DE202022101047U1 - Brake lining consisting of a duroplastic carrier plate and a friction lining block - Google Patents

Abstract

Brake lining (100) for a disc brake of a vehicle, the brake lining (100) having a carrier plate (10) and a friction lining block (20) which is connected to the carrier plate (10) and consists of more than one material component, characterized in that the carrier plate (10) was produced by pressing a duroplastic molding compound (10a).

Description

technical field

The invention relates to a brake pad produced by the integrated pressing of at least two molding compounds, in particular a duroplastic molding compound to form a carrier plate and at least one molding compound to form a friction lining block.

The invention also relates to a pressing tool for pressing and joining at least two molding compounds, in particular for forming a carrier plate consisting of a duroplastic material, with simultaneous production of a friction lining block consisting of at least one molding compound.

Furthermore, the invention relates to a brake lining for a vehicle, having a carrier plate formed from a duroplastic material and a friction lining block built up in layers from the friction lining segment and an intermediate layer, a so-called underlayer.

The invention also relates to a brake pad for a vehicle, having a carrier plate formed from a duroplastic material and a friction lining block, the friction lining block engaging in the surface of the carrier plate and forming a positive connection in addition to the chemical bond.

State of the art

For the integrated pressing of a friction lining material for a brake lining and a duroplastic material to form a carrier plate, prior art pressing tools are known with two pressing chambers one above the other and an associated pressing ram. The molding compound for the friction lining segment is placed, for example, in the lower part of the pressing chamber, the duroplastic molding compound for the carrier plate in the upper part of the pressing chamber. The workpiece, consisting of the friction lining segment and carrier plate, is pressed in a combined process.

In this process, there are physical limits to the production of brake pads with a duroplastic carrier plate. For example, the two compacts, friction lining segment and backing plate, cannot be pressed to a predetermined material density. In order to produce a predetermined material density, it is necessary for the respective pressed body to be subjected to a predetermined, specific pressing pressure (N/m ² ; Pa), for example.

The production of a brake lining, consisting of a duroplastic carrier plate and a friction lining block, composed in layers of a friction lining segment and an intermediate layer, a so-called underlayer, is currently not possible at all with the methods known in the prior art.

Due to the requirements placed on the carrier plate during operation, i.e. in the vehicle, it may be necessary to increase the mechanical resistance of the duroplastic carrier plate. This can be done, for example, by inserting a metal insert or a structural element into the carrier plate in layers. Predetermined positioning of the structural element is currently not possible with certainty using the method known from the prior art.

In the EP 1 006 289 A2 (Patent protection has expired) describes a brake pad for disc brakes, in particular for road and rail vehicles, the carrier plate being made of a duroplast (claim 1). A non-positive and positive connection between the carrier plate and the friction lining block is described, in that the material of the carrier plate engages in the areas of the friction lining block that are free of the carrier plate. The manufacturing process described is the injection molding process. In this case, a pre-pressed friction material block is placed in the injection mold, and the duroplastic mass is sprayed onto the friction material block (claim 2). Furthermore, it is described that the brake lining is characterized in that the carrier plate has at least one insert and/or an area with a material density that differs from the rest of the material of the carrier plate (claim 8). In the mechanically more highly stressed area, the carrier plate is provided with at least one insert (claim 9).

DE 102016107362 A1 relates to a method and for pressing at least one molding compound, in particular a friction lining compound for a brake pad, by means of a pressing tool and pressing onto a metal carrier plate. The pressing tool described is equipped with more than one press ram that can be controlled separately.

WO 2015/173768 A1 describes a co-moulding process for pressing a backing plate made of thermosetting material in connection with the pressing of a brake pad block, as described in the prior art. In addition, it is stated that the carrier plate is equipped with a supporting plate on the outside, the side facing away from the brake pad block. Necessary beads and fastening options for attaching sensors and accessories on and to the carrier plate can be embossed during the pressing process.

WO 2018/141604 A1 states that a brake pad consisting of a brake pad block and a duroplast carrier plate is produced in a co-moulding process, see description of the prior art. What is special about this application is that a metallic plate is pressed into the contact surface between the brake pad block and the carrier plate. This plate is riddled with openings and undercuts. The undercuts should be brought into contact with the surface of the friction lining block during the pressing process. This insert is intended to function as an electrical warning contact.

Presentation of the invention:

Task, solution, advantages

The object of the present invention is to propose a brake pad which is produced by integrated pressing of at least two molding compounds. The carrier plate consists of a duroplastic molding compound, the friction lining block is formed in layers, of a molding compound for the friction lining segment and a molding compound for the intermediate layer. The brake lining, consisting of the carrier plate and the friction lining block, can be produced in a simple manner with predefined properties in the volume segment.

According to the invention, the brake lining, consisting of at least one molding compound for forming the carrier plate and one to two molding compounds for pressing a friction lining block, is produced by means of a pressing tool with a pressing chamber, divided into at least three pressing chamber areas and several pressing rams assigned to this pressing chamber. The individual press stamps can be controlled individually.

The different molding compounds can be pressed in an integrated manner using several press rams, with the individual press rams being controlled individually. For this purpose, several molding compounds of different composition, for example as powdery granules, can be filled in layers into the compression chamber released by the 1st compression ram and pressed with at least one individually controllable compression ram in a first compression and reaction phase. The friction lining segment and the intermediate layer are preset in terms of material density.

After the first compression and reaction phase, the friction lining segment and the intermediate layer remain in the mold. The 1st press ram and the 2nd press ram release further press chamber volume for the addition of the duroplastic molding compound to form the carrier plate. The duroplast molding compound is preferably preheated and/or plasticized and placed in the compression chamber.

The integrated pressing process preferably takes place in that the 1st pressing stamp introduces the individually controllable pressing pressure via the friction lining segment and the intermediate layer into the duroplastic pressing compound. The individually controllable 2nd ram transfers the pressure directly into the duroplastic molding compound. The molding compound of the carrier plate is thus set in a predetermined manner with regard to the material density.

1. 1. Pressstempel (211a)
2. 2. Pressstempel (211b) Pressdorn (211c) Oberwerkzeug (215) Pressform/ Formenkörper (213)

können individuell vorgegeben werden.The process is a hot pressing process and is carried out in a temperature range of 130°C to 180°C. The temperatures in the components of the press mold:

1. 1. Press stamp (211a)
2. 2. Press stamp (211b) Press mandrel (211c) Upper tool (215) Press mold/ mold body (213)

can be specified individually.

All molding compounds used in this process belong to the group of thermoset materials. Under pressure and temperature, a chemical reaction takes place in the mold to harden the molding compounds, with the different molding compounds chemically reacting with one another in the contact areas, i.e. forming chemical compounds. The pre-selected time interval for the pressing process ensures a sufficiently high reaction level for the hardening of the molding compound so that the workpiece can be demoulded.

The friction lining block, consisting of the friction lining segment and the intermediate layer, undergoes an initial compression and reaction phase in the first compression chamber. The process parameters can be described as follows. Specific pressing pressure: 25MPa to 50MPa, temperature between 130°C and 170°C; the time interval is 20 sec to 120 sec;

The material density of the duroplastic carrier plate is preferably adjusted using the integrated pressing process. The following process data is usually required for this. Specific pressing pressure: 15 MPa to 35 MPa, temperature between 150°C and 180°C; the time interval is 300 to 400 seconds.

