Brake friction pad assembly
AssigneePneumo Abex Corporation
InventorsStanley F. Kulis, Jr., Richard L. Carpenter
Life of this patent
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Abstract
A novel brake friction pad assembly is provided with a backing plate element, and with one or more integrally joined different friction-generating pad, noise-damping pad, and backing pad elements carried by the backing plate element, such friction-generating pad, noise-damping pad, and backing pad elements being molded using specified particulate mixture molding compositions and preferred molding method steps.
Claims25
A brake friction pad assembly comprising:
- a backing plate means having opposed faces and at least one extrusion opening extending between said opposed faces;
- a molded friction-generating pad element in contact with one of said backing plate means opposed faces;
- and
- a molded noise-damping pad element which overlies and contacts a substantial portion of the other of said backing plate means opposed faces, said noise-damping pad element being joined to said friction-generating pad element by molded material contained within said extrusion opening.
A thermally curable molding composition mixture comprised of:
- approximately from 20.9 to 23.3 parts organic particles, approximately from 31.7 to 31.9 parts binder particles, approximately from 12.5 to 14.5 parts carbonaceous particles, approximately from 6.4 to 13.9 parts metallic particles, approximately from 16.3 to 21.8 parts mineral particles, approximately from 1.8 to 3.7 parts organic particles/binder particles curatives and approximately from 0.4 to 0.9 parts corrosion inhibitor(s), all said parts proportions being on a percentage volume basis.
A thermally curable molding composition mixture comprised of:
- approximately 25.7 parts organic particles, approximately 31.4 parts binder particles, approximately 10.6 parts carbonaceous particles, approximately 21.4 parts metallic particles, and approximately 10.9 parts mineral particles, all said parts proportions being on a percentage volume basis.
In a method of forming a brake friction pad assembly by compression molding a friction material in separable mold halves which have an interior mold cavity the steps of:
- placing a backing plate element having spaced-apart upper and and lower faces and at least one extrusion opening extending between said faces in the mold interior cavity in a position above a lower pad portion of the mold interior cavity which overlies a substantial portion of said backing plate element and below an upper pad portion of the mold interior cavity;
- placing a measured quantity of a friction-generating composition particulate mixture in the mold interior cavity on said backing plate element upper face;
- and
- closing the separable mold halves a sufficient distance to compress said friction-generating composition particulate mixture and extrude a portion of said mixture through said backing plate element extrusion opening to thereby fill said mold interior cavity upper and lower pad portions with said friction-generating composition particulate mixture contacting both said backing plate element spaced-apart upper and lower faces.
In a method of forming a brake friction pad assembly having distinct and separate friction-generating and noise-damping pad elements carried by a backing plate element by compression in a mold having separable halves with an included interior mold cavity, the steps of:
- placing a backing plate element having spaced-apart upper and lower faces and at least one extrusion opening extending between said faces in said mold interior cavity in a position above a noise-damper pad cavity portion and below a friction-generating pad cavity portion;
- placing a measured quantity of a noise-damping composition particulate mixture in said mold interior cavity on said backing plate element upper face over said extrusion opening;
- placing a measured quantity of a friction-generating composition particulate mixture in said mold interior cavity on said noise-damping composition particulate mixture;
- and
- closing the separable mold halves a sufficient distance to compress said friction-generating and noise-damping composition particulate mixtures and extrude at least a portion of said noise-damping composition particulate mixture through said backing plate element extrusion opening to fill said mold cavity noise-damper pad cavity portion with said noise-damping composition particulate mixture and said mold cavity friction-generating pad cavity portion with said friction-generation composition particulate mixture and with a portion of said noise-damping composition particulate mixture.
In a method of forming a brake friction pad assembly having distinct and separate friction-generating and noise-damping pad elements with an intermediately positioned distinct and separate backing pad element by the compression of molding compositions in a mold having separable halves with an included interior mold cavity, the steps of:
- placing a backing plate element having spaced-apart upper lower faces and at least one extrusion opening extending between said faces into said mold interior cavity in a position above a noise-damper pad element cavity position which overlies a substantial portion of said backing plate element and below a friction-generating pad element cavity portion;
- placing a measured quantity of a noise-damping composition particulate mixture in said mold interior cavity on said backing plate element upper face;
- placing a measured quantity of a backing composition particulate mixture in said mold interior cavity on said noise-damping composition particulate mixture.
- placing a measured quantity of a friction-generating composition particulate mixture in said mold interior cavity on said backing composition particulate mixture;
- and
- closing the separable mold halves a sufficient distance to compress said friction-generating backing and noise-damping composition particulate mixtures and extrude at least a portion of said noise-damping composition particulate mixture through said backing plate element extrusion opening to fill said mold interior cavity noise-damper pad element portion with said noise-damping composition particulate mixture and said mold interior cavity friction-generating pad element portion with said friction-generating composition particulate mixture, said backing composition particulate mixture, and a portion of said noise-damping composition particulate mixture.
Dependencies are inferred from the claim text.