Method for manufacturing a braking element with integrated sensor, in particular a brake pad, brake pad with integrated sensor, vehicle braking system and associated method

摘要

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.

主权项

1. A method for manufacturing sensorized brake elements for vehicles, comprising the steps of:
a) making at least one piezoceramic sensor integral directly with and onto a first surface of a metal support element of a braking element which is intended during use to be directed towards a vehicle element to be braked, the at least one piezoceramic sensor being able to convert mechanical energy received in a polarization direction of the at least one sensor, when subjected to a mechanical force, into electrical energy for emitting an electrical signal due to piezoelectric effect, the at least one sensor being selected from a group of piezoceramic sensors still operational at working temperatures at least equal to or greater than 200° C. and free from polymeric active components; b) providing an electrical circuit which is in contact with said first surface, to pick up said electrical signal and possibly processing the electrical signal and connecting said electrical circuit with a connector made integral with said metal support element; c) providing an electrically insulating layer, which is one of continuous or discontinuous, on the first surface so as to sandwich the at least said one piezoceramic sensor and said electrical circuit between the first surface and the electrically insulating layer, so as to embed them within said electrically insulating layer; d) providing a dampening and thermally insulating layer directly onto said electrically insulating layer and on the first surface so that the at least one piezoceramic sensor is directly and completely embedded within the dampening and thermally insulating layer with the interposition of the electrically insulating layer; and e) forming a block of friction material upon the dampening and thermally insulating layer, said block being held stiff by the metal support element.