Noise reducing brake pads

Abstract

A brake pad for a motor vehicle is provided. The brake pad includes a body having upper and lower edges and a friction surface extending between the upper and lower edges for engaging a rotor. A notch is located along a section of the upper edge of the brake pad. The notch has an arc length of about to about of an arc length of the pad and a depth of about to about of a height of the pad. During engagement with the rotor, the notch is configured to reduce squeal noise caused by tangential modes of the rotor.

Claims

1. A brake pad comprising: a body having upper and lower edges, a friction surface extending between the upper and lower edges for engaging a rotor, and a notch located along a section of the upper edge, wherein the notch has an arc length of about to about of an arc length of the brake pad and a depth of about to about of a height of the brake pad, and wherein, during engagement with the rotor, the notch is configured to reduce squeal noise caused by tangential modes of the rotor.

2. The brake pad of claim 1, wherein the notch is u-shaped.

3. The brake pad of claim 1, wherein the notch is centered along a midpoint of the arc length of the pad.

4. The brake pad of claim 1, wherein the arc length of the notch is about 40 mm to about 80 mm.

5. The brake pad of claim 1, wherein the depth of the notch is about 8 mm to about 12 mm.

6. The brake pad of claim 1, wherein the tangential modes include tension-compression natural vibration modes of the rotor.

7. The brake pad of claim 1, wherein the notch is positioned such that, during engagement with the rotor, there is minimal contact between the friction surface and the rotor at or near an outer diameter of the rotor in a circumferential direction.

8. The brake pad of claim 1, wherein the notch is positioned such that, during engagement with the rotor, there is relatively no contact between the friction surface and the rotor at an area of the rotor having a potential for high modal displacement in a tangential direction.

9. A brake pad assembly for a motor vehicle, comprising: a rigid backing structure; and a friction material carried by the rigid backing structure, the friction material having a notch located at a midpoint of an upper edge of the material, wherein the notch has an arc length of about to about of an arc length of the friction material and a depth of about to about of a height of the friction material, and wherein, during braking of the motor vehicle, the notch is configured to reduce squeal noise caused by rotor tangential modes.

10. The brake pad assembly of claim 9, wherein the notch is u-shaped.

11. The brake pad assembly of claim 9, wherein the arc length of the notch is about 40 mm to about 80 mm.

12. The brake pad assembly of claim 9, wherein the depth of the notch is about 8 mm to about 12 mm.

13. The brake pad assembly of claim 9, wherein the tangential modes include tension-compression natural vibration modes.

14. The brake pad assembly of claim 9, wherein the notch is positioned such that, during braking of the motor vehicle, there is minimal contact between the friction material and a rotor of the motor vehicle at or near an outer diameter of the rotor in a circumferential direction.

15. The brake pad assembly of claim 9, wherein the notch is positioned such that, during braking of the motor vehicle, there is relatively no contact between the friction material and a rotor of the motor vehicle at an area of the rotor having a potential for high modal displacement in a tangential direction.

16. A method of reducing brake squeal noise from rotor tangential modes, comprising: removing a portion of a brake pad along a section of an upper edge of the pad, the portion being positioned and sized to prevent contact between a friction surface of the pad and a rotor, during engagement of the friction surface with the rotor, at an area of the rotor having a potential for high modal displacement in a tangential direction.

17. The method of claim 16, wherein removing the portion comprises removing a u-shaped portion of the pad along a center section of the upper edge of the pad.

18. The method of claim 17, wherein removing the u-shaped portion comprises removing a notch having an arc length of about to about of an arc length of the pad and a depth of about to about of a height of the pad.

19. The method of claim 18, wherein the arc length of the notch is about 40 mm to about 80 mm and the depth of the notch is about 8 mm to about 12 mm.

20. The method of claim 16, wherein the portion is positioned and sized to minimize contact between the friction surface of the pad and the rotor at or near an outer diameter of the rotor in a circumferential direction.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) At least some features and advantages will be apparent from the following detailed description of embodiments consistent therewith, which description should be considered with reference to the accompanying drawings, wherein:

(2) FIG. 1 is a perspective view of a brake rotor illustrating out-of-plane vibrations associated with a bending mode of the rotor;

(3) FIG. 2 is a perspective view of a brake rotor illustrating tension-compression vibrations associated with a tangential mode of the rotor;

(4) FIGS. 3A-3C are schematic views of a brake rotor illustrating three different tangential modes of the rotor;

