Metal and graphite laminate

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 pierce the graphite foil material. In one embodiment, the first lamina has no perforations and is uniformly smooth. In another embodiment, the second surface also has a plurality of piercing structures and a third lamina comprising graphite foil is mated to the second surface.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a U.S. continuation application under 35 U.S.C. §111(a) claiming priority under 35 U.S.C. §§120 and 365(c) to International Application No. PCT / CA2014 / 000579, filed Jul. 21, 2014, which claims the priority benefit of Canadian Patent Application No. 2,821,897, filed Jul. 26, 2013, the contents of which are incorporated by reference herein in their entirety for all intended purposes.FIELD OF THE INVENTION[0002]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[0003]There is a growing need for lighter, stiffer, cheaper structural materials, preferably with all three qualities, with which to make better products.[0004]Stainless steel laminated with graphite foil is a widely used material that has properties that make it suitable for many purposes,...

AI Technical Summary

Benefits of technology

The invention is about a special sheet material that has a hard layer with raised structures on its surface. These structures are made by piercing the surface of a graphite foil material that is mated to the hard layer. The resulting material has a unique texture and can be used as a noise damping shim in brairng systems. The technical effect of this invention is the creation of a special sheet material that has a unique texture and can be used as a noise damping shim in brabraking systems.

Problems solved by technology

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.

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.

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.

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