Abstract: A light-weight, sound-damped, composite brake rotor for a vehicle braking system includes a rotor hat and an annular rotor cheek supported by, and cast around, the rotor hat. The rotor hat includes an axially-protruding central hub and an integral flange that extends radially from and circumferentially around the central hub. The rotor cheek includes a top ledge and a bottom ledge that overly a top annular surface and a bottom annular surface, respectively, of the integral flange. An annular interfacial boundary present between an underside of the top and/or bottom ledges and their respective adjacent annular surfaces of the integral flange includes a vibration damping interface. The brake rotor derives its vibration-deadening and sound-damping effects from the vibration damping interface through the occurrence of relative frictional contacting movement.

Abstract: One or more layers of vibration damping material are placed on one or more selected surface regions of a body portion of a vibratile metal article. The layer of damping material is covered with a thin metal sheet. The selected surface may be recessed in the body portion to receive the damping material. The covering sheet may be formed of the same metal composition as body portion, or of a compatible metal composition. The peripheral edges of the covering sheet are ultrasonically welded to the surface of the article body portion to confine the damping material against the selected surface(s) so that the damping material forms a vibration damping interface(s) with the surface(s) of the article. The damping material may function as a coulomb damping material, or a viscous damping material, or both.

Abstract: Various embodiments of the invention include products and parts including a frictional damping means and methods of making and using the same.

Abstract: An exemplary embodiment of a brake caliper has a housing with a first chamber and a second chamber. The brake caliper also has a first piston that moves in response to fluid pressure in the first chamber and has a second piston that moves in response to fluid pressure in the second chamber. A brake pad has a leading end portion that is acted upon by the first piston and has a trailing end portion that is acted upon by the second piston. A fluid passage leads to the first chamber. The trailing end portion contacts an associated rotor before the leading end portion contacts the rotor.

Abstract: A brake rotor providing reduced brake pad radial taper wear by providing brake rotor friction surface indent patterns. For example, the indent patterns are the form of radial-biased grooves or linearly arranged cross-drill hole sets, patterned in a configuration that balances brake pad wear, thereby reducing brake pad radial taper wear in a manner tuned specifically for a given type of brake caliper and brake pad material, wherein the reduction in brake pad radial taper wear is accomplished with virtually no penalty to brake pad life.

Abstract: A brake assembly includes a brake pad, a bracket supporting the brake pad and having a first portion, a second portion spaced apart from the first portion, and a linkage interconnecting the first and second portions. The linkage is configured to transfer tensile loads between the first and second portion, but is characterized by the absence of any bending modes. The absence of bending modes prevents excitation of the linkage, thereby reducing sound generated during application of the brake assembly.

Abstract: The invention provides a method for manufacturing a friction damped disc brake rotor, including the steps of: (A) providing a ceramic coating on an insert, wherein the insert has a body with tabs extending therefrom to hold the insert in a desired position within a mold; (B) washing the ceramic coating off of the tabs; (C) positioning the insert into the mold; and (D) casting a rotor cheek of the disc brake rotor in the mold around the insert such that a portion of each tab is bonded with the rotor cheek, and such that the coating is substantially non-bonded with the rotor cheek so that the coating provides a proper interfacial boundary between the body and the cheek for damping, and the at least partial bonding of each tab with the rotor cheek prevents corrosion-causing exterior elements from reaching the interfacial boundary when the friction damped disc brake rotor is in use.

Abstract: A brake system is provided for minimizing brake pulsation feedback caused by surface variations of a brake system corner component. The brake system includes at least one sensing device configured to measure a pressure pulse caused by the surface variation of a brake system corner component. A controller module is in communication with the at least one sensing device and a hydraulic brake circuit. The controller module is configured to receive an output from the at least one sensing device and to adjust line pressure in the hydraulic brake circuit to substantially minimize brake pulsation feedback.

Abstract: A Coulomb friction damped disc brake rotor, wherein damping is provided Coulomb friction in generally coextensive relation with the braking surfaces of the one or more rotor cheeks. The Coulomb friction damped disc brake rotor has at least one interfacial boundary formed in at least one rotor cheek disposed in generally coextensive relation to the braking surface thereof. The interfacial boundary provides a mechanically distinguishable surface boundary between two surfaces which are in mutual contact such that a state of Coulomb friction exists therebetween.

Abstract: A Coulomb friction damped disc brake caliper bracket, wherein damping is provided by Coulomb friction, most preferably at the outboard tie-bar thereof, by a Coulomb bar peripherally welded thereto. An inner surface of the Coulomb friction bar is in abutting contact with the external surface of the tie-bar, whereby because of the continuous peripheral edge welding, corrosion cannot find entry into the interface of the two surfaces, yet the two surfaces form are free to vibrate one as to the other in Coulomb friction fashion to thereby provide damping and reduction of brake squeal and other noise.