This opens up the possibility of using prefabricated material segments for the integrated pressing process. The friction lining block can be inserted into the 1st bale chamber area as a preform consisting of a friction lining segment and an intermediate layer.

This enables the introduction of an intermediate layer molding compound as a material conglomerate that is dosed onto the friction lining molding compound in a predetermined layer thickness. The 2nd press ram remains in the starting position, i.e. in the zero position of the press mold. The 1st ram is lowered to a position that corresponds to the predetermined dosing layer thickness.

The pressing masses metered into the first press chamber as conglomerates can be pre-compacted with a separate pressure plate after the respective metering.

The molding compounds used for the intermediate layer are selected in terms of their chemical composition such that the intermediate layer has a damping effect on structure-borne noise transmission and/or strengthens the chemical bond between the friction lining segment and the duroplast carrier plate.

With regard to the chemical composition, the molding compounds used for the intermediate layer are selected in such a way that the intermediate layer can serve as a recording medium for electrical wear sensors.

The intermediate layer can preferably also be formed as a semi-finished product (22b), e.g. from a rolled material. The intermediate layer is brought into a pre-plasticized form and corresponds to the contour of the friction lining block (20).

The intermediate layer (22) can be formed from semi-finished products (22b), e.g. a glass fiber fabric, which is wetted with a phenolic resin solution or dusted with phenolic resin powder. The fabric mats to be placed in the 1st baling chamber are cut to match the contour of the friction lining block (22).

A brake lining (100) consisting of a thermoset carrier plate (10) and a friction lining block (20) can preferably be produced in such a way that the friction lining segment (21) engages in the body of the carrier plate (10) with a predefined penetration depth (27). The two compacts, carrier plate (10) and friction lining segment (21) are thus chemically and positively connected to one another. Shown in 14 a , 14 b and 14 c .

The setting of the predetermined embedding of the friction lining block (20) in the contour of the carrier plate is preferably carried out by moving the 1st press ram and the 2nd press ram into defined dosing positions ( 11a ). The position of the 1st compression ram (211a) defines the position of the friction lining block (20) in the compression chamber and the volume of duroplastic molding material that can be accommodated in the volume segment (212c). The position of the 2nd ram (211b) defines the storage volume of duroplastic material in the pressing chamber area (212b). Thus, the recording volumes for the duroplastic molding compound are defined and the carrier plate (20) can be dosed in the pressing chamber area (212 c) and in the pressing chamber area (212 b) in a predetermined material layer thickness and pressed in a predetermined material density.

Preferably, a brake lining (100) as in 15 a , 15 b and 15 c shown, consisting of a duroplast carrier plate (10) and a friction lining block (20), are produced in such a way that the friction lining block (20) consists of layers of a friction lining segment (21) and an intermediate layer (22). The intermediate layer (22) can preferably engage in the body of the carrier plate (10) with a predefined penetration depth (28). The position of the depth of penetration (28) into the carrier plate (10) and the layer thickness of the intermediate layer (22) are selected in such a way that the friction lining segment (21) has no contact surface with the carrier plate (10) ( 15c ).

A further advantage of the method according to the invention is the possibility of incorporating a structural element (23), ie a body of different density, in a predetermined position into the carrier plate (10) ( 1b ). The structural element (23) can have a grid-like structure, for example.

So that the vertical position of the insert part is defined within the carrier plate, it is proposed that a lower material level of pre-compacted, duroplastic molding compound be placed in the released compression chamber areas (212a) and (212b). See step 6B and 6C in 5d .

Furthermore, it is proposed to add the remaining amount of duroplastic molding compound to the free pressing chamber areas, according to step 6E in 5d , after the structure element (23) is deposited on the lower material layer, step 6D in 5d . In the integrated pressing process in step 7B in 12b , the plasticized mass flows around or through the insert.

Furthermore, the pressing tool makes it possible to keep material-free areas (25) free in the duroplastic carrier plate by means of placeholders. Press pistons, so-called press mandrels (211c), are used for this purpose, which can be controlled separately and are brought into position before the compression of the duroplastic mass.

The procedure according to 5a , 5b and 5c , can be done by means of a single-acting press 4a or an opposing press 4b be performed. The implementation of the procedure, accordingly 5d , is pressed using a press with opposing pressing directions ( 4b ), possible.

The rams can be equipped with servo-hydraulic or servo-electric drives. It makes sense that the functional processes 5a , 5b , 5c , 5d organized in a press machine in which the press tool runs through several stations. Defined functions are carried out in the respective stations. The proposed pressing tools (200) can be designed in such a way that several proposed pressing chambers and each pressing chamber are assigned several individually controllable pressing rams in one tool. This means that more than one composite brake pad (100) should be produced in each tool at the same time.

The steel backing plates of the brake linings for passenger vehicles are usually dimensioned with a material thickness of 5.0 to 6.0 mm. Due to design adjustments, the carrier plates made of duroplastic material will have a material thickness of 5.0 to > 10.0 mm.

Additional brake pad elements such as metal plates (90) and acoustic wear indicators (80) are preferably attached using fasteners, e.g. screws or pins, to the surface of the duroplastic carrier plate on the side facing away from the brake pad block (20).

In addition to being mechanically fixed, the metal plates (90) can also be connected to the duroplast carrier plate with a layer of adhesive.

The metal plates (90) can be coated on the outer surface with a material that dampens structure-borne noise, e.g. rubber, so that noise-generating vibration transmissions to the brake caliper are reduced or prevented.

Fastening elements (71) are preferably designed as pins on the duroplast carrier plate (10), consisting of corrosion-resistant metal, and are compressed and/or glued into the prefabricated drill hole.

In the case of particularly high-stress fastenings on the duroplast carrier plate (10), it may be necessary to use insert elements (72), e.g. threaded inserts. The threaded inserts are screwed into pre-drilled holes with the external thread in the Duroplast plate and/or glued in the drill hole. The components to be fixed are connected to the internal thread of the insert elements by means of screw connections (73). For an M3 screw connection, for example, an insert element (72) with a penetration depth of approx. 6 mm into the carrier plate is required.

