Abstract: Brake pads are prepared using a formulation of friction material of the copper-free type (Low-Steel or Organic Non-Asbestos) and at least one friction surface of a brake disc, which is intended to cooperate with the brake pad, is covered with an anti-wear and anti-corrosion coating consisting of a surface layer of chromium carbide particles (Cr3C2) dispersed in a metallic matrix consisting of a NiCr alloy, and coupled to a second layer consisting of selected combinations of metallic materials, chosen from the group consisting of: Cr3C2-high density NiCr, NiAl alloys, FeNiCrMoSiC alloys, metallic nickel, NiCr alloys, and/or any combination of the above.

Abstract: Methods and equipment for determining conditions of adhesion between a first and a second mechanical element are disclosed. The mechanical elements are attached respectively to a first and second support, which are immersed in an electrolyte together with a counter-electrode and a reference electrode to form an electrochemical cell. The second mechanical element is a working electrode being connected to an insulated electric wire that is also connected to the counter-electrode. A first uncovered face of the second element is pressed against the first element. A potential is applied to the second element of at least one predetermined value and/or a predetermined electrical current. The method can include detecting the electrical current that is transmitted through the electrolyte as a function of the potential applied and/or the potential that is established as a function of the predetermined current.

Abstract: A method and system for powder coating non electrically conductive elements, preferably brake pads. A pre-treatment station is upstream of an electrostatic powder coating deposition station and a baking station for melting and polymerizing the powder coating in order to form a coating layer on a surface to be coated. The pre-treatment station causes the elements to be coated to conduct electrically by uniformly wetting said elements by means of creating poorly mineralized water covalent bonds on at least one surface to be coated, in an amount aimed at producing a measurable weight increase in the non electrically conductive elements, which then causes them to conduct electrically. The water adsorbed and/or deposited is subsequently eliminated within the baking station.

Abstract: Method for creating a brake pad with a block of friction material, in which sodium hydroxide and sodium silicate are dissolved in water, the aqueous solution of sodium hydroxide and sodium silicate is mixed with commercial metakaolin until a wet paste is obtained, the wet paste is formed and dried until a dried geopolymeric aggregate is obtained, the aggregate is ground to a powder, the dried ground aggregate is used as an exclusive or almost-exclusive inorganic geopolymeric binder in a friction material compound and the raw compound is hot-molded under a pressure greater than a water saturation pressure at the molding temperature.

Abstract: Various machines, systems, and methods for generating calibration data for a sensorized brake pad are disclosed. In some embodiments, a system includes a fixture, a brake pad retainer, a pressure plate, an actuator and a controller. The actuator applies a pressure to the sensorized brake pad and signals from the pressure sensors are received. Calibration data is generated based on the signals received from the pressures sensors when the pressure is applied to the sensorized brake pad.

Abstract: A geopolymeric ink formulation for direct 3D printing containing a geopolymeric formulation whose components are present in such proportions as to be subjected to a geopolymerization reaction and to provide, at the end of the reaction, a solid geopolymer and wherein the formulation, before and during at least a part of the geopolymerization reaction, wherein three-dimensional chemical bonds have not yet been formed, forms a reversible-gel, non-Newtonian, viscoelastic fluid. The formulation is extruded through a 3D printing tool equipped with nozzle into strands according to a geometry such as to create a three-dimensional structure on one or more layers. The extrusion preferably takes place within a hydrophobic liquid, such as oil.

Abstract: Various systems, devices, and methods for detecting and/or responding to the temperature of brakes are disclosed. Certain embodiments relate to inhibiting or preventing the overheating of the brakes of such vehicles, such as could occur when a hot runner condition is present.

Abstract: Various brake pads with thermoelectric energy harvesters are disclosed. In some embodiments, the brake pad comprising a backplate, a pad of friction material, and a TEG module. The backplate can comprise a through-hole in which elements of the TEG module are positioned.

Abstract: Various braking devices, systems, and methods are disclosed. In some embodiments, the braking device includes a support element, a block of friction material supported by the support element, at least one piezoceramic sensor supported by the support element and interposed between the block of friction material (and the support element, and a protective element located at the piezoceramic sensor and embedding the latter. The protective element can have one or more layers of resin-based material applied to protect the piezoceramic sensor and direct a predetermined part of the external compression force onto an area of the support element surrounding the piezoceramic sensor. In some embodiments, a signal transduction device is provided and includes at least one piezoceramic sensor supported on a support element and has an integral protective coating having properties of mechanical and temperature resistance.

Abstract: A vehicle braking unit comprising a support designed to be positioned in use close to an element to be braked, braking elements which are carried in a movable way by the support, actuation elements which are carried by the support for pushing the braking elements against the element to be braked and first and second guide surfaces that are integral, respectively, to the braking elements and to the support, and that cooperate together to guide and support the braking elements when they are moved towards the element to be braked by the activation of the actuation elements; the first and/or the second guide surfaces are covered by a sliding coating consisting of a polymeric resin layer with solid lubricants and/or anti-friction materials being dispersed therein, that has been cured at a temperature greater than 300° C.

