Durable high friction coating (DHFC) for brake application

A brake shim comprising:

• a metal substrate;
• a first durable high friction coating (DHFC) layer deposited on a first surface of the metal substrate;
• and
• a second DHFC layer or an adhesive layer deposited on a second surface of the metal substrate opposite the first surface, wherein the first and second DHFC layers comprise:
• one or more binders comprising phenoxy in aqueous solution, polyurethane in aqueous solution form, melamine formaldehyde, bisphenol A epoxy, urea-formaldehyde, or a combination thereof in a range from at least 70 weight % to less than 95 weight %;
• one or more fillers in a range from at least 5 weight % to less than 30 weight %;
• an elastomeric polymer in a range from at least 1 weight % to less than 8 weight %;
• and
• one or more additives in a range from at least 0.5 weight % to less than 2 weight %, wherein the one or more binders, the one or more fillers, the one or more additives, and the elastomeric polymer are mixed in liquid form and are cured to form the first and second DHFC layers.

A method to manufacture a durable high friction coating (DHFC) for a brake system, the method comprising:

• mixing a binder, a filler, an elastomeric polymer, and an additive in liquid form to form a mixture, wherein the binder comprises phenoxy in aqueous solution, polyurethane in aqueous solution form, melamine formaldehyde, bisphenol A epoxy, urea-formaldehyde, or a combination thereof and is in a range from at least 70 weight % to less than 95 weight %, the filler is in a range from at least 5 weight % to less than 30 weight %, the elastomeric polymer is in a range from at least 1 weight % to less than 8 weight %, and the additive is in a range from at least 0.5 weight % to less than 2 weight % in the mixture;
• loading the mixture onto a coil material to form a layer of DHFC;
• and
• curing the layer of DHFC on the coil material through heat treatment.