character list

• 1a: die Draufsicht von einem Bremsbelag (100), bestehend aus einer Duroplast- Trägerplatte (10) und einem Reibbelagblock (20) sowie materialfreie Bereiche (25) in der Duroplast- Trägerplatte (10).
• 1b: eine Schnittdarstellung durch einen Bremsbelag (100), bestehend aus einer Duroplast- Trägerplatte (10) und einem Reibbelagblock (20). Der Reibbelagblock (20) ist schichtweise aufgebaut, aus dem Reibbelagsegment (21) und einer Zwischenschicht (22). Die Zwischenschicht (22) dient der Herstellung einer besseren Bindung zwischen der duroplastischen Trägerplatte (10) und dem Reibbelagsegment (21). Des Weiteren dient die Zwischenschicht (22) der Geräuschreduzierung beim Einsatz des Bremsbelags (100) in einer Bremse. Die Zwischenschicht (22), dient ebenfalls als Aufnahmemedium von elektrischen Verschleißsensoren (81). In einer vordefinierten Position innerhalb Trägerplatte (10) eingearbeitet ist, ein Einsatzelement (23), bestehend aus einem Material mit abweichender Materialdichte zur duroplastischen Trägerplatte. Das Einsatzelement (23) ist vom Material der duroplastischen Trägerplatte vollständig umschlossen und/oder durchdrungen.
• 2: eine Schnittdarstellung eines Presswerkzeug, Stand der Technik. In einem Pressvorgang werden die duroplastische Pressmasse (10a) sowie die Reibbelag-Pressmasse (21a) zu einem Bremsbelag geformt. Die Form besteht aus zwei übereinander angeordnete Presskammern. Die untere Presskammer wird mit der Pressmasse für das Reibbelagsegment (21a) befüllt, in der obere Presskammer befindet sich die duroplastische Pressmasse (10a) zur Ausbildung der Trägerplatte (10). Zum Pressen bewegt sich das Oberwerkzeug (215b) nach unten und verdichtet die zwei Pressmassen gegen den feststehenden Pressstempel (211).
• 3a: eine Schnittdarstellung durch die in 3b gezeigte Darstellung. In 3a wird die Grundidee dieser Technologie dargestellt. Es werden drei Pressmassen (10a) (21a) (22a) mittels mindestens zwei Presstempel (211a) (211b), wobei jeder Pressstempel individuell ansteuerbar ist, zu einem Bremsbelag (100), bestehend aus einer Duroplast-Trägerplatte (10) und einem Reibbelagblock (20), verdichtet.
• 4a: ist eine Prinzipdarstellung einer Presse (310) mit einem Presswerkzeug (200) gezeigt. Das Oberwerkzeug (215a) ist mit dem Pressenjoch (313) verbunden. Ferner ist das Pressenjoch (313) über Spannzylinder (312) verfahrbar mit dem Grundrahmen (311) der Presse (300) verbunden. Somit kann der Raum für die Dosiereinheiten freigegeben werden. Ferner kann beim Pressen vom Pressenjoch (313), über das Oberwerkzeug (215a) eine Gegenkraft zu den Pressstempeln (211a) und (211b) auf die Pressmassen ausgeübt werden.
• 4b: ist eine Prinzipdarstellung einer Presse (320) mit einem Presswerkzeug (200) gezeigt. Das Oberwerkzeug (215b) ist mit dem Pressenjoch (313) über einen Antrieb (321) verbunden. Durch den Antrieb (321) kann der Raum für die Dosiereinheiten freigegeben werden. Ferner kann beim Pressen, der Antrieb (321) über das Oberwerkzeug (215b) eine Gegenkraft zu den Pressstempeln (211a) und (211b) auf die Pressmassen ausüben. Die Pressmassen werden somit vom individuell ansteuerbaren Oberwerkzeug (215) wie auch von den individuell ansteuerbaren Pressstempel (211a) und (211b) aktiv, d.h. von zwei Seiten, mit einer Presskraft beaufschlagt.
• 5a bis 5d zeigen Prozessabläufe zur integrierten Herstellung eines Bremsbelages (100), bestehend aus einer duroplastischen Trägerplatte (10) und einem Reibbelagblock (20). 5a stellt den Prozessablauf zur Herstellung eines Bremsbelages (100) dar, bei dem mindestens drei Pressmassen (10a, 21a, 22a) verwendet werden. 5b zeigt den Prozessverlauf, wenn die Zwischenschicht (22) als Halbfabrikat (22b) in die Pressform gegeben wird. Darüber hinaus wird in den 5c die Möglichkeiten dargestellt, einen vorgefertigten Reibbelagblock, einen sogenannten Vorpressling (21b) zu verwenden. Der in einem ausgelagerten Prozess herstellte Vorpressling besteht, schichtweise aufgebaut, aus dem Reibbelagsegment (21b) und der Zwischenschicht (22b). Die Prozessschritte zur Einbindung einer Materialstruktur (23), in einer vordefinierten Position innerhalb duroplastischen Trägerplatte (10), wird in den 5d beschrieben. Nachfolgende Figuren zeigen einzelne Verfahrensschritte anhand einer Schnittzeichnung durch ein Presswerkzeug (200):
• 6a: während der Dosierung der Pressmasse (21a) für das Reibbelagsegment (21), entsprechend dem Schritt 1 A in 5a, 5b und 5d. Der äußere Pressstempel (211b) befindet sich in der Grundposition und gibt kein Dosiervolumen frei. Wie in 3b zu erkennen ist, wird der 1. Pressstempel (211a) vollumfänglich von dem 2. Pressstempel (211b) umschlossen. Der individuell ansteuerbare 1. Presstempel befindet sich in einer vorgegebenen Dosierposition, d.h. es ist ein vorgegebenes Volumen in der 1. Presskammer (212a) vorhanden. Die Pressmasse (21a) kann gravimetrisch oder volumetrisch in den Presskammerbereich (212 a) dosiert werden. Die Materialoberfläche der Pressmasse (21a) befindet auf dem Niveau der Formoberfläche, d.h. auf der Nullposition der Form und kann bei der Dosierung waagerecht, glattgezogen werden.
• 7a: während der Vorverdichtung der dosierten Reibbelagmasse (21a) mittels der Andruckplatte (220), im Schritt 2A, gemäß 5a, 5b und 5d.
• 8a: während der Dosierung einer Kornschüttung als Zwischenschicht-Material (22a) in Schritt 3 A, dargestellt in 5a und 5d. Der äußere Pressstempel (211b) befindet sich in der Grundposition und gibt kein Dosiervolumen frei. Wie in 3b zu erkennen ist, wird der 1. Pressstempel (211a) vollumfänglich von dem 2. Pressstempel (211b) umschlossen. Der individuell ansteuerbare 1. Presstempel befindet sich in einer vorgegebenen Dosierposition, d.h. es ist ein vorgegebenes Volumen im Presskammerbereich (212d), oberhalb der Reibbelagmasse (21a) vorhanden. Die Pressmasse der Zwischenschicht (22a) kann vor der Dosierung gravimetrisch oder volumetrisch portioniert sein. Die Materialoberfläche der Pressmasse (22a) befindet auf dem Niveau der Formoberfläche, d.h. auf der Nullposition der Form und kann bei der Dosierung waagerecht, glattgezogen werden.
