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 performations 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.

What is claimed is: 
     
         1 . A laminate sheet comprising:
 a relatively hard material having first and second surfaces, the first surface having a plurality of piercing structures, each structure having a tip; and   a graphite foil material mated to the relatively hard material, such that at least some of the piercing structures pierce the graphite foil material.   
     
     
         2 . The laminate sheet of  claim 1 , wherein the relatively hard material is not perforated and the second surface is flat. 
     
     
         3 . The laminate sheet of  claim 1 , wherein at least some of the piercing structures extend completely through the graphite foil material to expose their tips. 
     
     
         4 . The laminate sheet of  claim 3 , wherein at least some of the exposed tips of the piercing structures are turned over, onto or into the graphite foil material. 
     
     
         5 . The laminate sheet of  claim 1 , wherein the piercing structures do not extend completely through the graphite foil material. 
     
     
         6 . The laminate sheet of  claim 1 , wherein the relatively hard material comprises metal. 
     
     
         7 . The laminate sheet of  claim 6 , wherein the relatively hard material comprises steel. 
     
     
         8 . The laminate sheet of  claim 1 , wherein the relatively hard material has a thickness of at least 0.2 mm. 
     
     
         9 . The laminate sheet of  claim 8 , wherein the relatively hard material has a thickness of at least 5.0 mm. 
     
     
         10 . A multi-layer laminate sheet, comprising:
 a dual sided sheet of a relatively hard material having texturing on two surfaces thereof, the surface texture having a plurality of piercing structures, each structure having a tip; and   two outer layers of a graphite foil material, one layer being disposed on each surface of the dual sided sheet, the graphite foil material being mated to the relatively hard material such that at least some of the piercing structures of the relatively hard material pierce the graphite foil material.   
     
     
         11 . The laminate sheet of  claim 10 , wherein the relatively hard material is not perforated. 
     
     
         12 . The laminate sheet of  claim 10 , wherein at least some of the piercing structures extend completely through one of the layers of graphite foil material to expose their tips. 
     
     
         13 . The laminate sheet of  claim 12 , wherein at least some of the exposed tips of the piercing structures are turned over, onto or into the graphite foil material. 
     
     
         14 . The laminate sheet of  claim 10 , wherein the piercing structures do not extend completely through the graphite foil material. 
     
     
         15 . The laminate sheet of  claim 10 , wherein the relatively hard material comprises metal. 
     
     
         16 . The laminate sheet of  claim 15 , wherein the relatively hard material comprises steel. 
     
     
         17 . The laminate sheet of any  claim 10 , wherein the relatively hard material has a thickness of at least 0.2 mm. 
     
     
         18 . The laminate sheet of  claim 17 , wherein the relatively hard material has a thickness of at least 5.0 mm. 
     
     
         19 . A noise damping shim comprising a first layer of a relatively hard material having first and second surfaces, the first surface having a plurality of piercing structures, 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. 
     
     
         20 . The noise damping shim of  claim 19  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.