DE3617846A1 - METHOD FOR PRODUCING A BRAKE SHOE FOR DISC BRAKES AND BRAKE SHOE THEREOF - Google Patents

Description

The invention relates to a method for Her position of a brake shoe for disc brakes, esp especially for partial brake disc brakes, which consist of a Carrier plate, an intermediate layer and a friction layer and on the brake shoe.

It is known for disc brake pads between the Carrier plate and the friction layer an intermediate layer to arrange. The intermediate layer can with respect to the desired properties, such as insulation, noise damping, corrosion protection, bond strength, etc., different components to the base of a heat contain curable plastic and still has the Task, the connection of the friction material with the  To improve the carrier plate and thus the shear strength increase the surface of the covering.

It is also known to be made in the intermediate layer thermosetting plastic, e.g. Phenolic resin, Epoxy resin and the like, reinforced by short glass to provide pieces of fiber.

The brake shoe is generally manufactured in such a way that the intermediate layer in powder form a mold is inserted and together with the powdered friction material and the carrier plate, the is coated with a heat-activated adhesive, is pressed into a brake shoe.

This results in good strength values, in Transitional area between the friction layer and the intermediate layer is the dividing line between the last two Layers are not exactly defined, as they are completely the same pour the intermediate layer powder moderately into the Mold not possible under production conditions is. So it can be due to increasing wear of the pad the partial sanding of the intermediate layer before Er range from one to the wear limit of the friction lining undesirable change in the coefficient of friction.

In addition, the technical effort involved in pressing of a powdery interlayer material Lich because there is a separate one for the intermediate layer material Weighing and dosing equipment required on every press dig is.  

To avoid these disadvantages one is certain Use cases transitioned to the intermediate layer material by rolling or the like to an intermediate to process layered board. You cover with glue layered base plate, intermediate layer plate and powdered friction material into the die and compresses the whole into one unit. this leads to to largely exactly definable dividing surfaces between friction material and intermediate layer and simplified also the production process compared to pressing a powdery intermediate layer. It appears however, that the strength values are made in this way brake shoes did not reliably reach the desired height achieve because of the manufacturing process of Intermediate plate by rolling or the like. a seal the surface of the intermediate plate, which is the Adherence between friction material and intermediate plate nega tiv influenced.

The adjustment of the intermediate layer to adapt the respective requirements, such as insulation, Ge noise reduction, bond strength, corrosion protection and the like, there are narrow limits in this method sets because the required minimum strength values only with a few mixture variants of the Zwi layer material can be achieved.

The object of the invention is to provide a method for position of a brake shoe and a brake shoe create, with or with the simplified Pro a high shear strength of the linings Maintaining the other desired positive  Properties of the intermediate layer, such as noise reduction, Thermal insulation, corrosion protection and the like the brake shoe can be combined. The invention draws This is characterized in that the intermediate layer material (compound), a heat activated adhesive and possibly additives for setting the desired Viscosity mixed together and the pasty Ge mixed onto a glass fiber network and the same moderate, i.e. in uniform thickness, on the glass fiber network passed, e.g. distributed by squeegees, whereupon the interlayer material is dried.

From the dried intermediate layer obtained in this way material, preferably as a web, can be cut / Punch an intermediate layer that matches the carrier plate plate piece can be obtained from the web and then with the carrier plate and a powdered friction layer material by pressing and heating to the fer brake shoe when the plastic material hardens get connected.

The heat-activated adhesive that is in the intermediate layer material is incorporated, ensures on the carrier plates side of the intermediate plate for a good connection of the Carrier plate with intermediate plate. A good connection the friction material with the intermediate plate results characterized in that when the intermediate plate is manufactured there is a flat surface that defines a defined one Separation line between friction material and intermediate layer material ensures the surface of the intermediate plate on this dividing line but a sufficient one Roughness has a particularly good interlocking  leads with the friction material. This increases the shear strength of the surface considerably, in contrast to an otherwise intermediate rolling and / or pressing process in the Intermediate layer for the production of an intermediate plate, that makes the surface too smooth. It also increases the skeletal supporting structure of the fiber optic network the strength of the intermediate plate and thus contributes to the necessary shear strength of the covering against the Carrier plate not insignificantly reliable.

As has been shown, it can be put in between Layered, heat activated glue also acti by solvents for light bonds four. One makes this fact expediently thereby take advantage of the fact that by applying a drop of solution medium a slight adhesion between the carrier plate and Interlayer plate produced according to the invention manufactures.

A carrier plate pre-assembled in this way leads to a significant relief in the pro production, as for the completion of the brake shoe only two parts, namely the pre-assembled carrier plate and the powdery friction material by pressing and heating to form a brake shoe.

Glass fabric with the following data is advantageously used for production:
Glass fiber fabric with leno weave

Thread distribution of the warp threads approx. 4-8 per cm Thread distribution of the weft threads approx. 2-3 per cm Thread thickness approx. 0.6-1.2 mm

The intermediate plate produced according to the invention can for various purposes can be optimized.

Examples 1 to 3 give the composition of the Compounds as the starting material for the intermediate layer in% by weight.

Example 1 Optimization of thermal insulation
Example 2 Optimization of bond strength
Example 3 Optimization of noise reduction

The invention is based on the Darge in the drawing presented examples.

Fig. 1 illustrates a pictorial representation of the process flow.

Fig. 2 to 5 show an embodiment of the individual parts and the brake shoe in the diagram.

In Fig. 6 is a cross section through a fiction, manufactured according to the brake shoe.

In the manufacture of the intermediate plate one goes appropriately so that first a large track in one go running process is continuously produced.

