Brake calipers, molds and method of producing brake calipers are disclosed including a brake caliper mold for molding a brake caliper, the brake caliper mold comprising: a first mold section; a second section half; a core member configured to form a piston bore, the core member comprising: a tower configured to form a tower window in a bridge of the brake caliper and a piston bore extension to form a piston bore of the brake caliper; and four locator forming surfaces located on the tower, each of the four locator forming surfaces configured to form a separate lateral data reference surface on the brake caliper, the lateral data reference surfaces capable of being used for subsequent machining of the brake caliper to predetermined tolerances.

An axle disconnect system including an actuator having an energizable coil in an overmold that is at least partially surrounded by a coil housing. An armature is in sliding engagement with the housing such that the magnetic flux through the magnetic circuit is uninterrupted. Disposed between one of (i) the housing or armature and (ii) a sliding collar is a slide ring. The sliding collar is located directly radially inward from the slide ring. A first end portion of the sliding collar has a set of axially extending teeth. Radially inward from the first end portion of the sliding collar is a return spring groove having a return spring. An outer surface of a second end portion of an output gear has a set of axially extending teeth that are selectively engageable with the teeth on the first end portion of the sliding collar.

The present disclosure provides a fibrous preform, comprising an annulus having at least one of an outer diameter portion or an inner diameter portion, the outer diameter portion extending radially inward from an outer diameter of the fibrous preform and the inner diameter portion extending radially outward from an inner diameter of the fibrous preform. In various embodiments, the fibrous preform further comprises a medial diameter portion disposed between the outer diameter and the inner diameter, wherein the medial diameter portion comprises a first needling profile, and the at least one of the outer diameter portion or the inner diameter portion comprises a second needling profile. In various embodiments, the first needling profile is less than the second needling profile.

A method of making carbon fiber material according to various embodiments of the present disclosure includes forming a polymer resin to have a polydispersity index (PDI) that is less than approximately 2.5. The method further includes spinning the polymer resin to create an acrylic fiber having an acrylic fiber length. The method further includes oxidizing the acrylic fiber while stretching the acrylic fiber to create an oxidized fiber that has an oxidized fiber length that is at least one of greater than or equal to approximately 100 percent (100%) of the acrylic fiber length. The method further includes carbonizing the oxidized fiber to create a carbon fiber.

A hybrid torque tube for a brake assembly may comprise a tube portion having a centerline axis, and a conical back-leg portion extending from the tube portion. A stator spline may be formed on a radially outward surface of the tube portion. A foot may be formed on a radially inward surface of the tube portion. The tube portion is formed using a first manufacturing process and at least one of the conical back-leg, stator spline, or foot is formed using additive manufacturing.

The present disclosure provides a fibrous preform, comprising an annulus having at least one of an outer diameter portion or an inner diameter portion, the outer diameter portion extending radially inward from an outer diameter of the fibrous preform and the inner diameter portion extending radially outward from an inner diameter of the fibrous preform. In various embodiments, the fibrous preform further comprises a medial diameter portion disposed between the outer diameter and the inner diameter, wherein the medial diameter portion comprises a first needling profile, and the at least one of the outer diameter portion or the inner diameter portion comprises a second needling profile. In various embodiments, the first needling profile is less than the second needling profile.

A long-strand carbon composite brake housing for use on aircraft is formed from a thermoplastic material carrying long-strand carbon fibers, with the composition, concentration, and orientation of the fibers being such as to optimize the strength of the resultant carrier plate, and particularly in regions subject to high stress and the like. A hydroforming technique accommodates the appropriate positioning of the thermoplastic carbon composition in the desired regions of varying concentrations, compositions, and orientations to achieve a carrier plate for aircraft brake assemblies that is lightweight while being reliable and durable in use.

Brake disks with integrated heat sink are provided. Brake disk includes a fiber-reinforced composite material and an encapsulated heat sink material impregnated into the fiber-reinforced composite material. The encapsulated heat sink material comprises a heat sink material encapsulated within a silicon-containing encapsulation layer. Methods for manufacturing the brake disk with integrated heat sink and methods for producing the encapsulated heat sink material are also provided.

A latex of a carboxyl group-containing nitrile rubber contains an ,-ethylenically unsaturated nitrile monomer unit in a content of 8 to 60 wt % and having an iodine value of 120 or less, wherein the total content of potassium and sodium contained in the latex is 2,300 to 10,000 ppm by weight with respect to the whole latex.

The present invention provides a construction waste filler brake pad for a friction material production process comprising the steps to be constructed. The material is sorted to remove the fiber impurities and then calcined to form a filler. The filler is calcined and cooled and then immersed soak, dehydrate and dry to produce the mixture to be mixed; all materials are fully fused and released after the barrel is generated. Construction of rubbish filler brakes friction material. The construction waste filler brake pad of the embodiment of the present invention. Rubbing material production process with advantage for the production of construction waste filler brake pads friction material thermal good stability.