NuPad Brake Pads- safer, cheaper, cleaner, quieter, longer lasting, lighter

At some angle, speed, force and friction, sliding objects harmonically vibrate or judder such as chalk screeching on a blackboard, chair legs juddering  on a floor, a wine glass ‘singing’, or brakes squealing.


Brake noise… continues to be the single largest brake warranty item, even after many hundreds of hours are spent on both brake dynamometer and vehicle to eliminate brake noises for each new vehicle…”


What’s the cause? “In the last few decades, there have been extensive studies …done by many researchers around the world… Despite these efforts, still no general solution exists.” 


One common no-solution, is chamfering, that reduces friction area which reduces brake performance and safety (from being too small), increases brake wear (from reduced pad volume) while releasing more toxic brake dust (from faster wear). Chamfering also results in brakes too big and heavy for what is functionally a smaller pad. Unneeded weight reduces EV range, fuel economy, performance, and handling.


Brake noise/squeal results from the ± manufacturing tolerances that all brake components are subject to:  

‍    •caliper: piston, cylinder, slide-pins and holes, and attachment bosses and holes; 

‍    • brake pad backing plate: imperfect flatness;

‍    • disc: axle-hub disc flange face and bearing bores;

‍    • vehicle: cast/machined caliper mounting bracket: lugs, bosses and bolt holes;

‍    • the jigs, fixtures, and tooling used in manufacture, and their changing condition with use;

‍    • and final brake and vehicle condition at installation, damage, burrs and defects. 


Once assembled and installed, all these small individual ± tolerances randomly combine so that the piston, is always slightly non-perpendicular to the disc and therefore the pad always makes random perimeter contact with the disc, sometimes inline with disc rotation. When the piston forces the slightly tilted pad flat against the disc, the piston itself must also tilt to remain flat against backing plate. This requires flexing the rigid caliper which continually springs back creating a high frequency juddering squeal.


The solution?, NuPad. 


NuPad has a very slightly raised friction centre (Fig 1) that contacts the disc while the pad is at the the piston angle and wears flat immediately flat to the angle of the disc. This eliminates caliper flex judder and squeal.  


With no chamfers NuPads are safer, make less dust, are cheaper, quieter, longer lasting, and lighter.

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In addition, NuPad is a ‘no-cost’ solution. On a standard brake grinder two slightly angled flats, or facets, are ground from the pad centre to each end at about a 0.1 degree / 0.010” / 0.2 mm slope, to create the required imperceptibly higher contact centre. It can be done in one pass using two angled grinding wheels (pat pend). A four faceted shallow pyramid face and other raised centre geometries can also work.


Methods have been devised to validate these hypotheses.


The NuPad recent patent application is for sale with world coverage available.

Get first-to-market advantage, rights to sub-license and decades of huge earnings from a small capital outlay.


Contact: Winston MacKelvie, Inventor, (*90 IPs). 

winstonworks@me.com Tel 1-450-243-6850 Txt 1-450-330-4293 

www.inventure.ca/NuPad







Some Background


“Brake noise, even for vehicle manufacturers, continues to be the single largest brake warranty item, even after many hundreds of hours are spent on both brake dynamometer and vehicle to eliminate brake noises for each new vehicle platform,” observes Bob Peters chief engineer, friction material engineering with Akebono Brake Corporation. “The fact is that brake noise is nearly impossible to simulate on the computer and, consequently, most noise mitigation work is done on actual parts, using both special noise dynamometers and on the vehicle. This is expensive and time-consuming.” [and unsuccessful]

‍    https://thebrakereport.com/aftermarket-search-quieter-brake/ 

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Inventor’s early rough R&D; Easily reproducible


A.  New, painted white and installed. 

B. After a few brakings. Wear way off-centre - a recipe for judder-squeal NHV.

C.  Same pad made into a NuPad, repainted used, showing flat centred wear.

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Quotes:

“In the last few decades, there have been extensive studies on analysis and investigation of disc brake vibrations done by many researchers around the world on the possibility of eliminating brake vibration to improve vehicle users' comfort. Despite these efforts, still no general solution exists.”

‍    https://www.researchgate.netpublication258725751


“Friction-induced vibration and noise emanating from car disc brakes is a source of considerable discomfort and leads to customer dissatisfaction. The high frequency noise above 1 kHz, known as squeal, is very annoying  and very difficult to eliminate.” 

‍    https://www.researchgate.net/publication/258994745_Recent_Studies_of_Car_disc_Brake_Squeal

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“New Jersey lawsuit claims genuine Audi replacement brake pads and rotors are defective on Q7 model.

Audi Q7 squeaky brakes have caused a class-action lawsuit filed for all New Jersey  citizens who had brakes installed by Audi dealers between July 19, 2012, to the  present.”

‍    Media News  

‍ 

“In the last few decades, there have been extensive studies on analysis and investigation of disc brake vibrations done by many researchers around the world on the possibility of eliminating brake vibration to improve vehicle users' comfort. Despite these efforts, still no general solution exists.”  

www.researchgate.netpublication258725751 


“…. I hate brake squeal, I actually have an existing noise on my truck, tried 2 sets of different pads and rotors front and back and still can’t get rid of the noise!”

‍    J. Dutton, Florida, Auto parts sales