Canadian Patents Database / Patent 2299110 Summary

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(12) Patent: (11) CA 2299110
(54) English Title: BRAKE PLATE AND METHOD AND APPARATUS OF MANUFACTURING SAME
(54) French Title: PLAQUE DE FREINS AINSI QUE METHODE ET APPAREIL DE FABRICATION
(51) International Patent Classification (IPC):
  • F16D 69/04 (2006.01)
  • B23D 79/00 (2006.01)
  • B23P 15/18 (2006.01)
(72) Inventors :
  • ARBESMAN, RAY (Canada)
(73) Owners :
  • NUCAP INDUSTRIES INC. (Not Available)
(71) Applicants :
  • ARBESMAN, RAY (Canada)
(74) Agent: AIRD & MCBURNEY LP
(74) Associate agent:
(45) Issued: 2006-09-05
(22) Filed Date: 2000-02-18
(41) Open to Public Inspection: 2000-08-18
Examination requested: 2001-03-23
(30) Availability of licence: N/A
(30) Language of filing: English

(30) Application Priority Data:
Application No. Country/Territory Date
2,262,214 Canada 1999-02-18

English Abstract

The invention is a plate for holding a friction material in a brake assembly. The plate preferably comprises a contact surface for attaching the friction material to the plate, a second surface opposing the contact surface; and a plurality of retaining structures formed on the contact surface, each retaining structure comprising a projecting member extending from a point between the contact surface and the second surface, so that the member extends outwardly from the contact surface for engagement with the friction material.


French Abstract

L'invention concerne une plaque destinée à supporter un matériau de frottement dans un ensemble de frein. La plaque comprend de préférence une surface de contact pour la fixation du matériau de frottement à la plaque, une deuxième surface opposée à la surface de contact ; et une pluralité de structures de retenue formées sur la surface de contact, chaque structure de retenue comprenant un élément en saillie s'étendant à partir d'un point entre la surface de contact et la deuxième surface, de sorte de que l'élément s'étende vers l'extérieur à partir de la surface de contact pour venir en prise avec le matériau de frottement.


Note: Claims are shown in the official language in which they were submitted.




CLAIMS

1. A brake backing plate for holding a friction material in a brake assembly,
the
plate being produced by a cutting apparatus which includes a plurality of
knives,
each knife having a cutting edge, the edge having a plurality of teeth
connected
thereto, each tooth having a leading surface that is transverse to the axis of
the
knife and angled in the manner of a plow,

the plate comprising:

(a) a contact surface, and

(b) a plurality of parallel rows of integral retaining structures cut or
scored from the contact surface, each row defining an axis on the plate,
each retaining structure comprising:

(i) a projecting member extending outwardly from the contact
surface and projecting at a sideward angle from the axis of the row for
engagement with the friction material, the sideward angle of the projecting
member being formed by the plow angle of one of the teeth; and

(ii) a depression surface abutting the projecting member, the
depression surface extending into the contact surface, without perforating
the contact surface.

2. The plate of claim 1, wherein each retaining structure in a row is coaxial
and is
configured so that its depression surface extends away from its projecting
member and (l) extends in the opposite direction of the depression surfaces of
the retaining structures in a first adjacent row and (ii) extends in the same
direction as the depression surfaces of the retaining structures in a second
adjacent row.



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3. The plate of any one of claims 1-2, wherein the plate comprises a plurality
of
pairs of rows of retaining structures, each pair of rows comprising a first
row
comprising retaining structures having projecting members angled in a first
sideward direction and a second row comprising retaining structures having
projecting members angled in a second opposite sideward direction.

4. The plate of claim 1, wherein the area of the plate covered by retaining
structures
comprises an area approximately equal to the area of the friction material to
be
coupled to the plate.

5. The plate of any one of claims 1-4, wherein the position of the retaining
structures in the rows comprises a staggered configuration between adjacent
rows.

6. The plate of any one of claims 1-5, wherein the contact surface is curved
or
substantially flat.

7. The plate of any one of claims 1-6, wherein the plate comprises a disk
brake
backing plate.

8. The plate of any one of claims 1-6, wherein the plate comprises a drum
brake
backing plate.

9. The plate of any one of claims 1-8, wherein the projecting member is in the
form
of a burr having a curved shape, the burr curving away from the abutting
depression surface.



17




10. The plate of any one of claims 1-9, wherein the plate comprises a metal or
a
metal composite plate.

11. A brake pad for use in a brake assembly, the brake pad comprising:

(a) a friction material; and

(b) a brake backing plate coupled to the friction material, the plate
comprising
a plate in accordance with claim 1.

