Method for producing an automotive friction material with optimized multi dimensional construction

An automotive friction material with multi-dimensional construction, the automotive friction material comprising:

• a base friction plate;
• a friction-disc base layer bonded to and supported by the base friction plate, the friction-disc base layer comprising woven fibrous materials, carbon materials, or a composite material formed as an annular ring having an inner radial portion and an outer radial portion;
• a bonding resin disposed between the base plate and the friction-disc base layer and bonding the friction-disc base layer to the base friction plate;
• a first friction modifier disposed over the friction-disc base layer within the inner radial portion;
• and
• a second friction modifier disposed over the friction-disc base layer within the outer radial portion, and
• wherein a thickness of the first friction modifier and the second friction modifier is largest at an inner radius of the friction-disc base layer and smallest at an outer radius of the friction-disc base layer.

A system for producing an automotive friction material with optimized multi-dimensional construction, the system comprising:

• an automotive friction material comprising:
• a base friction plate;
• a friction-disc base layer bonded to and supported by the base friction plate, the friction-disc base layer comprising first fibers interwoven with second fibers, wherein overlap between the first fibers and the second fibers defines apex areas;
• and
• a hardness resin disposed only on the apex areas, the hardness resin configured to increase hardness relative to the first fibers and second fibers;
• a multi-nozzle printing array;
• a pump in fluid communication with the multi-nozzle printing array;
• a computerized print array controller in electronic communication with the pump and the multi-nozzle printing array;
• the computerized print array controller executing control logic or instructions generating outputs to the multi-nozzle printing array and the pump to produce the automotive friction material, wherein the control logic includes:
• a first control logic for cutting a friction-disc material into segments each having a predetermined size and shape;
• a second control logic for assembling the segments into the friction-disc base layer;
• a third control logic for bonding the friction-disc base layer, made of the segments, to the base friction plate;
• and
• a fourth control logic for utilizing the multi-nozzle printing array to deposit the hardness resin overtop the apex areas.