(5) FIG. 4 is a perspective view of the rotor of FIGS. 3A-3C illustrating the tangential mode of FIG. 3B in greater detail;

(6) FIG. 5 is a schematic view of a conventional brake pad positioned on a rotor;

(7) FIG. 6 is a schematic view of an exemplary brake pad in accordance with the present disclosure positioned on a rotor;

(8) FIG. 7 is a perspective view of an exemplary disk braking system in accordance with the present disclosure;

(9) FIG. 8 is an exploded view of the disk braking system of FIG. 7 illustrating an exemplary embodiment of a brake pad assembly in accordance with the present disclosure;

(10) FIG. 9 is a graph illustrating brake noise associated with a conventional brake pad;

(11) FIG. 10 is a graph illustrating brake noise associated with a brake pad in accordance with the present disclosure having a 7 mm deep notch; and

(12) FIG. 11 is a graph illustrating brake noise associated with a brake pad in accordance with the present disclosure having a 10 mm deep notch.

(13) Although the following detailed description makes reference to illustrative embodiments, many alternatives, modifications, and variations thereof will be apparent to those skilled in the art. Accordingly, it is intended that the claimed subject matter be viewed broadly.

DESCRIPTION OF THE EMBODIMENTS

(14) Reference will now be made in detail to various embodiments, examples of which are illustrated in the accompanying drawings. The various exemplary embodiments are not intended to limit the disclosure. To the contrary, the disclosure is intended to cover alternatives, modifications, and equivalents.

(15) As above, during a braking event, the rotor and pads of a disk braking system, such as, for example, a system 50 as illustrated in FIG. 7, may experience both normal and tangential forces at their interface. Forces acting normal to the rotor and pad surfaces (i.e., normal forces) can induce bending or out-of-plane vibrations in the rotor and pad, which can be associated with rotor bending modes as illustrated, for example, in FIG. 1. Forces acting tangentially on the surfaces of the rotor (i.e., tangential forces) also may develop tension-compression vibrations within the rotor, which can be associated with rotor tangential modes (otherwise referred to as in-plane or circumferential modes) as illustrated, for example, in FIG. 2. These modes result in radiation of high frequency sounds from the brake system, otherwise referred to as squeal noise.

(16) In the audible frequency range (i.e., about 20 Hz to about 20 kHz) a typical disk brake rotor 1 (see FIGS. 3 and 4) has up to 20 pairs (sin and cosine) of the bending modes and 3 pairs (sin and cosine) of the tangential modes at distinct resonant frequencies. The three rotor tangential modes are illustrated, for example, in FIGS. 3A-3C. As above, while both bending and tangential rotor modes can be responsible for brake squeal noise generation, the bending modes contribution to squeal noise is already well studied and understood, resulting in a variety of effective countermeasures available when needed. For example, the length of lining material on the brake pads may be shortened to avoid modal alignment between the pad and rotor bending modes, which can promote the creation of system unstable modes. At the same time, however, the generation of squeal noises due to the rotor tangential modes often is not addressed. Various embodiments of the present disclosure, therefore, contemplate providing effective countermeasures against squeal noises produced by rotor tangential modes.

(17) In accordance with various embodiments, for example, the present disclosure contemplates a brake pad design that may reduce the energy input from the surface contact between the pad and rotor surfaces, which would otherwise excite rotor tangential modes, thereby eliminating any potential for brake squeal noise caused by such modes. FIG. 4, for example, is a perspective view of the rotor 1 of FIGS. 3A-3C illustrating the tangential mode of FIG. 3B in greater detail. As shown in FIG. 4, in the rotor tangential mode, points P on a diametric line D move in phase in the tangential (or circumferential) direction, wherein the absolute vibration amplitude increases along with the distance from the rotor axis A and has its maximum value at the outer diameter of the rotor 1. Thus, the easiest way to excite the rotor tangential mode is to excite the rotor at the outer diameter of the rotor in its circumferential direction.

(18) As illustrated in FIG. 5, when engaged with the rotor 1 (i.e., during a braking event), a conventional brake pad 10 generally covers the outer diameter of the rotor within an arc length L.sub.arc of the pad 10. Therefore, the pad 10 has a tendency to excite the rotor tangential modes via the surface contact between the pad 10 and the rotor 1 at the outer diameter of the rotor 1. Various embodiments of the present disclosure, therefore, propose a unique brake pad design that minimizes the surface contact between the pad and rotor at the outer diameter of the rotor 1.

