Method for manufacturing a braking element with integrated sensor, in particular a brake pad, brake pad with integrated sensor, vehicle braking system and associated method

A method for manufacturing sensorized brake elements for vehicles, comprising the steps of:

• a) making at least one piezoceramic sensor integral directly with and onto a first surface of a metal support element of a braking element which is intended during use to be directed towards a vehicle element to be braked, the at least one piezoceramic sensor being able to convert mechanical energy received in a polarization direction of the at least one sensor, when subjected to a mechanical force, into electrical energy for emitting an electrical signal due to piezoelectric effect, the at least one sensor being selected from a group of piezoceramic sensors still operational at working temperatures at least equal to or greater than 200° C. and free from polymeric active components;
• b) providing an electrical circuit which is in contact with said first surface, to pick up said electrical signal and possibly processing the electrical signal and connecting said electrical circuit with a connector made integral with said metal support element;
• c) providing an electrically insulating layer, which is one of continuous or discontinuous, on the first surface so as to sandwich the at least said one piezoceramic sensor and said electrical circuit between the first surface and the electrically insulating layer, so as to embed them within said electrically insulating layer;
• d) providing a dampening and thermally insulating layer directly onto said electrically insulating layer and on the first surface so that the at least one piezoceramic sensor is directly and completely embedded within the dampening and thermally insulating layer with the interposition of the electrically insulating layer;
• and
• e) forming a block of friction material upon the dampening and thermally insulating layer, said block being held stiff by the metal support element.