Method of manufacturing disk brake pad

Plastic and nonmetallic article shaping or treating: processes – With severing – removing material from preform mechanically,... – To form particulate product

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264236, 264259, B29C 7100

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056414447

ABSTRACT:
A method of forming a disk brake pad having a friction member composed of a bonding layer having a low porosity and a matrix layer having a high porosity and laminated on the bonding layer. The method does not require a pre-forming step. A material formed by pelletizing a mixture of components for the friction member and a non-pelletized material are fed one after the other into a cavity defined by a mold and a back plate. Also, since the pelletized material is compacted beforehand, the bonding layer formed from the pelletized material exhibits a sufficiently low porosity, so that the bonding layer can prevent moisture from infiltrating therethrough. Thus, the back plate is less likely to develop rust. Also, the bonding strength between the back plate and the bonding layer is improved. Further, since pelletized material forming the bonding layer penetrates into the matrix layer in a complicated manner, the bond strength between the bonding layer and the matrix is also improved.

REFERENCES:
patent: 5413194 (1995-05-01), Kulis, Jr. et al.
Abstract of Japanese Kokai No. 54-113649 (May 9, 1979).
Abstract of JP 5-331452 (Dec. 14, 1993).
Abstract of JP 6-74267 (Mar. 15, 1994).

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