07-26 | 2018-06-18 | Metal and graphite laminate |
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CA2821897A CA2821897C (en) | 2013-07-26 | 2013-07-26 | Metal and graphite laminate |
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CA2821897C true CA2821897C (en) | 2016-08-16 |
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EP (1) | EP3024648B1 (en) |
JP (2) | JP6208336B2 (en) |
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CA (1) | CA2821897C (en) |
RU (1) | RU2604226C1 (en) |
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-
2013
- 2013-07-26 CA CA2821897A patent/CA2821897C/en active Active
-
2014
- 2014-07-21 WO PCT/CA2014/000579 patent/WO2015010183A1/en active Application Filing
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- 2014-07-21 US US14/907,350 patent/US20160167341A1/en not_active Abandoned
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US20160167341A1 (en) | 2016-06-16 |
US20150204400A1 (en) | 2015-07-23 |
US11059267B2 (en) | 2021-07-13 |
CA2821897A1 (en) | 2015-01-26 |
CN108162510A (en) | 2018-06-15 |
WO2015010183A1 (en) | 2015-01-29 |
JP2016525024A (en) | 2016-08-22 |
CN105593011B (en) | 2018-01-05 |
EP3024648A4 (en) | 2017-06-21 |
EP3024648A1 (en) | 2016-06-01 |
EP3024648B1 (en) | 2019-05-15 |
JP6208336B2 (en) | 2017-10-04 |
RU2604226C1 (en) | 2016-12-10 |
US20180297326A1 (en) | 2018-10-18 |
JP2018027693A (en) | 2018-02-22 |
CN105593011A (en) | 2016-05-18 |
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