Patent Application

App. No. 12/776,122

Abstract

Claims (48)

1 . A hybrid brake pad, comprising:

a backing plate;

a semi-metallic portion having a central groove, and connecting with the backing plate;

a first ceramic composite portion adjacent to the semi-metallic portion, and connecting with the backing plate; and

a second ceramic composite portion opposite the first ceramic composite portion, and connecting with the backing plate.

2 . The hybrid brake pad according to claim 1 , further comprising:

a wear indicator layer between the backing plate and the semi-metallic portion.

3 . The hybrid brake pad according to claim 2 , further comprising:

a wear indicator layer between the backing plate and the first and second ceramic composite portions.

4 . The hybrid brake pad according to claim 1 , wherein the semi-metallic portion is of a single-piece construction, and having a first half, a second half, and a connecting portion.

5 . The hybrid brake pad according to claim 1 , wherein the first ceramic portion and the second ceramic portion are entirely separated by the semi-metallic portion.

6 . The hybrid brake pad according to claim 1 , wherein the semi-metallic portion comprises steel fibers.

7 . The hybrid brake pad according to claim 1 , wherein the first ceramic composite portion and the second ceramic composite portion comprise at least one of ceramic, aramid, Kevlar or glass fibers.

8 . The hybrid brake pad according to claim 1 , wherein the first ceramic composite portion and the second ceramic composite portion comprise non-metallic fibers.

9 . The hybrid brake pad according to claim 1 , further comprising an underlayer that bonds the backing plate to the first ceramic composite portion, the second ceramic composite portion, the semi-metallic portion.

10 . The hybrid brake pad according to claim 1 , wherein the first ceramic composite portion and the second ceramic composite portion are bonded to the semi-metallic portion.

11 . A method of making a hybrid brake pad using a press, comprising:

providing a backing plate;

placing the backing plate into the press;

providing a pre-form insert;

placing the pre-form insert into the press over the backing plate;

providing friction material;

placing the friction material into the press; and

engaging the press.

12 . The method of claim 11 , further comprising:

placing an underlayer material over the backing plate when it is in the press, and before placing the preform insert.

13 . The method of claim 12 , further comprising:

placing a wear indicator material within the underlayer material, and before placing the preform insert.

14 . The method of claim 11 , further comprising:

placing a wear indicator layer material over the backing plate when it is in the press, and before placing the preform insert.

15 . The method of claim 11 , further comprising:

a mold that forms a central groove in the pre-form insert.

16 . The method of claim 11 , further comprising:

a mold that forms the shape of the friction material and the pre-form insert.

17 . A hybrid brake pad prepared by a process comprising the steps of:

providing a backing plate;

placing the backing plate into the press;

providing a pre-form insert;

placing the pre-form insert into the press over the backing plate;

providing friction material;

placing the friction material into the press; and

engaging the press.

18 . The hybrid brake pad prepared by the process of claim 17 , further comprising:

placing an underlayer material over the backing plate when it is in the press, and before placing the preform insert.

19 . The hybrid brake pad prepared by the process of claim 18 , further comprising:

placing a wear indicator material within the underlayer material, and before placing the preform insert.

20 . The hybrid brake pad prepared by the process of claim 19 , further comprising:

placing a wear indicator layer material over the backing plate when it is in the press, and before placing the preform insert.

Assignments (8)