Pre Finish Metals, Incorporated

Material Sciences Corporation

Edward J Vydra

Richard Mark Hansen

Scott R Dobrusky

Michael R Loth

Mark R Monterastelli

Gregory Pardus

Timothy Alan Brinner

James A Rogers

Ronald L Millar

Thomas E Moore

A noise-damping composite is formed by providing a laminate of two metal layers separated by a much thinner viscoelastic layer which has an initial thickness of at least 1 mil., and then cold rolling the laminate to proportionally permanently reduce the thickness of each layer, until the thickness of the viscoelastic layer is less than 1 mil. and preferably less than 0.5 mil. The cold rolling may be through a set of adjustable rollers, and may be done in multiple passes with the rollers adjusted for each pass to further reduce the thickness. Alternatively, the laminate may be fed successively through a series of roller sets designed to successively reduce the thickness of the laminate.

Method of forming noise-damping material with ultra-thin viscoelastic layer

An apparatus and a method for bonding a laminate formed of at least two layers of sheet material superimposed on one another with adhesive therebetween and moved along a path. The apparatus includes a first laminator having an upper plate assembly having a first low-friction laminate-contacting surface for contacting a first layer of the laminate, and an upper heat exchanger thermally coupled to the upper plate assembly. The first laminator also includes a lower plate assembly having a second low-friction laminate-contacting surface for contacting a second layer of the laminate, wherein the first and second laminate-contacting surfaces are disposed in opposed relationship for accommodating passage of the layers of the laminate therebetween, and a lower heat exchanger thermally coupled to the lower plate assembly. The first laminator further includes a drive member coupled to at least one of the laminate-contacting surfaces for varying the distance between the surfaces to apply pressure to the layers of the laminate. The apparatus may also include a second laminator downstream of the first laminator and substantially identical to the first laminator. The heat exchangers of the first and second laminators can both be used for heating or cooling, or one for cooling and one for heating, depending upon the application.

Method and apparatus for forming a laminate

A noise damping composite includes a viscoelastic layer disposed between a pair of constraining metal layers, the viscoelastic layer including a pattern of adjacent stripes of different viscoelastic materials. Stripes of two or three different materials are disclosed. The viscoelastic layer can be applied in either liquid or solid form. In the former, it may be provided with mica platelets distributed throughout the layer.

Patterned noise damping composite

A noise-damping composite is formed by providing a sandwich of a viscoelastic layer between two metal skins, the viscoelastic layer including electrically conductive particles distributed therein. The sandwich is passed through a series of cells of an electro-galvanizing line, in each cell the sandwich passing through the nip formed between a charged electrically conductive contact roller and an electrically insulating pressure roller for applying sufficient pressure to insure conductivity from the metal skin engaging the contact roller through the viscoelastic layer to the other metal skin, so that the galvanizing metal is plated on only the outer surfaces of the two metal skins.

Method of forming noise-damping composite with externally galvanized

A disk brake pad assembly includes a rigid metal backing plate, a brake friction lining pad and a damping structure including a viscoelastic material disposed between the backing plate and the friction lining pad and fixed to each. In one embodiment the damping structure is a perforated metal plate having perforations filled with viscoelastic damping material. The damping plate may be provided along its opposite sides with constraining layers. Such a perforated damping structure may be disposed on either side of the backing plate.

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Northbrook, IL, United States of America

Edward J Vydra