• 9a: im Prozessschritt 4A, gezeigt in 5a und 5d, während der Vorverdichtung der dosierten Pressmasse für die Zwischenschicht (22a) mittels der Andruckplatte (220).
• 9b: im Schritt 4B, gezeigt in 5b. Die Zwischenschicht wird in diesem Schritt als Strukturelement auf die im Schritt 2A vorverdichtete Reibbelag- Pressmasse (21a) aufgelegt. Der äußere Pressstempel (211b) befindet sich in der Grundposition und gibt kein Dosiervolumen frei. Der individuell ansteuerbare 1. Presstempel (211a) befindet sich in einer vorgegebenen Dosierposition, d.h. es ist ein vorgegebenes Volumen in dem Presskammerbereich (212d), oberhalb der Reibbelagmasse (21a) bzw. des Vorpresslings (21b), vorhanden. Die Zwischenschicht kann alternativ als Strukturelement (22b) in das freigegebene Volumen der 1. Presskammer eingelegt werden.
• 9c: im Schritt 4C, entsprechend 5 c. Der äußere Pressstempel (211b) befindet sich in der Grundposition und gibt kein Dosiervolumen frei. Der individuell ansteuerbare 1. Presstempel (211a) befindet sich in einer vorgegebenen Aufnahmeposition, d.h. es ist ein vorgegebenes Presskammervolumen vorhanden. Der in einem externen Verfahren hergestellte Reibbelagblock (20b), bestehend aus einem Reibbelagsegment (21b) und einer Zwischenschicht (22b), kann somit in die Presskammer eingelegt werden. Dieser vorgefertigte Reibbelagblock (20b) wird als Vorpressling bezeichnet, da es Formstabil ist, gleichwohl im Material keine chemischen Vernetzungsreaktionen stattgefunden haben.
• 10a: im Schritt 5A, gemäß 5a, 5b und 5d. Der 2. Pressstempel (211b) verbleibt in der Grundstellung. Das Oberwerkzeug (215) verschließt den Presskammerbereich (212a/212d), gefüllt mit Reibbelag-Pressmasse (21a oder 21b), sowie mit Pressmasse der Zwischenschicht (22a oder 22b). Der individuell ansteuerbare 1. Pressstempel (211a) beaufschlagt die Pressmassen mit vorherbestimmtem Pressdruck Temeraturen und Zeitintervall. Die Pressmassen werden somit auf eine definierte Materialdichte gepresst. Die Vernetzungsreaktion in den Pressmassen der Presskammer hat begonnen, der zur Entformung notwendigen Vernetzungsgrad ist noch nicht erreicht. Der notwendige Gegendruck zum Pressstempel (211a) wird aufgebracht, von dem mit dem Pressenjoch (313) verbundenem Oberwerkzeug (215a) oder von einem Oberwerkzeug mit eigenem Antrieb (215b).
• 11a: während der Dosierung der duroplastischen Pressmasse (10a) zur Ausbildung der Trägerplatte (10), gemäß Schritt 6 A in den 5a, 5b und 5c. Zur Vorbereitung der Dosierung fahren Pressstempel (211a) sowie Pressstempel (211b) auf eine individuell ansteuerbare Dosierposition. Wie in 3b zu erkennen ist, wird der 1. Pressstempel (211a) vollumfänglich von dem 2. Pressstempel (211b) umschlossen. Der 1. Pressstempel gibt somit den Presskammerbereich (212c) frei, der 2. Pressstempel den Presskammerbereich (212b). Dadurch, dass das Volumen der Presskammer (212c) sowie der Presskammer (212b) individuell eingestellt werden können, ist die Möglichkeit gegeben, die Volumensegmente der Trägerplatte in vorherbestimmte Materialschichtdicke herzustellen.
• 12a: im Schritt 7A, entsprechen 5a, 5b und 5c. In diesem Schritt werden alle dosierten Pressmassen bzw. eingelegte Halbfabrikate in einem integrierten Vorgang verpresst, wobei in den Materialien eine Vernetzungsreaktion stattfindet. In den Kontaktflächen der unterschiedlichen Materialien zueinander, werden chemische Bindungen ausgebildet, d.h. die Materialien werden miteinander verschweißt. Der Pressdorn (211) ist individuell ansteuerbar. Ist die Dosierung der duroplastischen Pressmasse für die Trägerplatte abgeschlossen, fährt der Pressdorn (211c) formschließend in das Oberwerkzeug (215a/ 215b) und wirkt somit als Platzhalter für einen Hohlraum (40) in der Trägerplatte (10), dargestellt in 1 a. Der 1. Pressstempel (211a) sowie der 2. Pressstempel (211b) sind individuell ansteuerbar, dadurch kann die Trägerplatte in den Volumensegmenten (212b und 212c) mit individuell vorgegebenen Pressdrücken sowie individuell vorgegebenen Zeitintervalle beaufschlagt werden, wobei der Pressdruck von dem 1. Pressstempel (211a) über das Reibbelagsegment (21) und der Zwischenschicht (22) in das Volumensegment (212 c) der Trägerplatte übertragen wird. Der Pressdruck vom 2. Pressstempel (211b) wird direkt in das Volumensegment (212b) der Trägerplatte geleitet. Die Volumensegmente (212c sowie 212b) der Trägerplatte können somit auf vorherbestimmte Materialdichten eingestellt werden. Der notwendige Gegendruck zum 1. und 2. Pressstempel (211a/211b) wird aufgebracht, von dem mit dem Pressenjoch (313) verbundenem Oberwerkzeug (215a) oder von einem Oberwerkzeug mit eigenem Antrieb (215b). Die Temperaturen für die Bauteile 1. Pressstempel (211a), 2. Pressstempel (211b), Pressdorn (211c), Formenkörper (213) sowie dem Oberwerkzeug (215a/215b) sind individuell ansteuerbar. Der Zeitraum für den integrierten Pressvorgang wird derart gewählt, dass alle beteiligten Pressmassen eine vorherbestimmte, für die Entformung notwendige Formbeständigkeit aufweisen.
• 11b: während Schritt 6B, 5d. Die Dosierung der duroplastischen Masse für die unteren Materialebene der Trägerplatte, dient der Vorbereitung für die vorherbestimmte Positionierung eines Strukturelementes (23) innerhalb der Trägerplatte (10), gezeigt in 1b. Zur Vorbereitung der Dosierung fahren der 1. Pressstempel (211a) sowie der 2. Pressstempel (211b) auf eine individuell ansteuerbare Dosierposition, wobei die Position vom 2. Pressstempel (211b) gleich, oder weiter vom Nullpunkt Pressform entfernt ist als die Position von 1. Presstempel (211a). Wie in 3b zu erkennen ist, wird der 1. Pressstempel (211a) vollumfänglich von dem 2. Pressstempel (211b) umschlossen. Der 1. Pressstempel gibt somit die Presskammerbereich (212c) frei, der 2. Pressstempel die Presskammer (212b). Die Presskammerbereiche (212b/ 212 c) werden insoweit mit duroplastischer Pressmasse befüllt, dass sich im Schritt 6C, 5d, eine vorherbestimmte Materialschichtdicke einstellt.
