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Connecting the dots between the past,
present & future of bonding
Ryan French & Haroon Mohmand, 2013.08.29
2013-08-29 TRELLEBORG GROUP2
2013-08-29 TRELLEBORG GROUP3
bond
/bänd/
verb
joined securely to another thing, esp. by an adhesive, a
heat process, or pressure
2013-08-29 TRELLEBORG GROUP4
de·bond
/de-bänd/
verb
occurs when an adhesive stops sticking (adhering) to an
adherend or substrate material
2013-08-29 TRELLEBORG GROUP5
6 2012-12-06 TRELLEBORG GROUP
2013-08-29 TRELLEBORG GROUP7
bond (re-defined)
/bänd/
verb
joined securely to another thing, esp. by an adhesive, a
heat process, or pressure
passes the newly developed tap test (audible feedback
must be in such a way as to not allow dead space sound in
pre-defined areas outside of backplate features)
passes adhesive coverage (or disturbance?) test where
the shim is removed and an approximated surface area
determined by overlaying a circle dot matrix and counting
the area that shows no visual adherence
2013-08-29 TRELLEBORG GROUP9
Rubber
(noise damping)
TRELLEBORG GROUP10
Shim With Phenolic (1980’s – 1990’s)
Steel
(structural integrity)
Phenolic Adhesive
(Structural Bond)
2013-08-29
Rubber
(noise damping)
TRELLEBORG GROUP11
Shim With PSA (2000- present)
Steel
(structural integrity)
Pressure Sensitive
Adhesive
(noise damping, not dependent on bond
integrity)
2013-08-29
Temperature Effects on PSA’s
TRELLEBORG GROUP12
Adhesive Temperature
+-
2013-08-29
TRELLEBORG GROUP13
Daily Operating Temperatures
2013-08-29
TRELLEBORG GROUP14 2013-08-29
TRELLEBORG GROUP15
0%
1%
2%
3%
4%
5%
6%
1980 - 2000 2000 - 2008 2008 - present
Acceptable Noise Percentage
2013-08-29
TRELLEBORG GROUP16
Simple pad design
• No insulator retention features
• No insulator stress relief cuts
• No bond surface area concerns
• No pad/insulator shape concerns
Bonding substrate (backplate)
• Sandblasted
• Zinc coated
• Liquid paint
Complex pad design
• Large / multiple insulator retention features
• Added insulator stress relief cuts
• Bond surface area maximized
• Shapes evaluated for bond integrity
Bonding substrate (backplate)
• Liquid paint
• Some powder paint
(1980’s – 1990’s) (2000 – present)
2013-08-29
2012-12-06 TRELLEBORG GROUP17
TRELLEBORG GROUP18
Complex pad design
• Limited insulator retention features
• Very few insulators with relief cuts
• Bond surface area?????
• Pad/Insulator shapes evaluated for bond integrity?????
Bonding Substrate (Backing Plate)
• 100% powder paint
(today)
2013-08-29
TRELLEBORG GROUP19
Today’s end customers expect quieter brakes?
• Which is leading to warranty claims for even minor noise or
potential noise.
• Is this leaving the investigation team puzzled, so they report
all potential causes?
Lazy pad/insulator designs?
• Tighter packaging
• Limited and/or poor retention features
• Not utilizing relief slots
• Limited bonding surface area
• Poor pad/insulator shape
2013-08-29
2012-12-06 TRELLEBORG GROUP20
Shim Bonding (Connecting The Dots)

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