Description:BACKGROUND
Field of Invention
[001] Embodiments of the present invention generally relate to a composite coating and particularly to a nanoparticle-infused composite coatings for improving a brake pad performance.
Description of Related Art
[002] In automobiles, several components of a braking system, including those manufactured from cast iron and steel, are susceptible to corrosion. This vulnerability poses a significant challenge to the durability and safety of braking system parts. Corrosion within the braking system of a vehicle is particularly concerning, as it can compromise the integrity of critical components. While some degree of corrosion is expected and considered normal, certain instances warrant attention. For example, during rainstorms, thin rust films may form on the surface of brake rotors when vehicles are parked outside. Although this phenomenon typically dissipates upon driving and applying the brakes, it underscores the ongoing threat of corrosion within the braking system.
[003] Of particular concern is the corrosion of brake pads, where the backing plate serves as a crucial component. Backing plates, typically made of steel, are prone to corrosion, which can weaken the bond between the backing plate and the friction material. In severe cases, corrosion can lead to a detachment of frictional material from the backing plate, thereby increasing the vehicle's stopping distance and compromising safety.
[004] Addressing corrosion on the backing plate of brake pads presents a dual challenge. While selecting a higher grade of steel alloy offers one solution, applying an outer protective layer to shield the backing plate from environmental interactions is another. However, the inherent poor resistance of steel material to corrosion in humid environments necessitates effective interventions to mitigate the detrimental effects on braking system performance and safety.
[005] There is thus a need for a composite coating that can administer the aforementioned limitations in a more efficient manner.
SUMMARY
[006] Embodiments in accordance with the present invention provide a nanoparticle-infused Ni-P composite coating for automotive brake pad backing plates. The composite coating comprising: a multi-pass electroless nickel matrix. The composite coating further comprising nano-sized particles dispersed within the nickel matrix to improve corrosion resistance, wherein the Nano-sized particles are selected from Zinc Oxide (ZnO), Aluminum Oxide (Al2O3), Silicon Carbide (SiC), or a combination thereof.
[007] Embodiments in accordance with the present invention further provide a method for developing a nanoparticle-infused Ni-P composite coating for automotive brake pad backing plates. The method comprising steps of: providing a multi-pass electroless nickel matrix; dispensing nano-sized particles into the electroless nickel matrix to enhance corrosion resistance. The Nano-sized particles are selected from Zinc Oxide (ZnO), Aluminum Oxide (Al2O3), Silicon Carbide (SiC), or a combination thereof. The method further comprising the step of applying the nanoparticle-infused electroless nickel matrix onto the automotive brake pad backing plates.
[008] Next, embodiments of the present application may provide an efficient and cost-effective method for manufacturing the nanoparticle-infused Ni-P composite coating, offering a sustainable solution for enhancing the longevity and performance of automotive brake systems.
[009] Next, embodiments of the present application may provide a versatile coating solution that can be applied to various automotive components beyond brake pad backing plates, including fuel systems, turbochargers, transmission parts, and other critical steel and cast iron components, thereby offering comprehensive corrosion protection throughout the vehicle.
[0010] Next, embodiments of the present application may provide a method for optimizing the composition and distribution of nano-sized particles within the electroless nickel matrix, allowing for fine-tuning of the composite coating properties to meet specific performance requirements in different automotive environments.
[0011] Next, embodiments of the present application may provide a scalable manufacturing process for producing the nanoparticle-infused Ni-P composite coating, facilitating widespread adoption by automotive manufacturers and aftermarket suppliers, ultimately leading to safer and more reliable vehicles on the road.
[0012] Next, embodiments of the present application may provide a sustainable solution for reducing maintenance costs and downtime associated with corrosion-related issues in automotive brake systems, resulting in improved operational efficiency and overall customer satisfaction.
[0013] These and other advantages will be apparent from the present application of the embodiments described herein, demonstrating the potential for significant advancements in automotive corrosion protection technology and ensuring the continued advancement of vehicle safety and performance standards.
[0014] These and other advantages will be apparent from the present application of the embodiments described herein.
[0015] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above and still further features and advantages of embodiments of the present invention will become apparent upon consideration of the following detailed description of embodiments thereof, especially when taken in conjunction with the accompanying drawings, and wherein:
[0017] FIG. 1 illustrates a nanoparticle-infused Ni-P composite coating; according to an embodiment of the present invention;
[0018] FIG. 2 illustrates automotive brake pad backing plates, according to an embodiment of the present invention; and
[0019] FIG. 3 depicts a flowchart of a method for developing the nanoparticle-infused Ni-P composite coating for the automotive brake pad backing plates.
[0020] The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures. Optional portions of the figures may be illustrated using dashed or dotted lines, unless the context of usage indicates otherwise.
DETAILED DESCRIPTION
[0021] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the scope of the invention as defined in the claims.
[0022] In any embodiment described herein, the open-ended terms "comprising", "comprises”, and the like (which are synonymous with "including", "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of", “consists essentially of", and the like or the respective closed phrases "consisting of", "consists of”, the like.
[0023] As used herein, the singular forms “a”, “an”, and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.
[0024] FIG. 1 illustrates a nanoparticle-infused Ni-P composite coating 100 (hereinafter referred to as the composite coating 100), according to an embodiment of the present invention. The composite coating 100 may be capable of enhancing a corrosion resistance, a durability, and a longevity of automotive brake pad backing plates 200 (as shown in the FIG. 2). The composite coating 100 may further be used to protect other critical components from corrosion in harsh environment such as in automotive fuel systems, turbochargers, transmission parts, braking systems, and so forth. Embodiments of the present invention are intended to include or otherwise cover any other critical components made of steel and cast iron including known, related art, and/or later developed technologies. In an embodiment of the present invention, the composite coating 100 may be developed using a multi-pass electroless nickel matrix 102, and Nano-sized particles 104.