12. A method of manufacturing a brake backing plate for securing a friction
material
to a contact surface thereof, the plate comprising a contact surface for
attaching
the friction material to the plate, the method comprising the step of:

cutting or scoring a plurality of parallel rows of integral retaining
structures
from the contact surface, each row defining an axis on the plate, each
retaining structure comprising:

(a) a projecting member extending outwardly from the contact
surface for engagement with the friction material and projecting at
a sideward angle from the axis of the row for engagement with the
friction material; and

(b) a depression surface abutting the projecting member, the
depression surface extending into the contact surface, without
perforating the contact surface;

wherein the cutting or scoring is done by a cutting apparatus which
includes a plurality of knives, each knife having a cutting edge, the edge
having a plurality of teeth connected thereto, each tooth having a leading
surface that is transverse to the axis of the knife and angled in the



18




manner of a plow, so as to form the sideward angle in the projecting
member of each one of the plurality of retaining structures.

13. The method of claim 12, wherein each said retaining structure is made by
one
tooth.

14. The method of claim 13, wherein each tooth cuts or scores the contact
surface to
form a projecting member and an abutting depression surface.

15. The method of any one of claims 12-14, wherein each retaining structure in
a row
is coaxial and is configured so that its depression surface extends away from
its
projecting member and (i) extends in the opposite direction of the depression
surfaces of the retaining structures in a first adjacent row and (ii) extends
in the
same direction as the depression surfaces of the retaining structures in a
second
adjacent row.

16. The method of any one of claims 12-15, comprising forming the plurality of
pairs
of rows of retaining structures so that each pair of rows comprises a first
row
comprising retaining structures having projecting members angled in a first
sideward direction and a second row comprising retaining structures having
projecting members angled in a second opposite sideward direction.

17. The method of any one of claims 12-16, comprising cutting or scoring
retaining
structures on an area of the plate approximately equal to the area of the
friction
material to be coupled to the plate.



19




18. The method of any one of claims 12-17, wherein adjacent knives move in
opposing directions.

19. The method of claim 18, wherein adjacent knives cut or score rows of
retaining
structures so as to form a staggered configuration between adjacent rows.

20. The method of any one of claims 12-19, wherein the knives cut projecting
members in the form of a curved burr, the burr curving away from the abutting
depression surface.

21. The method of any one of claims 12-20, wherein the plate comprises a metal
plate or a metal composite plate.

22. The method of any one of claims 12-21, wherein the knives commence to move
parallel to the contact surface prior to impact with the plate.

23. The method of any one of claims 12-21, wherein the knives commence to move
parallel to the contact surface upon impact with the plate.

24. An apparatus for manufacturing a brake backing plate having a plurality of
retaining structures cut or scored from a contact surface thereof for
retaining a
friction material, comprising:

a cutting means for cutting a plurality of parallel rows of integral retaining
structures on the contact surface, each row defining an axis on the plate,
each retaining structure comprising:



20


(a) a projecting member extending outwardly from the contact
surface and projecting at a sideward angle from the axis of the
row for engagement with the friction material; and
(b) a depression surface abutting the projecting member, the
depression surface extending into the contact surface, without
perforating the contact surface;
wherein the cutting means comprises a plurality of knives, each knife
having a cutting edge, the edge having a plurality of teeth connected
thereto, each tooth having a leading surface that is transverse to the axis
of the knife and angled in the manner of a plow, so as to form the
sideward angle in the projecting member of each one of the plurality of
retaining structures upon impact with the contact surface; and
a driving means for impacting the cutting means and the contact surface
of the plate to form the retaining structures.

25. An apparatus as in claim 24, wherein the knives form adjacent pairs of
parallel
rows which are oriented in opposite directions.

26. The apparatus of claim 24, wherein each knife comprises a plurality of
parallel
rows of teeth, the teeth positioned to comprise a staggered configuration
between adjacent rows.

27. The apparatus of any one of claims 24-26, wherein each knife further
comprises
removable tooth inserts in locking engagement with the knife along the cutting
edge.

21



28. The apparatus of any one of claims 24-26, wherein each knife further
comprises
removable blank inserts in locking engagement with the knife, each blank
insert
having a flat surface at the cutting edge.

29. The apparatus of any one of claims 24-28, wherein the apparatus further
comprises:
at least one drive member slidably connected to at least one side of each of
the
plurality of knives;
at least one slide member slidably connected to the drive member;
wherein during impact between the knives and the contact surface, the slide
member is adapted to move away from the contact surface, the slide member
being adapted to move the drive member generally parallel to the contact
surface, the drive member being adapted to move the knives generally parallel
to
the contact surface.

30. The apparatus of claim 29, wherein the slide member comprises an inclined
sliding surface, the sliding surface being adapted to move the drive member
generally parallel to the contact surface upon movement of the slide member.

31. The apparatus of any one of claims 29-30, wherein the at least one slide
member
comprises two slide members, the at least one drive member comprises first and
second drive members, and the at least one side of the each of the knives

22



comprises a first side and a second side, wherein the first drive member is
proximate to the first side of at least one knife, and the second drive member
is
proximate the second side of the remaining knives.

32. The apparatus of claim 31, wherein the first and second sides of alternate
knives
are proximate to the first and second drive members, respectively.

33. The apparatus of any one of claims 25-33, wherein adjacent knives move in
opposing directions upon impact with the contact surface.

34. The apparatus of any one of claims 25-33 further comprising a return means
for
returning the knives to a starting position.