• 11c: während Schritt 6C, 5d. In diesem Schritt wird die dosierte duroplastische Pressmasse für die Aufnahme eines Strukturelementes (23) vorbereitet. Der Pressdorn (211) ist individuell ansteuerbar. Ist die Dosierung der duroplastischen Pressmasse für die Trägerplatte abgeschlossen, fährt der Pressdorn (211c) formschließend in das Oberwerkzeug (215b) und wirkt somit als Platzhalter für einen Hohlraum (40) in der Trägerplatte (10). Der 1. Pressstempel (211a) sowie der 2. Pressstempel (211b) sind individuell ansteuerbar, dadurch kann die Trägerplatte im Volumensegment (212b) sowie im Volumensegment (212c) mit individuell vorgegebenen Pressdrücken sowie individuell vorgegebenen Zeitintervalle beaufschlagt werden, wobei der Pressdruck von dem 1. Pressstempel (211a) über das Reibbelagsegment (21) und der Zwischenschicht (22) in das Volumensegment (212c) der Trägerplatte übertragen wird. Der Pressdruck von dem 2. Pressstempel (211b) wird direkt in das Volumensegment (212b) der Trägerplatte geleitet. Der notwendige Gegendruck zum 1. und 2. Pressstempel (211a/211b) wird aufgebracht, von einem Oberwerkzeug mit eigenem Antrieb (215b), welcher in die freien Presskammerbereiche formschließend eintaucht. Die Temperaturen für die Bauteile 1. Pressstempel (211a), 2. Pressstempel (211b), Pressdorn (211c), Formenkörper (213) sowie dem Oberwerkzeug (215b) sind individuell ansteuerbar. Der Zeitraum für diesen Vorgang wird derart gewählt, dass die dosierte duroplastische Pressmasse, sich plastisch verformend, eine untere Materialebene ausbildet.
• 11d: während Schritt 6E, gemäß 5d.ln Vorbereitung zu dem Einlegen einer Materialstruktur (23) sowie zur Dosierung der restlichen duroplastischen Pressmasse (10a) behalten der 1. Pressstempel (211a) sowie der 2. Presstempel (211b) die vorherbestimmten Positionen bei. Das Strukturelement (23) wird in der Presskammer, auf die Materialebene der duroplastischen Trägerplatte 10, aufgelegt. Nachfolgend wird die restliche duroplastische Pressmasse (10a) in die Presskammer gegeben.
• 12b: im Schritt 7B, bei der Einbindung einer Materialstruktur (23) in die Trägerplatte (10), entsprechen 5d. In diesem Schritt werden alle dosierten Pressmassen bzw. eingelegte Halbfabrikate in einem integrierten Vorgang verpresst, wobei in den Pressmassen eine Vernetzungsreaktion stattfindet. In den Kontaktflächen der unterschiedlichen Materialien zueinander, werden chemische Bindungen ausgebildet, d.h. die Materialien werden miteinander verschweißt. Der Pressdorn (211) ist individuell ansteuerbar. Ist die Dosierung der duroplastischen Pressmasse für die Trägerplatte abgeschlossen, fährt der Pressdorn (211c) formschließend in das Oberwerkzeug (215a/ 215b) und wirkt somit als Platzhalter für einen Hohlraum (40) in der Trägerplatte (10). Der 1. Pressstempel (211a) sowie der 2. Pressstempel (211b) sind individuell ansteuerbar, dadurch kann die Trägerplatte in deren Volumensegmenten (212b und 212c) mit individuell vorgegebenen Pressdrücken sowie individuell vorgegebenen Zeitintervalle beaufschlagt werden, wobei der Pressdruck von dem 1. Pressstempel (211a) über das Reibbelagsegment (21) und der Zwischenschicht (22) in das Volumensegment (212c) der Trägerplatte übertragen wird. Der Pressdruck von dem 2. Pressstempel (211b) wird direkt in das Volumensegment der Trägerplatte (11b) geleitet. Die Volumensegmente der Trägerplatte können somit auf vorherbestimmte Materialdichten eingestellt werden, wobei das duroplastische Material der Trägerplatte die Geometrie der Materialstruktur (23) durchdring und/oder umschließt. Der notwendige Gegendruck zum 1. und 2. Pressstempel (211a/211b) wird aufgebracht, von dem mit dem Pressenjoch (313) verbundenem Oberwerkzeug mit eigenem Antrieb (215b), welcher die Presskammerbereiche verschließt oder formschließend in die Presskammerbereiche eintaucht. Die Temperaturen für die Bauteile 1. Pressstempel (211a), 2. Pressstempel (211b), Pressdorn (211c), Formenkörper (213) sowie dem Oberwerkzeug (215b) sind individuell ansteuerbar. Der Zeitraum für den integrierten Pressvorgang wird derart gewählt, dass die beteiligten Pressmassen die vorherbestimmte Materialdichte aufweisen.
• 13a: während der Werkstück- Entformung entsprechend Schritt 8 A, dargestellt in 5a, 5b und 5c. Das Oberwerkzeug (215a bzw. 215b) wird von der Form entfernt, die Pressstempel (211 a) und (211b) fahren in die Nullposition der Pressform. Der Bremsbelag (100) kann entnommen werden.
• 13b: während der Werkstück- Entformung entsprechend Schritt 8 A, dargestellt in 5d. Das Oberwerkzeug (215 b) wird von der Form entfernt, die Pressstempel (211 a) und (211b) fahren in die Nullposition der Pressform. Der Bremsbelag (100) kann entnommen werden.
• 14a und 14b zeigen einen Bremsbelag (100), bestehend aus einem Reibbelagsegment (21) und einer Duroplast- Trägerplatte (10). 14c zeigt im Detail X1 die Eindringtiefe (27) des Reibbelagsegments (21) hinein in die Trägerplatte (10). Das Reibbelagsegment (21) wird in seinem gesamten Umfang, mit der Eindringtiefe (27), von der Trägerplatte (10) umschlossen. Die Trägerplatte (10) und das Reibbelagsegment (21) sind somit chemisch wie auch formschlüssig verbunden.
• 15a und 14 b zeigen einen Bremsbelag (100), bestehend aus einem Reibbelagblock (20) und einer Duroplast- Trägerplatte (10). Der Reibbelagblock (20) ist schichtweise aufgebaut aus dem Reibbelagsegment (21) und der Zwischenschicht (22). 15c zeigt im Detail X2 die Eindringtiefe (28), der Zwischenschicht (22) hinein, in die Trägerplatte (10). Das Reibbelagsegment (21) hat keine Kontaktfläche mit der Trägerplatte (10). Die Zwischenschicht (22) wird in dem gesamten Umgang, mit der Eindringtiefe (28), von der Trägerplatte (10) umschlossen. Die Trägerplatte (10) und die Zwischenschicht (22), als Bestandteil des Reibbelagblockes (20), sind chemisch wie auch formschlüssig verbunden.
• 16a und 16b zeigen einen Bremsbelag (100), bestehend aus einem Reibbelagsegment (21), einer Zwischenschicht (22) und einer Duroplast- Trägerplatte (10). Weiterhin sind dargestellt, die Anbindung bzw. Montagemöglichkeiten von Zubehörteilen an die Trägerplatte, wie z.B. akustische Verschleißsensoren (80) und Metallplatten (90).

