Coating method for disc brake pads
AssigneeDelphi Technologies, Inc.
InventorRobert Anthony Lamport
Life of this patent
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Abstract
A method of coating disc brake pads to obscure and seal minor surface imperfections, thereby reducing scrap rates. A preform of friction lining material is coated prior to molding and curing the preform and bonding the same to the backing plate to form the brake pad assembly. The preform is coated with an aqueous composition containing a solids mixture of 5–50 vol. % resin and 50–95 vol. % non-resin solids. Advantageously, the coating composition has a 5–30 vol. % solids mixture content, which solids mixture includes 15–25 vol. % resin, 0–10 vol. % powdered elastomer, 5–15 vol. % carbon black, 20–50 vol. % inorganic fillers, 5–15 vol. % organic fibers and 1–10 vol. % inorganic flake material.
Claims20
A method of coating disc brake pads comprising a backing plate and a friction lining, the method comprising the steps of:
- coating a preform of friction lining material with a coating composition comprising water and a solids mixture of 5–50 vol. % resin and 50–95 vol. % non-resin solids;
- drying the coated preform;
- and
- molding and curing the coated preform, and bonding the coated preform to a backing plate, to form a brake pad having a friction lining of final desired thickness.
A method of coating disc brake pads comprising a backing plate and a friction lining, the method comprising the steps of:
- forming a wet mixture of a friction lining material and a slurry solution;
- pressing the wet mixture to extract at least a portion of the slurry solution to form a wet preform of thickness greater than a final desired thickness of the friction lining;
- coating the wet preform with a coating composition comprising 70–95 vol. % water and 5–30 vol. % of a solids mixture of 5–50 vol. % resin and 50–95 vol. % non-resin solids;
- drying the coated preform;
- and
- molding and curing the coated preform, and bonding the coated preform to a backing plate, to form a brake pad having the friction lining of final desired thickness.
A method of coating disc brake pads comprising a backing plate and a friction lining, the method comprising the steps of:
- forming a wet mixture of a friction lining material and a slurry solution;
- pressing the wet mixture to extract at least a portion of the slurry solution to form a wet preform of thickness greater than a final desired thickness of the friction lining;
- coating the wet preform with a coating composition comprising 70–95 vol. % water and 5–30 vol. % of a solids mixture comprising:
- 15–25 vol. % liquid phenolic-based resin;
- 0–10 vol. % powdered elastomer;
- 5–15 vol. % carbon black;
- 20–50 vol. % inorganic fillers;
- 5–15 vol. % organic fibers;
- and 1–10 vol. % inorganic flake material;
- drying the coated preform;
- and
- molding and curing the coated preform, and bonding the coated preform to a backing plate having a carbon black-containing coating thereon, to form a brake pad having the friction lining of final desired thickness.
Dependencies are inferred from the claim text.