35. The apparatus of claim 34, wherein the return means is at least one spring
attached to a first and second slide rod, the slide rods being located within
a first
and second guide slots defined proximate to the first and second side of each
knife.

36. The apparatus of any one of claims 24-35, wherein the plurality of knives
are
disposed longitudinally in relation to the plate.

37. The apparatus of any one of claims 24-36, wherein the knives are
substantially
parallel to each other.

23



38. The apparatus of any one of claims 24-37, wherein the plurality of knives
are
adapted to move generally parallel to the contact surface prior to impact with
the
plate.

39. The apparatus of any one of claims 24-37, wherein the plurality of knives
are
adapted to move parallel to the contact surface upon impact with the plate.

40. The apparatus of any one of claims 24-37, wherein the plate is stationary
and the
plate is punched by the knives.

41. The apparatus of any one of claims 24-40, wherein the knives are fixed in
the
direction perpendicular to the contact surface, and the plate is driven onto
the
knives.

42. The apparatus of claim 35, wherein the apparatus further comprises:
a press having a top movable portion and a bottom stationary portion;
a base plate secured to the top movable portion of the press;
two side plates secured to the base plate, the side plates projecting
downwardly
therefrom;
a positioning means for maintaining the knives proximate to each other; the
positioning means being connected to the side plates;

24



a force adjustment means for adjusting the force of impact of the knives
against
the contact surface; and
wherein the first and second slide rods are suspended from the base plate.

43. The apparatus of claim 42, wherein the force adjustment means comprises a
pressure plate generally parallel to the base plate and at least one spring
disposed between the base plate and the pressure plate, the pressure plate
being connected to the knives.

44. The apparatus of any one of claims 42-43, wherein the first and second
slide
rods impact the bottom stationary portion of the press prior to the knives
impacting the contact surface, thereby causing the knives to move generally
parallel to the contact surface prior to impact of the knives against the
contact
surface.

45. The apparatus of any one of claims 42-43, wherein the first and second
slide
rods impact the bottom stationary portion of the press substantially
simultaneously with the knives impacting the contact surface, thereby causing
the knives to move generally parallel to the contact surface substantially
simultaneously with impact of the knives against the contact surface.

25


Note: Descriptions are shown in the official language in which they were submitted.


CA 02299110 2000-02-18
BRAKE PLATE AND METHOD AND APPARATUS FOR MANUFACTURING SAME
TECHNICAL FIELD
This invention relates to brakes, and in particular to an improved brake
plate, as
well as a method and apparatus for manufacturing the plate.
BACKGROUND ART
The number of motor vehicles has increased greatly in recent years. There is
an
interest in methods of reducing the cost of manufacturing brakes and
replacement parts on the
part of both motor vehicle manufacturers and suppliers of parts for brakes.
This increased use
has also led to a significant increase in the after-market for brake
replacement and repair.
Brakes are also in increasing demand for motor vehicles such as airplanes,
trains, bicycles, all
terrain vehicles and motorcycles.
Brakes, as currently manufactured, combine two main parts, namely a plate
(often called a backing plate) and a friction pad. The plate is mounted in a
brake assembly, and
may be formed by making a plate with a variety of bosses, holes, or other
features for receiving
and retaining the friction pad. The need to use high speed low cost
manufacturing methods
often results in irregularities in the plate which may lead to difficulties in
attaching and/or
retaining the friction pad on the plate during braking, when the friction pad
is in contact with the
rapidly turning brake rotor, or even during the pre-installation handling of
the brake pad
assembly.
There are a variety of known ways of attaching a friction pad to a plate. One
such way is to attach the friction pad to the backing plates using rivets. One
disadvantage of
the riveting process is that it creates a rigid bond between the plate and the
friction pad, which
1


CA 02299110 2000-02-18
can, as a result of a sudden impact, lead to breaking of the friction pad.
Furthermore, this
process often requires one or more additional manufacturing steps with a
consequent increase
in cost. In addition, when the friction pad is worn down over time, the rivets
become exposed
and rub against the brake rotor, causing scoring on the rotor which is costly
to repair.
Another, more recently developed method of mounting the friction pad on the
plate is to use a pressurised molding process to mold the friction pad
directly onto the plate. In
this process, the friction pad may be prepared by blending the components of
the friction pad
into a pre-form or cake. A conventional pressurized molding system is used to
mold the friction
pad pre-form onto the plate. A layer of cement or glue if often applied to the
contact surface of
the plate to improve the adhesion between the plate and the friction pad.
As pressure is applied to the mold assembly, the pre-form becomes heated and
begins to flow, filling the mold and covering the appropriate surface of the
plate. In this
process, the pre-form material is intended to flow into and around the various
features to
improve the bond between the plate and the friction pad.
The plate is subjected to a number of forces, such as the jarring of the
moving
vehicle, as well as vibration caused by the rotor and noise. The problem with
the prior art
processes and plates is that features, such as holes and bosses, stamped into
the plate often
provided insufficient shear and/or tensile strength in the bond between the
friction pad and
plate. When additional features are stamped into the plate to increase bond
strength, additional
manufacturing steps are required, adding to the cost.
The most common prior art features stamped into plates are circular holes.
These holes often provide unsatisfactory results because, during the molding
process, the pre-
form cake does not completely fill all of the holes, which in turn, leads to
deficient bonding
2


