Brake Disk and Method of Making Same

2:

• The brake disk as claimed in claim 1, wherein the island formations are teardrop shaped.

3:

• The brake disk as claimed in claim 1, wherein the island formations are round.

4:

• The brake disk as claimed in claim 1, wherein the island formations are letter-shaped.

5:

• The brake disk as claimed in claim 1, wherein the island formations are figure eight shaped.

6:

• The brake disk as claimed in claim 1, wherein the island formations have peripheral edges which are at least partially rounded in shape.

7:

• The brake disk as claimed in claim 1, wherein both surfaces of the disk body have a plurality of spaced, raised island formations and channels extending between the island formations.

8:

• The brake disk as claimed in claim 1, wherein the spaced island formations extend over the entire area of the surface.

9:

• The brake disk as claimed in claim 1, wherein the disk body has a central opening and the opposite surfaces are annular surfaces, and each annular surface has a series of radially extending rows of island formations extending from the central opening to the outer periphery of the annular surface, the channels comprising radially extending spaces between the adjacent rows of island formations, and radially spaced gaps between adjacent island formations in each row.

10-24:

• (canceled)

26:

• The method of claim 25, wherein the finishing step comprises applying a first material to at least the outer surface of each island formation of the brake disk through vapor deposition;
• and applying at least a second material over the first material through vapor deposition.

27:

• The method of claim 26, wherein the finishing step comprises applying the first and second materials over the entire area of each annular surface.

28:

• The method of claim 25, wherein the finishing step comprises applying a three dimensional surface texture to at least the island formations of the brake disk.

29:

• The method of claim 28, wherein the three dimensional surface texture is applied over the entire area of each annular surface of the brake disk.

30:

• The method of claim 28, wherein the three dimensional surface texture has peaks, valleys and angular surfaces between the peaks and valleys.

31:

• The method of claim 28, wherein the surface texture is applied using a surface finishing technique selected from the group consisting of bead blasting, sanding, grinding, acid etching, photo-resist etching, roll forming, embossing, stamping, honing, lapping, polishing, blanching, milling, profiling and combinations thereof.

32:

• The method of claim 28, wherein the finishing step further comprises applying a first material as a first coating layer to at least the island formations after the surface texture is applied, the first material being applied through vapor deposition, wherein the first material is deposited onto the brake disk by energizing a first material source to cause charged particles of the first material source to be dissociated from the first material source and deposited on at least the island formations of the brake disk;
• and applying a compound as a second coating layer to the first coating layer of the brake disk through vapor deposition, wherein the second coating layer is deposited by energizing a second material source to cause charged particles of the second material source to be dissociated from the second material source, introducing a reactive gas which reacts with the charged particles of the second material forming the compound that is deposited on at least the island formations of the brake disk;
• wherein the combination of the surface finishing and the depositing causes at least the island formations of each annular surface to exhibit a selected three dimensional surface texture.

33:

• The method of claim 25, further comprising roughening a base surface of each channel to produce bumps.

34:

• A brake device, comprising:
• a brake component having at least one working surface which opposes a brake pad or brake shoe;
• the working surface having a plurality of spaced, raised island formations separated by channels, each island formation having an outer friction surface which engages an opposing portion of a brake shoe or brake pad during braking.

35:

• The brake device of claim 34, wherein each island formation has an outer periphery of predetermined ornamental shape.