ELIMINATING EXPENSIVE BRAKE SQUEAL with NuPad

All stiff ‘sliding’ objects will, at some slight, unpredictable angle, squeal, like chalk on a blackboard or neverending brake squeal. 

All pads and discs are always at some slight directed angle due to the unpredictable stacking of each component’s dimensional tolerance, such as between: 

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

‍ • pad backing plates: imperfect flatness;

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

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

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

‍ • final brake and vehicle condition at installation, damage, burrs, defects, and bolt torques;

In some brakes, the stack-angle is the squeal angle. As a result OEM’s must ‘fix’ many thousands of otherwise perfect brakes, under warranty, at great expense. “NuPad” is the no-cost final fix for squeal. 


‍      “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…”

‍        “In the last few decades, there have been extensive studies [of squeal] …done by many researchers around the world…Despite these efforts, still no general solution exists.”


One traditional no-fix for squeal is friction chamfering that reduces safety (smaller contact area), increases pad wear (reduced friction volume), and increases toxic brake dust (from faster wear), and 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 shims are another no-fix (8 per car), that cost OEM’s more millions. 


The right fix for squeal is NuPad with its very slightly raised centre (Fig 1) which contacts the disc first while the pad’s steel plate is forced flat against the caliper piston face. The pad centre then immediately wears flat to Its unique stacking angle thereby eliminating brake squeal and OEM warranty costs.


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. One way with a standard brake grinder is to finish the pad with two slightly angled flats, or facets, from the pad centre to each end at about a 0.1 degree / 0.010” / 0.2 mm slope. This creates 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 rounded, raised centre geometries can also work. The centre can also have a ‘pimple’ form for fast break-in.


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

‍ 

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 rounded, raised centre geometries can also work.


A method has been devised to validate this hypothesis.


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

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/ 

‍ 

Inventor’s early rough R&D; Easily reproducible


A.  Machined flat, painted white and installed. 

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

C.  NuPad, repainted used, showing flat centred wear after just a few stops.

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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.”

“BMW was hit this week with a class action lawsuit over excessive brake squeal. In July, we reported that a similar law suit against Audi was settled.” The Brake Report Aug 8 2021

‍ 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