CA 02299110 2000-02-18
between the plate and the pre-form. The incomplete hole fills can are clearly
visible, and often
raise quality concerns when inspected by buyers. The incomplete hole fills
also have an
aesthetically displeasing appearance, which can also make them less attractive
to customers.
Accordingly, it has become common practice in prior art plates to fill the
incomplete hole ~Ils
with putty and to paint over them, to both hide the unsatisfactory molding
results and to improve
appearance. These additional manufacturing steps have the added disadvantage
of increasing
the cost of manufacturing the disc brake.
Furthermore, the holes stamped by prior art processes reduce structural
strength
of the plate, and make it more vulnerable to the various forces acting on it.
These forces may
distort the shape of the plate, leading to uneven wear on the friction pad, or
can lead to
structural failure of the plate.
Another problem with brake plates is caused by the heat generated by friction.
The expansion and contraction values of the plate are different from those of
the friction
material. Braking generates heat so the plate and material are exposed to
frequent heating and
cooling. Since the expansion and contraction values differ, there may be a
separation between
the plate and the material, particularly where the plate is flat or has large
flat areas. Rust can
then form between the plate, which leads to noise and brake failure.
Accordingly, there is a need for a brake plate and a method of manufacturing
same which can provide improved bonding with the friction pad without
increasing the cost of
producing the plate
SUMMARY OF THE INVENTION
It is an object of the invention to provide a plate which provides an improved
bond between it and the friction pad, as well as increasing the structural
strength of the plate,
3


CA 02299110 2000-02-18
without increasing the cost of producing the plate. In addition, it is an
object of the invention to
provide a method and apparatus for manufacturing the plate which reduces time
and cost by
requiring fewer manufacturing steps, while at the same time retaining the
structural strength of
the backing plate.
Further features of the invention will be described or will become apparent in
the
course of the following detailed description.
The invention includes a plate for holding a friction material in a brake
assembly,
the plate comprising:
a contact surface for attaching the friction material to the plate,
a second surface opposing the contact surface;
a plurality of retaining structures formed on the contact surface, each
retaining structure
comprising a projecting member extending from a point between the contact
surface and the
second surface, so that the member extends outwardly from the contact surface
for
engagement with the friction material. The retaining structure may further
comprise a
depression surface abutting the projecting member, the depression surface
extending into the
contact surface. The contact surface may be curved or substantially flat. The
brake may
comprise a disk brake or a drum brake. The plate may comprise integral
retaining structures.
The retaining structures can be formed from the plate, and preferably cut or
scored. In a
variation, the projecting member may be a burr. The burr optionally comprises
a hook shape,
wherein a distal end of the hook points away from the depression adjacent to
the hook. The
retaining structures are optionally disposed in a plurality of rows. The rows
are optionally
substantially parallel. The rows may be usefully disposed longitudinally.
The invention also includes a method of manufacturing a brake plate for
securing
a friction material to a contact surface thereof, the method comprising
providing:
a contact surface for attaching the friction pad to the plate,
a second surface opposing the contact surface;
a plurality of retaining structures formed on the contact surface, each
retaining structure
comprising a projecting member extending from a point between the contact
surface and the
4


CA 02299110 2000-02-18
second surface, so that the member extends outwardly from the contact surface
for
engagement with the friction pad.
The invention includes a brake plate, preferably a drum brake plate or a disc
brake plate made according to a method of the invention or with the apparatus
of the invention.
In one method, the retaining structures are formed by cutting the contact
surface. The retaining structures are alternatively formed by scoring the
contact surface. In
another variation, the retaining structures are formed by cutting a plurality
of rows of retaining
structures on the contact surface. The rows are optionally substantially
parallel and/or disposed
longitudinally.
In one embodiment, the cutting is done by a plurality of knives, each knife
having
a cutting edge, the edge having a plurality of teeth connected thereto. Each
retaining structure
is preferably made by one tooth. Each tooth preferably cuts a projecting
member from the
contact surface to form an adjacent depression. The knives are preferably
disposed
longitudinally in relation to the plate. The knives may be substantially
parallel. Adjacent knives
preferably move in opposing directions. The plurality of knives are preferably
moving parallel to
the contact surface prior to impacting the plate. The plurality of knives
preferably commence to
move parallel to the contact surface upon impact with the plate. The plate may
be stationary
while it is punched by the knives. The knives are optionally fixed in the
direction perpendicular
to the contact surface and the plate is impacted onto the knives.
Another variation of the invention relates to an apparatus for manufacturing a
brake plate having a plurality of retaining structures formed on a contact
surface thereof for
retaining a friction material, comprising:
a means for cutting a plurality of retaining structures on the contact
surface, each
retaining structure comprising a projecting member extending from a point
between the contact
surface and the second surface, so that the member extends outwardly from the
contact
surface for engagement with the friction pad, the cutting means being adapted
to move
generally parallel to the contact surface to cut the retaining structures;
a driving means for impacting the cutting means and the contact surface of the
5