They show schematically:

• 1a : the top view of a brake lining (100), consisting of a duroplastic carrier plate (10) and a friction lining block (20) and material-free areas (25) in the duroplastic carrier plate (10).
• 1b : a sectional view through a brake lining (100), consisting of a thermoset carrier plate (10) and a friction lining block (20). The friction lining block (20) is built up in layers, from the friction lining segment (21) and an intermediate layer (22). The intermediate layer (22) is used to create a better bond between the duroplastic carrier plate (10) and the friction lining segment (21). The intermediate layer (22) also serves to reduce noise when the brake lining (100) is used in a brake. The intermediate layer (22) also serves as a recording medium for electrical wear sensors (81). Incorporated in a predefined position within the carrier plate (10) is an insert element (23), consisting of a material with a material density that differs from the duroplastic carrier plate. The insert element (23) is completely surrounded and/or penetrated by the material of the duroplastic carrier plate.
• 2 : a sectional view of a pressing tool, prior art. The duroplastic molding compound (10a) and the friction lining molding compound (21a) are formed into a brake lining in a pressing process. The mold consists of two press chambers arranged one above the other. The lower compression chamber is filled with the molding compound for the friction lining segment (21a), and the upper compression chamber contains the duroplastic molding compound (10a) for forming the carrier plate (10). For pressing, the upper tool (215b) moves below and compresses the two molding compounds against the fixed ram (211).
• 3a : a sectional view through the in 3b shown representation. In 3a the basic idea of this technology is presented. Three pressing masses (10a) (21a) (22a) are pressed by means of at least two rams (211a) (211b), each ram being individually controllable, to form a brake lining (100), consisting of a duroplast carrier plate (10) and a friction lining block (20), condensed.
• 4a : a schematic representation of a press (310) with a pressing tool (200) is shown. The punch (215a) is connected to the press yoke (313). Furthermore, the press yoke (313) is movably connected to the base frame (311) of the press (300) via clamping cylinders (312). In this way, the space for the dosing units can be freed up. Furthermore, when pressing from the press yoke (313), via the upper tool (215a), a counterforce to the press dies (211a) and (211b) can be exerted on the pressing masses.
• 4b : a schematic representation of a press (320) with a pressing tool (200) is shown. The upper tool (215b) is connected to the press yoke (313) via a drive (321). The space for the dosing units can be released by the drive (321). Furthermore, during pressing, the drive (321) can exert a counterforce to the pressing dies (211a) and (211b) on the pressing masses via the upper tool (215b). The pressing masses are thus actively, ie from two sides, subjected to a pressing force by the individually controllable upper tool (215) as well as by the individually controllable press rams (211a) and (211b).
• 5a until 5d show processes for the integrated production of a brake lining (100), consisting of a duroplastic carrier plate (10) and a friction lining block (20). 5a represents the process sequence for producing a brake pad (100) in which at least three molding compounds (10a, 21a, 22a) are used. 5b shows the course of the process when the intermediate layer (22) is placed in the compression mold as a semi-finished product (22b). In addition, in the 5c shown the possibilities of using a prefabricated friction lining block, a so-called preform (21b). The preform produced in an outsourced process consists of layers of the friction lining segment (21b) and the intermediate layer (22b). The process steps for incorporating a material structure (23) in a predefined position within the thermoset support plate (10) is in the 5d described. The following figures show individual process steps using a sectional drawing through a pressing tool (200):
• 6a : during the dosing of the molding compound (21a) for the friction lining segment (21), according to step 1 A in 5a , 5b and 5d . The outer ram (211b) is in the basic position and does not release any dosing volume. As in 3b can be seen, the 1st ram (211a) is completely surrounded by the 2nd ram (211b). The individually controllable 1st press ram is in a predetermined dosing position, ie there is a predetermined volume in the 1st press chamber (212a). The pressing compound (21a) can be metered gravimetrically or volumetrically into the pressing chamber area (212a). The material surface of the molding compound (21a) is at the level of the mold surface, ie at the zero position of the mold and can be smoothed horizontally during dosing.
• 7a : during the pre-compression of the metered friction lining mass (21a) by means of the pressure plate (220), in step 2A, according to 5a , 5b and 5d .
• 8a : during the dosing of a bulk grain as an intermediate layer material (22a) in step 3 A, shown in 5a and 5d . The outer ram (211b) is in the basic position and does not release any dosing volume. As in 3b can be seen, the 1st ram (211a) is completely surrounded by the 2nd ram (211b). The individually controllable first press ram is in a predetermined dosing position, ie there is a predetermined volume in the press chamber area (212d) above the friction lining mass (21a). The molding compound of the intermediate layer (22a) can be portioned gravimetrically or volumetrically before dosing. The material surface of the molding compound (22a) is at the level of the mold surface, ie at the zero position of the mold and can be smoothed horizontally during dosing.
• 9a : in process step 4A shown in 5a and 5d , during the pre-compaction of the dosed molding compound for the intermediate layer (22a) by means of the pressure plate (220).
• 9b : in step 4B shown in 5b . In this step, the intermediate layer is placed as a structural element on the friction lining molding compound (21a) precompacted in step 2A. The outer ram (211b) is in the basic position and does not dispense volume free. The individually controllable 1st press ram (211a) is in a predetermined dosing position, ie there is a predetermined volume in the press chamber area (212d) above the friction lining compound (21a) or the preform (21b). Alternatively, the intermediate layer can be inserted as a structural element (22b) into the released volume of the 1st baling chamber.
• 9c : in step 4C, accordingly 5 c . The outer ram (211b) is in the basic position and does not release any dosing volume. The individually controllable 1st compression ram (211a) is located in a predetermined receiving position, ie there is a predetermined compression chamber volume. The friction lining block (20b) produced in an external process, consisting of a friction lining segment (21b) and an intermediate layer (22b), can thus be inserted into the press chamber. This prefabricated friction lining block (20b) is referred to as a preform because it is dimensionally stable, although no chemical crosslinking reactions have taken place in the material.
• 10a : in step 5A, according to 5a , 5b and 5d . The 2nd press ram (211b) remains in the basic position. The upper tool (215) closes the compression chamber area (212a/212d), filled with friction lining molding compound (21a or 21b) and with molding compound of the intermediate layer (22a or 22b). The individually controllable 1st press ram (211a) applies the press masses with predetermined press pressure temperatures and time interval. The molding compounds are thus pressed to a defined material density. The cross-linking reaction in the molding compound of the pressing chamber has started, but the degree of cross-linking required for demolding has not yet been reached. The necessary counter-pressure to the ram (211a) is applied by the upper tool (215a) connected to the press yoke (313) or by an upper tool with its own drive (215b).
• 11a : During the dosing of the thermoset molding compound (10a) to form the support plate (10), according to step 6 A in the 5a , 5b and 5c . To prepare for dosing, the ram (211a) and ram (211b) move to an individually controllable dosing position. As in 3b can be seen, the 1st ram (211a) is completely surrounded by the 2nd ram (211b). The 1st ram thus releases the bale chamber area (212c), the 2nd ram the bale chamber area (212b). The fact that the volume of the pressing chamber (212c) and the pressing chamber (212b) can be set individually makes it possible to produce the volume segments of the carrier plate with a predetermined material layer thickness.
