A method of manufacturing a brake pad including a friction pad and a mounting structure includes providing a cure mold; filling the cure mold with granulated thermoset plastic to form the mounting structure and particulate friction material to form the friction pad; and press curing in a single step the filled cure mold to form the brake pad.

A friction material is discloses for a braking pad comprising a binder comprising a mixture of a phenolic resin or a phenol formaldehyde resin and of a thermoplastic. The total amount of said phenolic resin or phenol formaldehyde resin and of said thermoplastic is between 2 and 60% in volume of said friction material. The ratio in volume between phenolic resin or phenol formaldehyde resin and the thermoplastic is from 20 to 80% in volume. Preferably the thermoplastic has a melting temperature between 120 and 350 C. and comprises a polyamide or a thermoplastic polymer with NH bond, either in the backbone or in the pendant group. More preferably the thermoplastic material is chosen in the group constituted by PA4, PA6, PA1, PA11, PA12, PA410, PA610, PA66, PA612.

An electric parking brake actuator mounting assembly includes a brake backplate of a drum brake, having a rear surface opposite to a front surface configured to be facing a brake drum when the brake backplate is mounted on a motor vehicle, wherein the rear surface of the brake backplate includes a support base configured to receive a pull spindle of an electromechanical actuator, a supporting bracket including at least one coupling plate, configured to be attached to the rear surface of the brake backplate, and an actuator mounting surface configured to be coupled to and support the electromechanical actuator, wherein the actuator mounting surface includes a spindle seat, configured to receive the pull spindle of the electromechanical actuator, and a pin lock seat, configured to receive and lock an engagement pin of the electromechanical actuator.

A method of forming a composite component is provided. The method includes locating a fibrous preform, providing a slurry, mixing the slurry with sacrificial fibers, injecting the slurry into the fibrous preform, heating the fibrous preform, forming channels in the fibrous preform, and densifying the fibrous preform. The sacrificial fibers are suspended in the fibrous preform along an injection pathway such that heating the sacrificial fibers forms the channels along the injection pathway as the sacrificial fibers are burned away.

A method for manufacturing a braking band may include providing a braking band with a base band having an upper face and a lower face, where the base band being is made of titanium or titanium alloy. The method may also include directly depositing a material in particulate form consisting of ceramic and metal and/or intermetallic particles above at least the upper face and/or the lower face so to create an upper coating layer and/or lower coating layer. A braking band for a brake disc may have a base band entirely made of titanium alloy and having an upper face and a lower face, an upper coating layer, and a lower coating layer joined to the base band along the lower face. The upper coating layer and the lower coating layer consist of a mixture of ceramic and metal and/or intermetallic particles.

A friction material containing a fiber base material, a binder, an organic filler, and an inorganic filler, wherein the copper content in the friction material in terms of elemental copper is 0.5% by weight or less relative to the whole friction material, and a particulate or fibrous aluminum alloy and zinc oxide are contained as the inorganic filler.

The disk brake device includes a brake disk, a brake lining, and a brake caliper. The brake lining includes a friction member and a base plate for supporting the friction member. When a plurality of bolt holes are projected onto a rear face of the base plate in a direction of an axle, a boundary passes through areas of the projected bolt holes. The brake caliper includes an inner pressing surface that applies a load on an inner area and an outer pressing surface that applies a load on an outer area. The load applied on the inner area from the inner pressing surface is different from the load applied on the outer area from the outer pressing surface. In this way, it is possible to suppress stress imposed on bolts while suppressing a local temperature rise in the brake disk.

A multi-plate clutch is comprised of: one or more core plates respectively coupled with a first rotary body rotatable about an axis; one or more reaction plates arranged alternately with the core plates and respectively coupled with a second rotary body rotatable about the axis, the reaction plates receiving the pressure force from the driver mechanism to brake the first rotary body relative to the second rotary body; one or more friction members respectively fixed to faces on the respective core plates, the faces to come into contact with the reaction plates, and including a bundle of warp yarns and a bundle of weft yarns mutually weaved perpendicular to each other, the yarns being formed of carbon fibers; and a plurality of bottomed grooves formed on faces on the respective reaction plates, the faces to come into contact with the core plates.

A carbon-carbon composite preform including a plurality of layers including carbon fibers or carbon-precursor fibers, the layers include a first exterior layer defining a first major surface, a second exterior layer defining a second major surface, and at least one interior layer disposed between the first exterior layer and the second exterior layer, the at least one interior layer having a peripheral region that forms a portion of an outer surface of the preform. The preform includes needled fibers, where at least some needled fibers extend through two or more layers. The preform has an exterior region and a core region, where the exterior region includes at least the peripheral region of at least one interior layer. The needled fibers define a first needled fiber number density (NFND) in the exterior region and a second greater NFND in at least a portion of the core region.

The present invention provides a friction material for a disc brake pad, which is able to suppress chipping of an edge of the friction material that occurs under the high speed and high load braking conditions and further to suppress the deterioration of the braking effectiveness under the high speed and high load braking conditions while satisfying laws and regulations relating to the required amount of the content of the copper component. A friction material composition that contains 0.5-10 weight % of a resilient graphitic carbon particle relative to the total amount of the friction material composition as a carbon type lubricant and contains the total amount of a copper component contained in the friction material composition is less than 5 weight % relative to the total amount of the friction material composition.