Abstract: The invention provides a method for manufacturing a friction damped disc brake rotor, including the steps of: (A) providing a ceramic coating on an insert, wherein the insert has a body with tabs extending therefrom to hold the insert in a desired position within a mold; (B) washing the ceramic coating off of the tabs; (C) positioning the insert into the mold; and (D) casting a rotor cheek of the disc brake rotor in the mold around the insert such that a portion of each tab is bonded with the rotor cheek, and such that the coating is substantially non-bonded with the rotor cheek so that the coating provides a proper interfacial boundary between the body and the cheek for damping, and the at least partial bonding of each tab with the rotor cheek prevents corrosion-causing exterior elements from reaching the interfacial boundary when the friction damped disc brake rotor is in use.

Abstract: A tilted vane brake rotor. The tilted vanes are tilted in the sense of being oriented with respect to the inside disc surfaces at other than 90 degrees, defined by an acute intersection angle with respect to either of the inside disc surfaces. The tilted vanes may be, for example, paired and oriented serially around the circumference of the rotor discs so as to provide a series of vane pairs in the form of: a series of alternately inverted V-shapes, a series of same oriented V-shapes, or a series of X-shapes.

Abstract: An exemplary embodiment of a brake caliper has a housing with a first chamber and a second chamber. The brake caliper also has a first piston that moves in response to fluid pressure in the first chamber and has a second piston that moves in response to fluid pressure in the second chamber. A brake pad has a leading end portion that is acted upon by the first piston and has a trailing end portion that is acted upon by the second piston. A fluid passage leads to the first chamber. The trailing end portion contacts an associated rotor before the leading end portion contacts the rotor.

Abstract: An exemplary embodiment includes an automotive brake component, such as a brake drum or a brake rotor, and an inlay coupled to the automotive brake component. The inlay constituting at least a portion of a braking surface that is acted upon during a braking event. The inlay damping vibrations in the automotive brake component when the component is vibrated.

Abstract: A method for providing an estimate of brake pad thickness. The method employs fusion of sensors, if used, and driver brake modeling to predict the vehicle brake pad life. An algorithm is employed that uses various inputs, such as brake pad friction material properties, brake pad cooling rate, brake temperature, vehicle mass, road grade, weight distribution, brake pressure, brake energy, braking power, etc. to provide the estimation. The method calculates brake work using total work minus losses, such as aerodynamic drag resistance, engine braking and/or braking power as braking torque times velocity divided by rolling resistance to determine the brake rotor and lining temperature. The method then uses the brake temperature to determine the brake pad wear, where the wear is accumulated for each braking event. A brake pad sensor can be included to provide one or more indications of brake pad thickness from which the estimation can be revised.

Abstract: A friction damped brake drum for reducing vibrations in a brake drum.

Abstract: The invention provides a method for manufacturing a powertrain component enclosure member, including the steps of: (A) positioning at least one insert into a mold, wherein the insert is provided with a coating to prevent bonding between the insert and the casting material; and (B) casting a wall of the powertrain component enclosure member in the mold around the insert such that a major portion of the insert is substantially non-bonded with the casting material to provide a proper interfacial boundary with the casting material for damping.

Abstract: A brake rotor providing reduced brake pad radial taper wear by providing brake rotor friction surface indent patterns. For example, the indent patterns are the form of radial-biased grooves or linearly arranged cross-drill hole sets, patterned in a configuration that balances brake pad wear, thereby reducing brake pad radial taper wear in a manner tuned specifically for a given type of brake caliper and brake pad material, wherein the reduction in brake pad radial taper wear is accomplished with virtually no penalty to brake pad life.

Abstract: A Coulomb friction damped disc brake caliper bracket, wherein damping is provided by Coulomb friction, most preferably at the outboard tie-bar thereof. In one form, at least one clamping member applies compressive force externally to the caliper bracket, and in a second form, at least one interfacial boundary is internally disposed in the caliper bracket. Provided thereby is a mechanically distinguishable surface boundary between two surfaces which are in mutual contact such that a state of Coulomb friction exists therebetween.

Abstract: A method of brake noise suppression via brake system pressure modulation is disclosed that includes detecting a brake apply and modulating a brake system pressure to disrupt formation of a friction instability upon detection of the brake apply. The brake system pressure can be modulated at each brake apply detected, only when the brake apply detected is of a brake apply type that is indicative of brake noise, or when the system actually detects brake noise. Further, the system can determine whether a brake apply is associated with a noise-inducing friction instability; and modulate the brake system pressure to disrupt formation of the noise-inducting friction instability by hindering development of the limit cycle associated with the noise-inducing friction instability.