[0025] In an embodiment of the present invention, the multi-pass electroless nickel matrix 102 may be engineered to provide a uniform and adherent layer on a surface of the brake pad backing plates 200 for ensuring effective protection against corrosion and wear.
[0026] In an embodiment of the present invention, the multi-pass electroless nickel matrix 102 may be formed by depositing multiple layers of electroless nickel onto a substrate using successive immersion processes. Each immersion cycle results in the deposition of a new layer of the electroless nickel by gradually building up a thickness and a strength of the composite coating 100. This multi-pass approach ensures uniform coverage and enhances the adhesion of the nickel matrix to the substrate surface, providing improved resistance to corrosion and wear. In another embodiment of the present invention, the electroless nickel deposition process may be controlled to achieve specific thicknesses and compositions of the nickel-phosphorus alloy layers within the multi-pass electroless nickel matrix 102. By adjusting parameters such as an immersion time, a temperature, and a chemical composition of a plating solution, properties of the electroless nickel matrix may be adjusted to meet a desired performance requirements of the composite coating 100.
[0027] In an embodiment of the present invention, the nano-sized particles 104 may be dispersed within the electroless nickel matrix 102 to enhance specific properties of the composite coating 100. The nano-sized particles 104 may be, but not limited to, Zinc Oxide (ZnO), Aluminum Oxide (Al2O3), Silicon Carbide (SiC), or a combination thereof, chosen for their superior corrosion resistance and mechanical properties. Embodiments of the present invention are intended to include or otherwise cover any nano-sized particles 104 including known, related art, and/or later developed technologies.
[0028] In an embodiment of the present invention, dispersion techniques may be employed to ensure a uniform distribution of the nano-sized particles 104 within the electroless nickel matrix 102. The dispersion techniques allows for a thorough integration of nano-sized particles 104 into the electroless nickel matrix 102. The dispersion techniques may be, but not limited to, an ultrasonic agitation, a mechanical stirring, and so forth. Embodiments of the present invention are intended to include or otherwise cover any dispersion techniques including known, related art, and/or later developed technologies.
[0029] FIG. 2 illustrates the automotive brake pad backing plates 200, according to an embodiment of the present invention. These backing plates 200, when coated with the nanoparticle-infused Ni-P composite coating 100, exhibit improved resistance to corrosion, thereby extending the service life of automotive brake systems and ensuring enhanced safety and performance on the road.
[0030] In some embodiments of the present invention, the nanoparticle-infused Ni-P composite coating 100 may comprise duplex layers, such as multiple layers of electroless nickel matrix are deposited with nano-sized particles dispersed within each layer. This duplex layering may enhance the durability and the corrosion resistance of the composite coating 100 by providing an added protection to the automotive brake pad backing plates 200.
[0031] FIG. 3 depicts a flowchart of a method 300 for developing the nanoparticle-infused Ni-P composite coating 100 for the automotive brake pad backing plates 200, according to an embodiment of the present invention.
[0032] At step 302, the nanoparticle-infused Ni-P composite coating 100 may be developed by providing the multi-pass electroless nickel matrix 102.
[0033] At step 304, the nanoparticle-infused Ni-P composite coating 100 may be developed by dispensing the nano-sized particles 104 into the electroless nickel matrix 102 to enhance the corrosion resistance.
[0034] At step 306, the nanoparticle-infused electroless nickel matrix 102 may be applied onto the automotive brake pad backing plates 200.
[0035] While the invention has been described in connection with what is presently considered to be the most practical and various embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
[0036] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined in the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements within substantial differences from the literal languages of the claims. , Claims:CLAIMS
We Claim:
1. A nanoparticle-infused Ni-P composite coating (100) for automotive brake pad backing plates (200), the composite coating (100) comprising:
a multi-pass electroless nickel matrix (102); and
Nano-sized particles (104) dispersed within the nickel matrix (102) to improve corrosion resistance, wherein the Nano-sized particles (104) are selected from Zinc Oxide (ZnO), Aluminum Oxide (Al2O3), Silicon Carbide (SiC), or a combination thereof.
2. The composite coating (100) as claimed in claim 1, wherein the nano-sized particles (104) are evenly distributed within the nickel matrix (102).
3. The composite coating (100) as claimed in claim 1, wherein the automotive brake pad backing plates (200) are made of a steel material.
4. The composite coating (100) as claimed in claim 1, wherein duplex layers of the composite coating (100) is applied on the automotive brake pad backing plates (200).
5. A method for developing a nanoparticle-infused Ni-P composite coating (100) for automotive brake pad backing plates (200), comprising:
providing a multi-pass electroless nickel matrix (102);
dispensing nano-sized particles (104) into the electroless nickel matrix (102) to enhance corrosion resistance, wherein the Nano-sized particles (104) are selected from Zinc Oxide (ZnO), Aluminum Oxide (Al2O3), Silicon Carbide (SiC), or a combination thereof; and
applying the nanoparticle-infused electroless nickel matrix (102) onto the automotive brake pad backing plates (200).
6. The method (300) as claimed in claim 5, wherein the nano-sized particles (104) are evenly distributed within the nickel matrix (102).
7. The method (300) as claimed in claim 5, wherein the automotive brake pad backing plates (200) are made from a steel material.

Date: May 29, 2024
Place: Noida

Dr. Keerti Gupta
Agent for the Applicant
(IN/PA-1529)