Abstract: A metallic support of a brake pad delimited between a first and a second face, and having a perimeter edge substantially perpendicular to the first and second faces. The first face receives a block or layer of friction material, and the second face receives a dampening element. The first face has at least one projecting part extending cantilevered spaced apart from the perimeter edge so as to be completely embedded within the block or layer of friction material. The at least one projecting part is delimited at the top by a first surface upon which there is at least one first cavity filled with the block or layer of friction material. The second face has at least one second cavity forged as the at least one projecting part. At the at least one first cavity, there is at least one first relief shaped as the at least one first cavity.

Abstract: Various braking devices, systems, and methods are disclosed. In some embodiments, the braking device includes a support element, a block of friction material supported by the support element, at least one piezoceramic sensor supported by the support element and interposed between the block of friction material (and the support element, and a protective element located at the piezoceramic sensor and embedding the latter. The protective element can have one or more layers of resin-based material applied to protect the piezoceramic sensor and direct a predetermined part of the external compression force onto an area of the support element surrounding the piezoceramic sensor. In some embodiments, a signal transduction device is provided and includes at least one piezoceramic sensor supported on a support element and has an integral protective coating having properties of mechanical and temperature resistance.

Abstract: A method in which at least one piezoceramic sensor, which converts every mechanical force to which it is subjected into an electrical signal and having a Curie temperature higher than 200° C., is solidarized directly onto the surface of a metal support element of a vehicle braking element, which during use faces a vehicle element to be braked. While in contact with such a surface, an electrical circuit is implemented that picks up and eventually processes the electrical signal, the electrical circuit being connected with a connector integrated with the metal support element. An electrically insulating layer sandwiches the at least one piezoceramic sensor and the electrical circuit, and a block of friction material with an underlying damping layer is formed upon the electrically insulating layer. After forming the block of friction material, the piezoceramic sensor is polarized by applying a predetermined potential difference thereto by means of the connector.

Abstract: A method for the production of braking elements for vehicles, in particular brake pads, includes a die forming step by means of fine and/or traditional shearing of a metal support and a molding step upon the metal support of a block of friction material. The friction material is selected from the group of asbestos free materials, while the metal plate is made of an aluminum alloy selected from the group consisting of aluminum alloys subjected to precipitation hardening (age-hardening alloys) and is made from the fine and/or traditional shearing of a metal sheet when the alloy is in a solubilized state. The alloy is not age hardened until a friction material baking step in order to gain the mechanical properties needed for its operation.

Abstract: Methods, devices, and systems, for analyzing and managing data generated by a sensor-equipped braking system for vehicles, comprising a support element a block of friction material, at least one sensor interposed between the block of friction material and the support element, comprising at least one central control unit capable of receiving in real time from the sensor means at least the basic data related to one or more of the pressure of the activated braking system, the temperature of the activated braking system, the braking torque, the residual braking torque when the braking system is deactivated, and the wear on the braking system during and after activation thereof. The system can also include one or more auxiliary sensors.

Abstract: Various residual braking torque indication devices, systems, and methods are described. The devices, systems, and methods can include a sensorized brake pad. An output signal of the sensorized brake pad can be processed to provide an indication of a residual braking torque. The residual braking torque indicator can be calibrated to reference data to provide an actual measurement of the residual braking torque.

Abstract: Various braking devices, systems, and methods are disclosed. In some embodiments, the braking device includes a support element, a block of friction material supported by the support element, at least one piezoceramic sensor supported by the support element and interposed between the block of friction material (and the support element, and a protective element located at the piezoceramic sensor and embedding the latter. The protective element can have one or more layers of resin-based material applied to protect the piezoceramic sensor and direct a predetermined part of the external compression force onto an area of the support element surrounding the piezoceramic sensor. In some embodiments, a signal transduction device is provided and includes at least one piezoceramic sensor supported on a support element and has an integral protective coating having properties of mechanical and temperature resistance.

Abstract: Various systems, devices, and methods for detecting and/or responding to the temperature of brakes are disclosed. Certain embodiments relate to inhibiting or preventing the overheating of the brakes of such vehicles, such as could occur when a hot runner condition is present.

Abstract: Various antilock braking systems, devices, and methods using sensorized brake pads are disclosed. In some embodiments, the present disclosure provides a method for improving the performance of an antilock braking (ABS) and anti-slip regulation (ASR) system of a vehicle. The method can include detecting the actual value of the coefficient of friction (e.g., between a tire and the ground), updating the coefficient of friction during braking using the braking torque data derived from at least one braking pad of each wheel, and adjusting brake force. For example, the brake force can be adjusted as a function of and/or to be approximately equal to the value of the actual tire-road friction during braking.

Abstract: Various braking devices, systems, and methods are disclosed. In some embodiments, the braking device includes a support element, a block of friction material supported by the support element, at least one piezoceramic sensor supported by the support element and interposed between the block of friction material (and the support element, and a protective element located at the piezoceramic sensor and embedding the latter. The protective element can have one or more layers of resin-based material applied to protect the piezoceramic sensor and direct a predetermined part of the external compression force onto an area of the support element surrounding the piezoceramic sensor. In some embodiments, a signal transduction device is provided and includes at least one piezoceramic sensor supported on a support element and has an integral protective coating having properties of mechanical and temperature resistance.