(19) In accordance with various embodiments, for example, the present disclosure contemplates brake pads having a notch located along a section of an upper edge of the pad to reduce the surface contact between the pad and rotor at the outer diameter of the rotor. In other words, each of the exemplary brake pads described herein has a notch that is positioned along the arc length L.sub.arc of the pad, wherein the arc length L.sub.arc is configured to align with the outer diameter of the rotor when the pad is engaged with the rotor. The pad, therefore, does not cover the entire outer diameter of the rotor (i.e., with its arc length L.sub.arc), which functions to shift down the effective radius of the surface contact area (i.e., between the pad and rotor), thereby reducing the energy input from the rotor/pad interaction to prevent excitation of the rotor tangential modes.

(20) As described above, as used herein the terms rotor tangential modes or tangential modes of the rotor refer to the forces acting tangentially on the surfaces of a brake rotor (i.e., tangential forces), which develop tension-compression vibrations within the rotor as illustrated, for example, in FIG. 2. These modes are known to result in radiation of high frequency sounds from the brake system, otherwise referred to as squeal noise.

(21) FIG. 6 illustrates an exemplary embodiment of a brake pad 100 in accordance with the present disclosure. The brake pad 100 includes a body 102 having an upper edge 103, a lower edge 104, and a friction surface 105 extending between the upper and lower edges 103, 104. As above, when positioned within a braking system (see FIGS. 7 and 8) of a vehicle (not shown), the friction surface 105 is configured to engage a rotor, such as, for example, the rotor 1 to stop and/or slow the vehicle.

(22) In various embodiments, for example, brake pads in accordance with the present disclosure may comprise an assembly including a rigid backing structure and a friction material that is carried by the rigid backing structure. As illustrated in FIGS. 7 and 8, a brake pad assembly 200 may include a rigid backing structure 201, such as, for example, a metallic backing plate, and a friction material 202 that is carried by the rigid backing structure 201. The friction material 202 is made, for example, from a material and/or combination of materials which have a high coefficient of friction and which may also absorb and disperse large amounts of heat. In various embodiments, for example, the friction material 202 may include a non-asbestos organic, semi-metallic, and/or ceramic material.

(23) Those of ordinary skill in the art would understand, however, that brake pad assemblies in accordance with the present disclosure may include various types and/or configurations of backing structures and friction materials, which are formed from various materials, based on a particular braking application. Furthermore, brake pad assemblies in accordance with the present disclosure may include additional components and/or materials, including, for example, a shim (not shown) attached to an outer surface of the backing structure to help correct small differences (which may sometimes also lead to noise) between the backing structure and a caliper to which it is attached.

(24) As perhaps best shown in FIG. 8, in various exemplary embodiments, the friction material 202 is bound to a surface of the backing plate 201 to create a friction surface 205 that is configured to face the brake rotor 1 when positioned within the motor vehicle (not shown), and an opposite surface of the backing plate 201 is configured to be attached to a caliper 70 when positioned within the vehicle. In various embodiments, for example, two brake pads (i.e., assemblies 200) may be contained within the brake caliper 70 (i.e., positioned over a cheek portion of the rotor 1) with their friction surfaces 205 facing the rotor 1. In this manner, when the brakes are applied, the caliper 70 clamps or squeezes the two pads 200 together onto the spinning rotor 1 to slow and/or stop the vehicle.

(25) With reference again to FIG. 6, the body 102 of the pad 100 further includes a notch 106 that is located along a section of the upper edge 103 of the pad 100, such as, for example, a center section of the upper edge 103 as shown in FIG. 6. And, as above, the notch 106 is configured to reduce squeal noise caused by tangential modes of the rotor 1 during engagement of the pad 100 with the rotor 1. In other words, the notch 106 is positioned and sized, such that during engagement with the rotor 1, there is minimal contact between the friction surface 105 of the pad 100 and the rotor 1 at or near an outer diameter D.sub.out of the rotor 1 in a circumferential direction C. As above, for example, with reference to FIG. 4, the absolute vibration amplitude of the rotor 1 increases along with the distance from the rotor axis A with a maximum value at the outer diameter D.sub.out of the rotor 1. Accordingly, depending on the resonant frequency that may be created in the rotor 1, and the corresponding tangential mode related to that frequency (see FIGS. 3A-3C), various areas along the outer diameter D.sub.out of the rotor 1 may have potential for high modal displacement in a tangential direction of the rotor 1. Thus, in various embodiments, the notch 106 may be positioned and sized such that, during engagement with the rotor 1, the brake pad 100 does not cover the entire outer diameter D.sub.out of the rotor (i.e., with its arc length L.sub.arc), such that there is relatively no contact between the friction surface 105 and the rotor 1 at an area of the rotor 1 having a potential for high modal displacement in a tangential direction.

