Metal and graphite laminate

Abstract

The present invention is a laminate sheet having two laminae. The first lamina is a relatively hard material having first and second surfaces. The first surface has a plurality of raised and generally pointed piercing structures, each structure having a tip. The second lamina is graphite foil material, which is mated to the relatively hard material, such that at least some of the piercing structures pierce the graphite foil material. In one embodiment, the first lamina has no perforations and is uniformly smooth. In another embodiment, the second surface also has a plurality of piercing structures and a third lamina comprising graphite foil is mated to the second surface.

1 . A noise damping shim comprising a first layer of a ductile material having first and second surfaces, the first surface having a plurality of piercing structures extending therefrom, the first layer being mated to a second layer of a graphite foil material such that at least some of the piercing structures pierce the graphite foil material. 
     
     
         2 . The noise damping shim of  claim 1  for use in a braking system having a brake pad with a backing plate and having a piston, the shim being configured to act as an intermediate element between the backing plate and the piston. 
     
     
         3 . The noise damping shim of  claim 1  wherein the ductile material is not perforated and the second surface is flat. 
     
     
         4 . The noise damping shim of  claim 1 , wherein at least some of the exposed tips of the piercing structures are turned over, onto or into the graphite foil material. 
     
     
         5 . The noise damping shim of  claim 1 , wherein the piercing structures do not extend completely through the graphite foil material. 
     
     
         6 . The noise damping shim of  claim 1 , wherein the ductile material is metal. 
     
     
         7 . The noise damping shim of  claim 1 , wherein the ductile material comprises steel. 
     
     
         8 . The noise damping shim of  claim 1 , wherein the ductile material has a thickness of at least 0.2 mm. 
     
     
         9 . The noise damping shim of  claim 8 , wherein the ductile material has a thickness of at least 5.0 mm. 
     
     
         10 . A laminate sheet comprising:
 a ductile material having first and second faces, the first face having a plurality of curved barbs extending therefrom, each curved barb having a tip at a height above the first face, the ductile material not being perforated; and   a graphite foil lamina mated to a the ductile material, the graphite foil lamina having first and second faces, such that the piercing members pierce the first face of the graphite foil lamina, and the graphite foil lamina has a thickness greater than the heights of the tips of the piercing members so that some of the piercing members do not pierce the second face of the graphite foil lamina.   
     
     
         11 . The laminate sheet of  claim 10 , wherein each of the curved barbs has a nail-like or pin-like structure. 
     
     
         12 . The laminate sheet of  claim 10 , wherein the curved barbs are hook shaped. 
     
     
         13 . The laminate sheet of  claim 10 , wherein each of the curved barbs has a thickness not exceeding 0.05″ at any point. 
     
     
         14 . The laminate sheet of  claim 10 , wherein each of the curved barbs has a thickness not exceeding 0.04″ at any point. 
     
     
         15 . The laminate sheet of  claim 10 , wherein each of the curved barbs has been gouged out of the first face by one tooth of a multi-toothed knife travelling along the first face. 
     
     
         16 . The laminate sheet of  claim 10 , wherein the second face of the ductile material also has a plurality of curved barbs extending therefrom, each curved barb having a tip, and a second graphite foil lamina mated to the ductile material, such that at least some of the piercing members extending from the second face of the ductile material pierce the second graphite foil lamina. 
     
     
         17 . The laminate sheet of  claim 10 , wherein the second surface is flat and smooth. 
     
     
         18 . The laminate sheet of  claim 10 , wherein the ductile material has a Brinell hardness of more than 80. 
     
     
         19 . The laminate sheet of  claim 10 , wherein at least some of the curved barbs extend completely through the graphite foil material to expose their tips. 
     
     
         20 . The laminate sheet of  claim 19 , wherein at least some of the exposed tips of the curved barbs are turned over, onto or into the graphite foil material. 
     
     
         21 . The laminate sheet of  claim 20 , wherein the outer surface of the graphite foil is bubbled where bubbles correspond to the tips of the curved barbs after they are turned over, onto or into the graphite foil material. 
     
     
         22 . The laminate sheet of  claim 10 , wherein the curved barbs do not extend completely through the graphite foil material. 
     
     
         23 . The laminate sheet of  claim 10 , wherein the ductile material comprises metal. 
     
     
         24 . The laminate sheet of  claim 23 , wherein the ductile material comprises sheet steel. 
     
     
         25 . The laminate sheet of  claim 24 , wherein the sheet steel has a thickness of at least 0.2 mm. 
     
     
         26 . The laminate sheet of  claim 25 , wherein the sheet steel has a thickness of at least 5.0 mm.