A brake assembly and a method for manufacturing a brake assembly are provided. The brake assembly includes a brake pad affixed to a substrate. The brake pad extends from the substrate to a brake pad friction surface, and includes abradable cellular metal foam with the hardened ceramic particles.

Technologies are generally described for a composition for an under-layer of a brake pad of a brake disc rotor. The composition may include a fiber pack, a powdered rubber, at least one binder, and at least one filler, wherein the fiber pack includes aramid fibers up to about 3 wt %.

A friction material comprising a Fe part; a coating layer formed over a surface of the Fe part; and a friction part formed on a surface of at least a part of the coating layer wherein: the coating layer comprises a first coating layer and a second coating layer in order from Fe part side, the first coating layer is constituted of an alloy containing Cu, Ni and Fe such that Fe content be not less than 10 atom %, the second coating layer is constituted of an alloy containing Cu and Ni, or an alloy containing Cu, Ni and Fe such that Fe content be less than 10 atom %, an average thickness of the first coating layer is not less than 1.0 μm and not more than 6.0 μm; and an average thickness of the second coating layer is not less than 9.5 μm and not more than 24.0 μm.

A brake pad includes a friction material and a backing plate which are coupled to each other. An apparatus for manufacturing the brake pad includes a forming device forming friction material powder in the form of the friction material and attaching the formed friction material to the backing plate in a forming process, a quality stabilization device heating and pressing the friction material, and a heat treatment unit heating the brake pad at a predetermined temperature.

A method for producing a multi-layered wet friction material includes providing a bottom layer, providing a top layer produced independently of the bottom layer from different materials, and bonding the bottom layer to the top layer. The bottom layer and the top layer may be produced from different formulations and supplied as raw papers. A formulation of the top layer may include twenty to sixty percent (20%-60%) filler, ten to forty percent (10%-40%) wood pulp, five to ten percent (5%-10%) aramid, and twenty-five to thirty-five percent (25%-35%) phenolic resin. A formulation of the bottom layer may include ten to fifty percent (10%-50%) filler, ten to forty percent (10%-40%) wood pulp, five to ten percent (5%-10%) aramid, five to fifteen percent (5%-15%) carbon, and twenty-five to thirty-five percent (25%-35%) phenolic resin.

A brake drum for a drum brake, in particular of a motor vehicle, includes a cylindrical jacket and a support pot which axially adjoins the jacket and which has a hub ring portion to be secured to a wheel hub. The monolithic brake drum is formed at least in part of a fiber-reinforced plastic.

The present invention relates to a method and an apparatus for manufacturing a brake pad, which are configured to stabilize quality of the brake pad. The present invention provides a method of manufacturing a brake pad including a friction material and a backing plate which are coupled to each other, the method including: a preliminary process of preparing friction material powder and the backing plate; a forming process of forming the friction material powder in the form of the friction material and attaching the friction material to one surface of the backing plate; a quality stabilization process of heating and pressing the friction material after the forming process is completed; a heat treatment process of heating the brake pad at a predetermined temperature after the quality stabilization process is completed; and a grinding process of grinding the friction material.

A brake drum for a drum brake, in particular of a motor vehicle, includes a cylindrical jacket and a support pot which axially adjoins the jacket and which has a hub ring portion to be secured to a wheel hub. The monolithic brake drum is formed at least in part of a fiber-reinforced plastic.

A method for producing a multi-layered wet friction material includes providing a bottom layer, providing a top layer produced independently of the bottom layer from different materials, and bonding the bottom layer to the top layer. The bottom layer and the top layer may be produced from different formulations and supplied as raw papers. A formulation of the top layer may include twenty to sixty percent (20%-60%) filler, ten to forty percent (10%-40%) wood pulp, five to ten percent (5%-10%) aramid, and twenty-five to thirty-five percent (25%-35%) phenolic resin. A formulation of the bottom layer may include ten to fifty percent (10%-50%) filler, ten to forty percent (10%-40%) wood pulp, five to ten percent (5%-10%) aramid, five to fifteen percent (5%-15%) carbon, and twenty-five to thirty-five percent (25%-35%) phenolic resin.

A friction material includes a friction-generating layer, a core layer, and a base layer. The friction-generating layer presents a friction-generating surface and includes a friction-generating material. The friction-generating material includes friction-adjusting particles. The core layer is adjacent to the friction-generating layer and includes a core material. The core material includes core fibers. The base layer is adjacent to the core layer such that the core layer is disposed between the friction-generating and base layers. The base layer presents a bonding surface facing opposite the friction-generating surface of the friction-generating layer. The base layer includes a fibrous material. The fibrous material includes base fibers chosen from aramid fibers, carbon fibers, cellulose fibers, acrylic fibers, polyvinyl alcohol fibers, glass fibers, mineral fibers, and combinations thereof. A resin is present in at least one of the friction-generating layer, the core layer, and the base layer.