The starting point for the manufacturing process is formed by a compound consisting, for example, of one of the three mixtures mentioned above. This compound 1 is intimately mixed in a solvent kneader 4 with the addition of heat-activatable adhesive 2 and, if necessary, of viscosity-adjusting additives 3 until a paste-like, flowable mass is formed.

This paste can then be removed from a storage container 5 by means of a metering pump 6 . By the metering pump this mass is supplied in the correct amount to the doctor device 9 , which is formed in the manufacturing process specified by way of example as an air knife; the methods of roller or blanket doctoring can also be used. During the doctoring process, the pasty intermediate layer material is applied in a uniform thickness to a glass fiber network 7 removed from a roll / coil. So that this intermediate layer material does not adhere or stick to the transport device during the production process, siliconized paper 8 is also fed under the glass fiber network.

Depending on the degree of dryness that can be achieved for the various formulations in the drying section 10 , one-sided or double-sided siliconized paper is used. Double-sided siliconized paper is used when, after the drying section, the degree of drying of the intermediate layer that can be achieved in the continuous process is so low that there is a risk of the individual intermediate layer layers sticking together when being wound into a coil. In this case, which is also the basis of the production process according to FIG. 1, the double-sided siliconized paper would then be wound together with the band-shaped intermediate layer to form coils.

If the degree of dryness is sufficient, only siliconized paper is used on one side, which is then removed before winding to coils 12 . In both methods, a separating device 11 is provided after the drying section (for example circular knife shears) in which the strip material is split into the widths required for further processing before it is wound up into coils 12 of different widths.

After transport and storage, if necessary, intermediate plates are cut / punched out of the intermediate layer material 13 with the right width for the dimensional design of the intermediate plate in a cutting or punching device 15 .

When using double-sided siliconized paper, which was also wound onto the coil, this is removed from the band-shaped intermediate layer material at 14 before the punching / cutting process. After the punching / cutting process, in which the contour of the intermediate plate 24 ( FIG. 3) is determined according to the outer contour of the friction lining and the anchoring holes of the lining carrier plate, a small amount of solvent 16 is now added to the side of the intermediate plate 24 , which is the Carrier plate 22 ( Fig. 2) faces. This solvent causes a slight activation of the adhesive incorporated into the interlayer material. After feeding 17 of the lining carrier plate 22 , the intermediate plate 24 is now placed on the carrier plate according to the contours and pressed under light pressure 18 . The adhesive activated by the solvent causes a slight gluing between the carrier plate and the intermediate plate.

The now pre-assembled with the intermediate plate carrier plate ( Fig. 4) forms an independently manageable composite unit that can be stored in stock before further processing.

The pre-assembled carrier plate ( Fig. 4) is now inserted into the press 20 and pressed with the powdered friction material 19 to the brake shoe. Fig. 5 shows this brake shoe 21 , wherein it can be clearly seen that the outer contour of the intermediate plate 24 corresponds exactly to the outer contour of the friction lining 23 .

The brake shoe ( FIG. 5), which has a carrier plate 22 of a predetermined configuration and a friction lining 23 , contains an intermediate layer plate piece 24 , which is formed from a mixture of intermediate layer material and a heat-activatable adhesive, in which a glass fiber network 7 is embedded. The interlayer sheet piece is of uniform thickness and has a flat and roughened surface 26 and 27 .

By ensuring the necessary shear strength speed for the brake shoe, it is possible to change the properties th of the intermediate layer in a wide range Modification of the formulation of the interlayer compound for various requirements, such as thermal insulation, Ge noise reduction, bond strength and corrosion protection, to optimize and at the same time a simplified hand guarantee in production.

Claims (5)

1. A method for producing a brake shoe for discs, especially for brake pads, which consists of a carrier plate, an intermediate layer and a friction layer, the intermediate layer being made of a thermosetting plastic and an insert, preferably glass fibers, and wherein the intermediate layer in the form of a plate piece or the like. Herge is provided, which is connected to the carrier plate and the friction layer in a mold by pressing and curing to form a unit, characterized in that the intermediate layer material and a heat-activatable adhesive are mixed together and the mixture is applied in plate form to a glass fiber network and uniformly , ie in a uniform thickness, passed on the glass fiber network, for example distributed by doctor blade and then dried, and that the intermediate plate piece thus obtained is connected in a corresponding size with the carrier plate and a powdered friction layer material by pressing and heating to the finished brake shoe. 2. The method according to claim 1, characterized in that an adhesive is used that is also by a solution can be activated medium, and that the interlayer Plate piece using the solvent for the glue is adhered to the carrier plate, and that the pre-assembled carrier plate with a powder shaped friction layer material by pressing and heating is connected to the finished brake shoe.   3. Brake shoe for disc brakes, in particular for brake pad disc brakes, which consists of a carrier plate, an intermediate layer and a friction layer, the intermediate layer being made of a thermosetting plastic material and a reinforcement, preferably made of glass fibers, characterized in that the intermediate layer Plate piece ( 4 ) consists of a mixture of intermediate layer material and heat-activated adhesive, and contains an embedded glass fiber network ( 5 ) which is of uniform thickness and has roughened surfaces ( 6 , 7 ). 4. Brake shoe according to claim 3, characterized in that the intermediate layer plate piece ( 4 ) and carrier plate ( 2 ) forms an independently manageable unit. 5. Brake shoe according to claim 3 or 4, characterized records that the glass fiber network as a glass fiber fabric Warp threads of about four to eight threads per cm, weft has threads of approximately two to three threads per cm and the thread thickness in the range of approximately 0.6 to 1.2 mm lies.