CA 02299110 2000-02-18
plate to form the retaining structures.
The cutting means preferably comprises a plurality of knives, each knife
having a
cutting edge, the edge having a plurality of teeth connected thereto, each
tooth adapted to form
one of the plurality of retaining structures upon impact with the contact
surface.
The apparatus optionally further comprises:
at least one drive member slidably connected to at least one side of each of
the
plurality of knives;
at least one slide member slidably connected to the drive member;
Duuring impact between the knives and the contact surface, the slide member is
preferably
adapted to move away from the contact surface, the slide member being adapted
to move the
drive member generally parallel to the contact surface, the drive member being
adapted to
move the knives generally parallel to the contact surface.
The slide member may have an inclined sliding surface, the sliding surface
being
adapted to move the drive member generally parallel to the contact surface
upon movement of
the slide member. The at least one slide member can be two slide members, the
at least one
drive member can comprise first and second drive members, and the at least one
side of the
each of the knives can comprise a first side and a second side, wherein first
drive member is
proximate to the first side of at least one knife, and the second drive member
is proximate the
second side of the remaining knives. The first and second sides of alternate
knives are
preferably proximate to the first and second drive members, respectively. The
adjacent knives
preferably move in opposing directions upon impact with the contact surface.
The apparatus
may further comprise a return means for returning the knives to a starting
position. The return
means is optionally at least one spring attached to a first and second slide
rod, the slide rods
being located within a first and second guide slots defined proximate to the
first and second
side of each knife. The plurality of knives are preferably disposed
longitudinally in relation to
the plate. The apparatus knives are preferably substantially parallel to each
other.
The slide member and the plurality of knives are preferably adapted to move
generally parallel to the contact surface prior to impact with the plate. The
plurality of knives
are preferably adapted to move parallel to the contact surface upon impact
with the plate. The
6


CA 02299110 2000-02-18
plate is optionally stationary while punched by the knives. The knives are
optionally fixed in the
direction perpendicular to the contact surface, and the plate is driven onto
the knives. The
impacting means optionally comprises a press having a top movable portion and
a bottom
stationary portion.
The apparatus of optionally further comprises:
a base plate secured to the top portion of the press;
two side plates secured to the base plate, the side plates projecting
downwardly
therefrom;
a positioning means for maintaining the knives in proximate to each other; the
positioning means being connected to the side plates;
a force adjustment means for adjusting the force of impact of the knives
against
the contact surface, the force adjustment means having a pressure plate
generally parallel to
the base plate and at least one spring disposed between the base plate and the
pressure plate,
the pressure plate being connected to the knives;
wherein the first and second slide rods are suspended from the base plate.
The first and second sliding members preferably impact the bottom portion of
the press prior to
the knives impacting the contact surface, thereby causing the knives to move
generally parallel
to the contact surface prior to impact of the knives against the contact
surface. The first and
second sliding members preferably impact the bottom portion of the press
substantially
simultaneously with the knives impacting the contact surface, thereby causing
the knives to
move generally parallel to the contact surface substantially simultaneously
with impact of the
knives against the contact surface.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more clearly understood, preferred
embodiments thereof will now be described in detail by way of example, with
reference to the
accompanying drawings, in which:
Fig. 1 is a perspective view of a preferred embodiment of a plate according to
7


CA 02299110 2000-02-18
the present invention;
Fig. 2 is a perspective view of a preferred embodiment of an apparatus for
manufacturing the plate according to the present invention;
Fig. 3A is a plan view of the apparatus;
Fig. 3B is a magnified view showing the knives and teeth of the apparatus
shown
in Fig. 3A;
Fig. 4 is an elevation view of the apparatus with the side plates removed;
Fig. 5A is a cross-sectional view showing the apparatus impacting the bottom
of
a conventional press;
Fig. 5B is a cross-sectional view showing the knives beginning to cut into a
blank;
Fig. 5C is a cross-sectional view showing the knives completing the cut into a
blank;
Fig. 5D is a cross sectional view showing the apparatus impacting a press. The
spring is beneath the press. A spring or a nitro spring may be used.
Fig. 6 is a perspective view of an alternate preferred embodiment of a plate
according to the present invention;
Fig. 7 is a perspective view of a preferred embodiment of a knife with rows of
offset teeth for manufacturing the backing plate according to the present
invention. The figure
shows an insert allowing one or more teeth to be releasably inserted into the
knife.
Fig. 8A is a top plan view of a knife;
Fig. 8B is a side plan view of a knife;
Fig. 8C is a top plan view of a knife;
8


