Challenge 1: Disc & Pad Corrosion from Infrequent Use
In internal combustion vehicles, frequent friction braking continuously wipes surface rust off cast iron rotors. In EVs, mechanical brakes can sit cold and unused for days, allowing road salt and moisture to cause heavy disc corrosion and friction puck adhesion.
- Solution: Specialized anti-corrosion backing plates with electroplated zinc-nickel alloy coatings resisting 500+ hours in ASTM B117 salt spray.
- Solution: Friction compounds engineered with gentle rotor-cleaning abrasives that safely sweep away surface oxide films without scoring the rotor.
Challenge 2: Friction Surface Glazing (Cold Operation)
Because EV brake pads rarely reach typical operating temperatures (200°C–400°C), organic resin binders can degrade into a slippery glass-like glaze on the pad surface, causing sudden loss of friction when emergency hard braking is required.
- Solution: In-line thermal scorching during manufacturing burns off volatile surface resins prior to packaging.
- Solution: Low-temperature binder chemistry delivering consistent friction coefficient (μ 0.38) from the very first cold stop.
Challenge 3: Acoustic Squeal Amplification in Silent Cabins
Without engine noise to mask mechanical sounds, even minor brake squeals or groans become immediately noticeable and generate high customer warranty complaints.
- Solution: Multi-layer constrained viscoelastic rubber-steel shims custom-tuned for high-frequency vibration absorption.
- Solution: Precision CNC edge chamfering and radial slots to disrupt acoustic resonance frequencies.