(26) In various embodiments, for example, the notch 106 is u-shaped, with an arc length L.sub.arc-notch and a depth d, and is centered along a midpoint of an arc length L.sub.arc of the brake pad 100. In this manner, when the brake pad 100 is engaged with the rotor 1, the brake pad will not cover the entire outer diameter D.sub.out of the rotor 1 along its arc length L.sub.arc, thereby shifting down the effective radius of the contact area between the friction surface 105 and the rotor 1. Although, to maximize squeal noise reduction, it may be considered optimal to shift down the effective radius of the contact area across the total arc length L.sub.arc of the pad 100 (and not just along a portion of the arc length L.sub.arc), it may not always be feasible to do so. For example, when in use, a surface corrosion layer may develop at the rotor surface not swept by the pad 100, which may impact the overall appearance of the brake rotor 1 and affect customer perception of the quality of the vehicle.

(27) Accordingly, in accordance with various embodiments, the arch length L.sub.arc-notch of the notch 106 does not exceed about 50% of the total arc length L.sub.arc of the pad 100. It is generally considered that such a configuration will ensure that there is enough remaining lining material to clean up surface corrosion layers that could develop when, for example, the vehicle is parked in humid conditions. Thus, in various exemplary embodiments, the arch length L.sub.arc-notch of the notch 106 is about to about the arc length L.sub.arc of the pad 100, and the depth d of the notch 106 is about to about of a height H of the pad 100. In other words, for brake pads most commonly used in the automotive industry, the arch length L.sub.arc-notch of the notch 106 is about 40 mm to about 80 mm, and the depth d of the notch 106 is about 8 mm to about 12 mm.

(28) The present disclosure, however, contemplates pads having any number, configuration (i.e., dimension and/or geometry), and/or shape of notches 106 based on a particular application. Those of ordinary skill in the art would understand, therefore, that the brake pad 100 illustrated in FIG. 6 is exemplary only and intended to illustrate one embodiment of the present disclosure. Accordingly, brake pads in accordance with the present disclosure may also have various dimensions, shapes, and/or configurations, without departing from the scope of the present disclosure and claims. Moreover, to further reduce brake squeal noise, brake pads in accordance with the present disclosure may also utilize other known methods and techniques in combination with the disclosed notch design. As illustrated in FIG. 8, various additional embodiments contemplate, for example, employing slots 208 and additional notches 210 in combination with a notch 206 (the disclosed notch design) in order to also address squeal noise caused, for example, by rotor bending modes (i.e., to address noise issues not caused by rotor tangential modes).

(29) A disk brake system utilizing a brake pad design in accordance with the present disclosure, similar to the brake pad 100 illustrated and described above with reference to FIG. 6, was modeled in Adams, a Multibody Dynamics (MBD) simulation software by MSC Software. A disk brake system utilizing a conventional brake pad design similar to the brake pad 10 illustrated in FIG. 5 was also modeled in Adams for comparison purposes. To verify the expected noise reduction capabilities of the brake pads and assemblies in accordance with the present disclosure, brake system testing was conducted on a brake NVH dynamometer using SAE J2521 test procedure. The test results are shown in FIGS. 9-11.

(30) FIGS. 9-11 are graphs respectively illustrating the rotor tangential mode at a frequency of 9.8 kHz for the conventional brake pad (with no notch), a brake pad having a 7 mm deep u-shaped notch, and a brake pad having a 10 mm deep u-shaped notch. As illustrated in FIG. 9, the squeal noise produced by the modeled conventional brake pad (via the rotor tangential mode) far exceeded the target established noise level. In other words, the conventional pad produced a maximum noise of about 88 decibels, which exceeded the target level (which would be considered acceptable to a driver of the vehicle) of 70 decibels as measured at the wheel end.

(31) As illustrated in FIG. 10, although the squeal noise produced by the modeled brake pad with a 7 mm notch (via the rotor tangential mode) still exceeded the target established noise level in two instances, the occurrences of squeal noises exceeding the target was greatly reduced.