CA 02299110 2000-02-18
Fig. 8D is a side plan view of a knife;
Figs. 9A and B are perspective views of a releasable knife insert having
offset
teeth;
Figs. 9C is a perspective view of a releasable knife insert.
DETAILED DESCRIPTION OF THE INVENTION
The invention is a plate for holding a friction material in a brake assembly.
The plate
preferably comprises:
(a) a contact surface for attaching the friction material to the plate,
(b) a second surface opposing the contact surface;
(c) a plurality of retaining structures formed on the contact surface, each
retaining
structure comprising a projecting member extending from a point between the
contact surface and the second surface, so that the member extends outwardly
from the contact surface for engagement with the friction material.
The retaining structure may further comprise a depression surface abutting the
projecting member, the depression surface extending into the contact surface.
The brake plate, as well as the process and apparatus for manufacturing same
according to the present invention are useful in the field of manufacturing of
vehicle brake parts.
The plate is useful in brakes for any motor vehicle, such as cars, trucks,
airplanes, trains,
bicycles, all terrain vehicles or motorcycles.
Fig. 1 shows a brake plate 1 according to a preferred embodiment of the
present
invention. The plate 1 has a conventional shape and any suitable thickness
('/8 -'/Z of an inch),
and is preferably manufactured from metal or a metal composite adapted to
withstand the rigors
of a conventional braking system. The circular holes shown on the plate are
not necessary and
are included for illustrative purposes only. The backing plate has a contact
surface 2 for
molding a friction material (not shown) thereto by a conventional molding
process.
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CA 02299110 2000-02-18
Any suitable number of retaining structures 3 are connected to the first
surface of
the backing plate. Preferably, the retaining structures are integrally formed
by punching the
backing plate, as described in more detail below. Each retaining structure
includes a burr 4
projecting out of the first surface, which is located adjacent to a
corresponding depression 5
defined in the contact surface 2. Preferably, each burr is integrally formed
by cutting the burr
out of the first surface of the backing plate, which creates the corresponding
depression 5. The
projecting member extends from a point between the contact surface and the
second surface
36 (in figure 6, the second surface is opposite the contact surface and
appears as the flat
bottom surface of the plate), so that the member extends outwardly from the
contact surface for
engagement with the friction material. Each burr preferably has a curved
shape, which curves
away from its corresponding depression.
The retaining structures 3 are preferably arranged in longitudinally disposed
substantially parallel rows 6. Preferably, the position of the burr 4 and
depression 5 is identical
for each row, but alternates with adjacent rows, as shown in Fig. 1.
Preferably, the number of
rows is sufficient to cover substantially the entire surface area of the
backing plate 1 in order to
provide maximum bond strength. The depth of the depressions and the height of
the burrs
depends on the bond strength required for a particular application. Figure 6
shows a variation
of the plate in which there is increased space between the structures of each
row. The
retaining structures in each row are spaced apart farther than those in figure
1.
The plate 1 according to the present invention does not need to be coated with
an any adhesive to achieve the required bond strength with the friction
material. Since the plate
has a large number of projecting members, there will be no separation between
the plate and
the material as the plate and material are subjected to frequent heating and
cooling. The plate


CA 02299110 2000-02-18
lasts longer and is safer.
For a disc brake as shown in Figure 1, the height of the members may
preferably
be about 0.030 inches to 0.075 inches above the contact surface. There are
preferably at least
about 20 projecting members per square inch. The horizontal pitch (distance
between each
member) between members in the direction of chip formation may preferably
range between
0.120 and 0.250 inches. The pitch between rows is preferably about 0.100 to
0.200 inches.
The coverage of members on the contact surface is preferably at least about
65% for a disc
brake.
For a disc brake as shown in Figure 6, the height of the members may
preferably
be about 0.030 inches to 0.075 inches and more preferably about 0.045 to 0.060
inches above
the contact surface. There are preferably at least about 30 projecting members
per square
inch. The horizontal pitch (distance between each ) between members in the
direction of chip
formation may preferably range between 0.120 and 0.250 inches and is more
preferably 0.060
inches. The coverage of members on the contact surface is preferably at least
about 65% for a
disc brake.
The method of manufacturing the backing plate 1 according to the present
invention comprises placing the backing plate on a flat surface under a
conventional press and
punching the contact surface 2 of the backing plate with a series of
substantially parallel knives
10. Referring to Fig. 2, the knives are preferably disposed substantially
parallel to the
longitudinal axis of the backing plate. Each knife has a plurality of
preferably identical teeth 11
defined along a cutting edge thereof. Each tooth forms the depression 5 and
burr 4 of one
retaining structure 3. The configuration of the teeth may alternate from row
to row, such that
every other row has an identical configuration. In Fig. 6, a knife with offset
teeth is preferably
11