• 12a : in step 7A, correspond 5a , 5b and 5c . In this step, all metered molding compounds or inserted semi-finished products are pressed in an integrated process, with a cross-linking reaction taking place in the materials. Chemical bonds are formed in the contact surfaces of the different materials with one another, ie the materials are welded to one another. The press mandrel (211) can be controlled individually. Once the dosing of the duroplastic molding compound for the carrier plate has been completed, the press mandrel (211c) moves into the upper tool (215a/ 215b) in a form-closing manner and thus acts as a placeholder for a cavity (40) in the carrier plate (10), shown in 1 a . The 1st press ram (211a) and the 2nd press ram (211b) can be controlled individually, which means that the carrier plate in the volume segments (212b and 212c) can be subjected to individually specified press pressures and individually specified time intervals, with the press pressure being controlled by the 1st press ram (211a) is transferred via the friction lining segment (21) and the intermediate layer (22) into the volume segment (212c) of the carrier plate. The pressure from the 2nd ram (211b) is directed directly into the volume segment (212b) of the carrier plate. The volume segments (212c and 212b) of the carrier plate can thus be adjusted to predetermined material densities. The necessary counter pressure for the 1st and 2nd ram (211a/211b) is applied by the upper tool (215a) connected to the press yoke (313) or by an upper tool with its own drive (215b). The temperatures for the components 1st press ram (211a), 2nd press ram (211b), press mandrel (211c), mold body (213) and the upper tool (215a/215b) can be controlled individually. The period of time for the integrated pressing process is selected in such a way that all molding compounds involved have a predetermined dimensional stability necessary for demolding.
• 11b : during step 6B, 5d . The dosing of the duroplastic mass for the lower material level of the carrier plate is used to prepare for the predetermined positioning of a structural element (23) within the carrier plate (10), shown in 1b . To prepare for dosing, the 1st press ram (211a) and the 2nd press ram (211b) move to an individually controllable dosing position, the position of the 2nd ram (211b) being the same as or further away from the mold zero point than the position of the 1st ram (211a). As in 3b can be seen, the 1st ram (211a) is completely surrounded by the 2nd ram (211b). The 1st ram thus releases the bale chamber area (212c), the 2nd ram the bale chamber (212b). The press chamber areas (212b/ 212c) are filled with duroplastic molding compound to the extent that in step 6C, 5d , sets a predetermined material layer thickness.
• 11c : during step 6C, 5d . In this step, the dosed duroplastic molding compound is prepared for receiving a structural element (23). The press mandrel (211) can be controlled individually. When the dosing of the duroplastic molding compound for the carrier plate is complete, the press mandrel (211c) moves into the upper tool (215b) in a form-closing manner and thus acts as a placeholder for a cavity (40) in the carrier plate (10). The 1st press ram (211a) and the 2nd press ram (211b) can be controlled individually, which means that the carrier plate in the volume segment (212b) and in the volume segment (212c) can be subjected to individually specified pressing pressures and individually specified time intervals, with the pressing pressure being dependent on the 1. Press stamp (211a) is transferred via the friction lining segment (21) and the intermediate layer (22) into the volume segment (212c) of the carrier plate. The pressing pressure from the 2nd pressing ram (211b) is directed directly into the volume segment (212b) of the carrier plate. The necessary counter-pressure for the 1st and 2nd press ram (211a/211b) is applied by an upper tool with its own drive (215b), which dips into the free press chamber areas in a form-closing manner. The temperatures for the components 1st press ram (211a), 2nd press ram (211b), press mandrel (211c), mold body (213) and the upper tool (215b) can be controlled individually. The period of time for this process is selected in such a way that the dosed duroplastic molding compound, plastically deforming, forms a lower material level.
• 11d : during step 6E, according to 5d .In preparation for the insertion of a material structure (23) and for dosing the remaining duroplastic molding compound (10a), the 1st ram (211a) and the 2nd ram (211b) retain the predetermined positions. The structural element (23) is placed in the press chamber on the material plane of the duroplastic carrier plate 10. The remaining duroplastic molding compound (10a) is then placed in the compression chamber.
• 12b : in step 7B, when incorporating a material structure (23) into the support plate (10). 5d . In this step, all metered molding compounds or inserted semi-finished products are pressed in an integrated process, with a cross-linking reaction taking place in the molding compounds. Chemical bonds are formed in the contact surfaces of the different materials with one another, ie the materials are welded to one another. The press mandrel (211) can be controlled individually. Once the dosing of the duroplastic molding compound for the carrier plate is complete, the press mandrel (211c) moves into the upper tool (215a/ 215b) in a form-closing manner and thus acts as a placeholder for a cavity (40) in the carrier plate (10). The 1st ram (211a) and the 2nd ram (211b) can be controlled individually, which means that the support plate can be subjected to individually specified pressures and individually specified time intervals in its volume segments (212b and 212c), with the pressure being controlled by the 1st ram (211a) is transferred via the friction lining segment (21) and the intermediate layer (22) into the volume segment (212c) of the carrier plate. The pressing pressure from the 2nd pressing ram (211b) is directed directly into the volume segment of the carrier plate (11b). The volume segments of the carrier plate can thus be adjusted to predetermined material densities, with the duroplastic material of the carrier plate penetrating and/or enclosing the geometry of the material structure (23). The necessary counter pressure for the 1st and 2nd press ram (211a/211b) is applied by the upper tool with its own drive (215b) connected to the press yoke (313), which closes the press chamber areas or dips into the press chamber areas in a form-closing manner. The temperatures for the components 1st press ram (211a), 2nd press ram (211b), press mandrel (211c), mold body (213) and the upper tool (215b) can be controlled individually. The period of time for the integrated pressing process is selected in such a way that the molding masses involved have the predetermined material density.
• 13a : during part demolding according to step 8 A shown in 5a , 5b and 5c . The upper tool (215a or 215b) is removed from the mould, the rams (211a) and (211b) move to the zero position of the mould. The brake lining (100) can be removed.
• 13b : during part demolding according to step 8 A shown in 5d . The upper tool (215b) is removed from the mould, the rams (211a) and (211b) move to the zero position of the mould. The brake lining (100) can be removed.
• 14a and 14b show a brake lining (100) consisting of a friction lining segment (21) and a duroplast carrier plate (10). 14c shows in detail X1 the penetration depth (27) of the friction lining segment (21) into the carrier plate (10). The entire circumference of the friction lining segment (21) is surrounded by the carrier plate (10) with the penetration depth (27). The carrier plate (10) and the friction lining segment (21) are thus chemically and positively connected.
• 15a and 14 b show a brake lining (100) consisting of a friction lining block (20) and a duroplast carrier plate (10). The friction lining block (20) is built up in layers from the friction lining segment (21) and the intermediate layer (22). 15c shows in detail X2 the penetration depth (28) of the intermediate layer (22) into the carrier plate (10). The friction lining segment (21) has no contact surface with the carrier plate (10). The intermediate layer (22) is surrounded by the support plate (10) in its entirety with the penetration depth (28). The carrier plate (10) and the intermediate layer (22), as part of the friction lining block (20), are chemically and positively connected.
• 16a and 16b show a brake lining (100) consisting of a friction lining segment (21), an intermediate layer (22) and a duroplast carrier plate (10). Also shown are the connection or installation options for accessories on the carrier plate, such as acoustic wear sensors (80) and metal plates (90).