(32) Finally, as illustrated in FIG. 11, the squeal noise produced by the modeled brake pad with a 10 mm notch (via the rotor tangential mode) was well below the target established noise level. In other words, the brake pad with the 10 mm notch produced a maximum noise of about 54 decibels, which was well below the target level of 70 decibels.

(33) It was, therefore, determined that the disclosed brake pad design can significantly reduce brake squeal noise associated with rotor tangential modes, and that when utilizing notches having depths greater than about 8 mm, such noises may be completely reduced to an acceptable level.

(34) The present disclosure further contemplates methods of reducing brake squeal noise from rotor tangential modes, such as, for example, by using the brake pads 100 described above with reference to FIG. 6. In accordance with various exemplary embodiments, to reduce brake squeal noise from rotor tangential modes, a portion of the brake pad 100 may be removed along a section of an upper edge 103 of the pad 100. As above, in accordance with various embodiments, the removed portion may be positioned and sized to prevent contact between a friction surface 105 of the pad 100 and a rotor 1, during engagement of the friction surface 105 with the rotor 1, at an area of the rotor 1 having a potential for high modal displacement in a tangential direction.

(35) As above, with reference to FIG. 4, the absolute vibration amplitude of the rotor 1 increases along with the distance from the rotor axis A, with a maximum value at the outer diameter D.sub.out of the rotor 1. Accordingly, depending on the resonant frequency that may be created in the rotor 1, and the corresponding tangential mode related to that frequency (see FIGS. 3A-3C), various areas along the outer diameter D.sub.out of the rotor 1 may have potential for high modal displacement in a tangential direction of the rotor 1. Thus, as above, the removed portion may be positioned and sized such that, during engagement with the rotor 1, the brake pad 100 does not cover the entire outer diameter D.sub.out of the rotor (i.e., with its arc length L.sub.arc), such that there is relatively no contact between the friction surface 105 and the rotor 1 at such areas. In other words, the removed portion may be positioned and sized to minimize contact between the friction surface 105 of the pad 100 and the rotor 1 at or near the outer diameter D.sub.out of the rotor 1 in a circumferential direction.

(36) In various embodiments, for example, the removed portion may include a u-shaped portion, such as, for example, a u-shaped notch 106 that is located along a center section of the upper edge 103 of the pad 100. The notch 106 may have an arc length L.sub.arc-notch and a depth d, and be centered along a midpoint of an arc length L.sub.arc of the brake pad 100. In this manner, when the brake pad 100 is engaged with the rotor 1, the brake pad will not cover the entire outer diameter D.sub.out of the rotor 1 along its arc length L.sub.arc, thereby shifting down the effective radius of the contact area between the friction surface 105 and the rotor 1. In various embodiments, for example, the arch length L.sub.arc-notch of the notch 106 is about to about the arc length L.sub.arc of the pad 100, and the depth d of the notch 106 is about to about of a height H of the pad 100. In other words, for brake pads most commonly used in the automotive industry, the arch length L.sub.arc-notch of the notch 106 is about 40 mm to about 80 mm, and the depth d of the notch 106 is about 8 mm to about 12 mm.

(37) As above, however, the present disclosure contemplates pads having any number, configuration (i.e., dimension and/or geometry), and/or shape of notches 106 based on a particular application.

(38) While the present disclosure has been disclosed in terms of exemplary embodiments in order to facilitate better understanding of the disclosure, it should be appreciated that the disclosure can be embodied in various ways without departing from the principle of the disclosure. Therefore, the disclosure should be understood to include all possible embodiments which can be embodied without departing from the principle of the disclosure set out in the appended claims. Furthermore, although the present disclosure has been discussed with relation to automotive vehicles, those of ordinary skill in the art would understand that the present teachings as disclosed would work equally well for any type of vehicle having a braking system that utilizes pads and rotors.

(39) For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing quantities, percentages or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term about. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the written description and claims are approximations that may vary depending upon the desired properties sought to be obtained by the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

(40) It is noted that, as used in this specification and the appended claims, the singular forms a, an, and the, include plural referents unless expressly and unequivocally limited to one referent. Thus, for example, reference to a sensor includes two or more different sensors. As used herein, the term include and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.

(41) It will be apparent to those skilled in the art that various modifications and variations can be made to the system and method of the present disclosure without departing from the scope its teachings. Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the teachings disclosed herein. It is intended that the specification and embodiment described herein be considered as exemplary only.