CA 02299110 2000-02-18
used to create a checkerboard pattern (alternating retaining structure
pattern) between rows cut
by the same knife.
Fig. 2 shows the apparatus 12 for manufacturing the backing plate according to
the present invention. The apparatus is mounted to a conventional press in any
suitable
manner for punching the backing plate 1, as described above.
Referring to Figs. 2-4, the apparatus 12 includes a base plate 13 from which
two
side plates 14 are suspended by preferably four conventional screws 15.
Preferably, two
transverse slide rods 16 are suspended from four support springs (not shown)
which are each
attached to one of the screws at one end and to an end of the slide rod at the
other end. The
slide rods are slidably secured to the knives 10 by preferably locating in
guide slots 17 defined
in the knives. A biasing means, such as, for example, two return springs 18
are connected to
each slide rod to bias the slide rods toward each other. A pressure plate 19
is disposed above
the non-cutting edges of the knives. Preferably, a plurality of adjustment
springs 20 are
disposed between the base plate and the pressure plate to urge the two apart.
Two block
housings 21 are mounted transversely onto the base plate adjacent to the edges
of the knives.
A drive block 22 is mounted on each block housing by a slide bolt 23 which is
disposed
substantially parallel to the longitudinal axis of the knives. A slide block
24 is slidably mounted
in each housing adjacent to the drive block.
Fig. 5A shows the initial step of operation of the apparatus 12. A
conventional
press (not shown) drives the apparatus 12 onto a plate blank 25, such that the
slide block 24
preferably impacts the bottom surface of the press 26 before the knives 10
impact the blank.
The impact against the bottom surface of the plate drives the slide block up
relative to the drive
block 22, causing the slide block sliding surface 27 to exert a force on the
drive block
12


CA 02299110 2000-02-18
substantially parallel to the longitudinal axis of the knives. This force
causes each drive block to
move alternate knives along their longitudinal axis. Because only alternate
knives contact each
drive block before impact, adjacent knives are pushed in opposite directions
by each drive
block. Preferably, the knives are moving before the blank contacts the knives.
The teeth of the knives may be arranged along the longitudinal axis of the
knife,
so that they form a single row. There may be portions where no teeth are
present, as in Fig.
8D. Each tooth has a leading surface which is transverse to the axis of the
knife. The leading
surface may be angled to determine the burr shape, in the same manner as a
plow is angled.
All the teeth may have a similar leading angle or they may be varied.
In a knife variation, the teeth are offset, preferably so that the teeth are
arranged
in two or more rows, as shown in Fig. 9. Each knife thus cuts rows of teeth
along two
longitudinal axes (forming two rows that are preferably substantially
parallel) to provide a brake
pad as shown in Fig. 6.
Referring to Figs. 5B and 5C, the impact of the knives 10 against the blank 25
may be regulated by the biasing means, preferably adjustment springs 20 (shown
in Fig. 2).
The adjustment springs allow the apparatus 12 to be mounted on presses having
different force
specifications. The adjustment springs effectively ensure that a constant
force is exerted
against the knives, regardless of the force applied by the press. In a
variation, the springs are
located beneath the plate as shown in Fig. 5D. As the knives are pushed down
into the blank,
they also slide along the slide rods 16 parallel to their longitudinal axis,
such that adjacent
knives are moving in opposite directions as they cut. These simultaneous
downward and
sliding movements cause each tooth 11 of a knife to form one retaining
structure 3.
The apparatus is able to complete an entire plate in one punch. After the
press
13


CA 02299110 2000-02-18
lifts the apparatus 12, the slide block 24 is returned into its starting
position by gravity, and the
knives 10 and drive block 22 are returned to their starting positions by the
slide springs 19.
One skilled in the art could readily use the knives to prepare drum brake
plates.
During the process of molding and securing the friction material to the plate,
the
pre-form material is set into a mold and pressed against the plate. The
material flows into and
surrounds each retaining structure 3 to bond with the plate 1. The retaining
structures provide
improved tensile strength, as well as providing improved shear resistance. The
tensile and
shear strengths can be varied by changing either the depth of the cut (i.e.
the depression 5),
which also increases the height of the burr 4. These results are accomplished
using a two step
process, and without the need for additional features, such as holes, leading
to a decreased
manufacturing time and significant cost savings.
Figure 5D shows a variation of the apparatus in which a spring is mounted on a
fixed press bed so that the spring is beneath the press. The spring may be a
conventional coil
spring or a nitrogen spring. Any other suitable biasing means may be used. A
knife of the
invention is shown in Figs. 7 and 8. In these figures, the teeth of each knife
are aligned along
an axis defined by the knife. However, the teeth may be offset to provide a
brake pad of the
type shown in Fig. 6. Figure 7 shows a knife with offset teeth.
Figure 7 also shows that the knife may be made with releasable inserts. Broken
or dull teeth may be readily changed without discarding the knife. A blank
insert with no teeth
may also be used. Inserts may optionally be permanently fixed in the knife.
Figures 8A and 8B
show the knife with continuous teeth. Figs. 8C and 8D show the knife having a
blank surface
where no teeth are present. The plate will have no retaining surfaces formed
where the knife is
blank. Figs. 9A and 9B show offset teeth. Fig. 9C shows that the offset teeth
are preferably
14


CA 02299110 2000-02-18
about the same height above the knife.
It will be appreciated that the above description relates to the preferred
embodiment by way of example only. Many variations on the invention will be
obvious to those
knowledgeable in the field, and such obvious variations are within the scope
of the invention as
described and claimed, whether or not expressly described.

A single figure which represents the drawing illustrating the invention.

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Admin Status

Title Date
Forecasted Issue Date 2006-09-05
(22) Filed 2000-02-18
(41) Open to Public Inspection 2000-08-18
Examination Requested 2001-03-23
(45) Issued 2006-09-05

Abandonment History

There is no abandonment history.

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Filing $150.00 2000-02-18
Special Order $100.00 2001-03-14
Request for Examination $400.00 2001-03-23
Maintenance Fee - Application - New Act 2 2002-02-18 $100.00 2002-02-18
Maintenance Fee - Application - New Act 3 2003-02-18 $100.00 2003-02-18
Maintenance Fee - Application - New Act 4 2004-02-18 $100.00 2004-02-09
Maintenance Fee - Application - New Act 5 2005-02-18 $200.00 2005-02-16
Maintenance Fee - Application - New Act 6 2006-02-20 $200.00 2006-02-13
Final Fee $300.00 2006-06-14
Expired 2019 - Corrective payment/Section 78.6 $150.00 2006-06-14
Maintenance Fee - Patent - New Act 7 2007-02-19 $200.00 2007-01-12
Maintenance Fee - Patent - New Act 8 2008-02-18 $200.00 2008-02-15
Registration of Documents $100.00 2009-01-09
Maintenance Fee - Patent - New Act 9 2009-02-18 $200.00 2009-02-18
Registration of Documents $100.00 2009-11-25
Maintenance Fee - Patent - New Act 10 2010-02-18 $250.00 2010-01-27
Registration of Documents $100.00 2010-12-08
Maintenance Fee - Patent - New Act 11 2011-02-18 $250.00 2011-01-24
Maintenance Fee - Patent - New Act 12 2012-02-20 $250.00 2012-02-16
Maintenance Fee - Patent - New Act 13 2013-02-18 $250.00 2013-02-04
Maintenance Fee - Patent - New Act 14 2014-02-18 $250.00 2014-02-06
Maintenance Fee - Patent - New Act 15 2015-02-18 $450.00 2015-02-10
Maintenance Fee - Patent - New Act 16 2016-02-18 $450.00 2016-01-13
Maintenance Fee - Patent - New Act 17 2017-02-20 $450.00 2017-01-23
Registration of Documents $100.00 2017-09-14
Maintenance Fee - Patent - New Act 18 2018-02-19 $450.00 2018-01-09
Maintenance Fee - Patent - New Act 19 2019-02-18 $450.00 2019-01-07
Registration of Documents 2019-11-05 $100.00 2019-11-05
Current owners on record shown in alphabetical order.
Current Owners on Record
NUCAP INDUSTRIES INC.
Past owners on record shown in alphabetical order.
Past Owners on Record
ARBESMAN, RAY
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.

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Date
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Representative Drawing 2000-08-14 1 26
Claims 2003-05-07 11 301
Claims 2000-02-18 5 198
Description 2000-02-18 15 610
Drawings 2000-02-18 12 359
Abstract 2000-02-18 1 14
Claims 2001-10-30 11 318
Cover Page 2000-08-14 1 50
Claims 2004-06-17 11 315
Claims 2005-08-02 10 279
Representative Drawing 2006-08-03 1 33
Cover Page 2006-08-03 1 60
Assignment 2000-02-18 2 69
Prosecution-Amendment 2001-03-14 2 68
Correspondence 2001-04-10 1 14
Prosecution-Amendment 2001-03-23 2 68
Prosecution-Amendment 2001-04-23 1 12
Prosecution-Amendment 2001-04-30 1 30
Prosecution-Amendment 2001-11-09 54 2,193
Prosecution-Amendment 2001-11-19 2 23
Prosecution-Amendment 2001-10-31 13 359
Prosecution-Amendment 2001-10-30 15 475
Prosecution-Amendment 2002-06-03 77 3,575
Prosecution-Amendment 2002-06-18 2 24
Prosecution-Amendment 2002-11-07 4 150
Fees 2003-02-18 1 35
Prosecution-Amendment 2003-12-17 5 227
Prosecution-Amendment 2003-05-07 20 828
Fees 2002-02-18 1 34
Fees 2004-02-09 1 35
Prosecution-Amendment 2004-06-17 18 841
Fees 2005-02-16 1 33
Prosecution-Amendment 2005-08-02 11 316
Fees 2006-02-13 1 34
Prosecution-Amendment 2006-06-14 1 39
Correspondence 2006-06-14 1 39
Correspondence 2006-06-23 1 16
Fees 2007-01-12 1 33
Fees 2008-02-15 1 34
Assignment 2009-01-09 12 602
Fees 2009-02-18 1 33
Assignment 2009-11-25 14 1,108
Fees 2010-01-27 1 38
Assignment 2010-12-08 14 896
Fees 2011-01-24 1 38
Fees 2012-02-16 1 38
Fees 2013-02-04 1 38
Fees 2014-02-06 1 39
Correspondence 2015-08-06 4 141
Fees 2015-02-10 1 38
Correspondence 2015-08-24 2 152
Correspondence 2015-08-24 2 185