Reference List

100

brake pad

10

Duroplast carrier plate

10a

Carrier plate, molding compound

20

friction lining block

20 b

Friction lining block, pre-pressed

21

friction lining segment

21 a

Friction lining segment, molding compound/grain fill

21 b

Friction lining segment, pre-pressed

22

intermediate layer

22 a

intermediate layer, molding compound

22 b

intermediate layer, semi-finished product

23

structural element

25

Material-free area

27

Penetration depth, friction lining segment in the carrier plate

28

Penetration depth, intermediate layer in the carrier plate

40

cavity in the backing plate

70

drilling

71

fasteners

72

insert element

73

threaded screw

80

Acoustic wear sensor

81

Contact for electrical wear sensor

90

metal plate

200

pressing tool

211

Fixed press stamp

211 a

1. Press stamp

211 b

2. Press stamp

211 c

Press mandrel, placeholder for cavity

212 a

Press chamber area released by the 1st press ram for the friction lining segment

212 b

Press chamber area released by the 2nd press ram for the carrier plate

212 c

Compression chamber area released by the 1st compression ram for the carrier plate

212d

Compression chamber area released by the 1st compression ram for the intermediate layer

213

mold body

214

direction of movement

215

upper tool

215 a

Upper tool connected to the press yoke

215 b

Upper tool, with its own drive

220

pressure plate

300

Press

310

Press with one-sided pressing direction

311

base frame

312

clamping cylinder

313

press yoke

320

Press with opposite pressing direction

321

Drive upper stamp

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• EP 1006289 A2 [0009]
• DE 102016107362 A1 [0010]
• WO 2015173768 A1 [0011]
• WO 2018141604 A1 [0012]

Claims (31)

Brake lining (100) for a disc brake of a vehicle, the brake lining (100) having a carrier plate (10) and a friction lining block (20) which is connected to the carrier plate (10) and consists of more than one material component, characterized in that the carrier plate (10) was produced by pressing a duroplastic molding compound (10a). Brake lining (100) according to claim 1 , characterized in that the friction lining block (20) is built up in layers, from a friction lining segment (21) and an intermediate layer (22), the intermediate layer (22) being arranged between the carrier plate (10) and the friction lining segment (21). Brake lining (100) according to claim 1 or 2 , characterized in that the friction lining block (20) has or consists of a friction lining segment (21), and the friction lining segment (21) engages with the penetration depth (27) in the contour of the carrier plate (10) and the chemical bond between the carrier plate (10) and friction lining block (20) in addition, produces a form-fitting connection. Brake lining (100) according to one of the preceding claims, characterized in that the friction lining block (20) is built up in layers, from a friction lining segment (21) and an intermediate layer (22), and the intermediate layer (22) with the penetration depth (28) into the contour of the carrier plate (10) and, in addition to the chemical bond between the carrier plate (10) and the intermediate layer (22), produces a form-fitting connection. Brake pad (100) according to one of the preceding claims, characterized in that the brake pad segment (21) has no direct contact surface to the carrier plate (10), i.e. the layer thickness of the intermediate layer (22) is greater than the penetration depth of the intermediate layer (28) into the support plate (10). Brake lining (100) according to one of the preceding claims, characterized in that an electrical wear indicator (81) is or will be inserted into the intermediate layer (22) arranged between the friction lining segment (21) and the duroplast carrier plate (10). Brake pad (100) according to one of the preceding claims, characterized in that accessories, in particular metal sheets (90) and/or acoustic wear indicators (80), are connected to the carrier plate by upsetting metal fastening elements (71) in the bores (70). and/or glued. Brake pad (100) according to one of the preceding claims, characterized in that accessories, in particular metal sheets (90) and/or acoustic wear indicators (80), are connected to the carrier plate by metal insert elements (72) being screwed into the bores (70) and / or are glued. Brake lining (100) according to one of the preceding claims, produced by pressing at least two molding compounds, in particular a friction lining compound (21a) to form a friction lining block (20) and a duroplastic pressing compound (10a) to form a carrier plate (10) for a brake lining (100 ), by means of a pressing tool (200) with at least three pressing chamber areas (212a, 212b, 212c) and several pressing rams (211a, 211b) assigned to these pressing chamber areas, characterized in that the individual pressing rams (211a, 211b) can be controlled individually. Brake pad (100) according to any one of the preceding claims, characterized in that the pressing ram (211a) is pressed against the pressing mass (21a) in the pressing chamber region (212a) with an individually adjustable pressure and/or speed of pressure build-up and/or duration and/or stroke becomes. Brake lining (100) according to one of the preceding claims, characterized in that the pressing mass (21a) in the pressing chamber area (212a) undergoes a first compression and reaction phase. Brake lining (100) according to one of the preceding claims, characterized in that the pre-compacted friction lining mass (21a) is pressed against the pressing mass (10a ) in the bale chamber area (212c). Brake lining (100) according to any one of the preceding claims, characterized in that the pressing die (211b) is pressed against the pressing mass (10a) in the pressing chamber region (212b) with an individually adjustable pressure and/or speed of pressure build-up and/or duration and/or stroke become. Brake lining (100) according to one of the preceding claims, characterized in that the individual press dies (211a, 211b) are subjected to different temperatures. Brake pad (100) according to any one of the preceding claims, characterized in that the individual press dies (211a, 211b) for dosing the quantity of the molding compound (10a, 21a, 22a) are positioned in such a way that predefined receiving areas (212a, 212b, 212c, 212d ) are formed within the press chamber. Brake pad (100) according to one of the preceding claims, characterized in that in a first compression chamber area (212a), preferably a central area, the friction lining block (20) is pressed or pre-compacted with the first press ram (211a). The carrier plate (10) is pressed in a second pressing chamber area (212b) with the second pressing ram (211b) and in a third pressing chamber area (212c) with the first pressing ram (211a). Brake lining (100) according to one of the preceding claims, characterized in that individual press dies (211a, 211b) have contact pressure surfaces with different geometries and/or different sizes. Brake lining (100) according to one of the preceding claims, characterized in that individual press dies (211a, 211b) have contact pressure surfaces which are not parallel to one another, at least in certain areas. Brake lining (100) according to one of the preceding claims, characterized in that at least one intermediate layer (22) with a different chemical composition is arranged between the duroplast carrier plate (10) and the friction lining segment (21). Brake pad (100) according to one of the preceding claims, characterized in that the intermediate layer (22) is formed from a powdered granulate as the third molding compound and is introduced into the compression chamber area (212d). Brake lining (100) according to one of the preceding claims, characterized in that several pressing compounds (10a, 21a, 22a) with different chemical compositions are formed into a brake lining (100) with the several pressing dies (211a, 211b). , consisting of a carrier plate (10), a friction lining segment (21) and an intermediate layer (22). Brake pad (100) according to one of the preceding claims, characterized in that the following manufacturing steps are or were carried out: a) Step 1 A: Placing the first pressing die (211 a) in such a way that a first pressing chamber region (212 a) for receiving the pressing compound for the friction lining segment (21a) is formed; and b) introducing the pressing compound (21a) into the pressing chamber area (212a); c) Step 2 A: By applying a pressure plate (220) to the opening of the bale chamber area (212 a) or by immersing the pressure plate (220) into the opening of the bale chamber area (212 a), by means of a lifting movement of the pressure plate (220), takes place at simultaneous counter-movement of the ram (211a) precompression of the molding compound (21a); d) Step 3 A: Placing the first press die (211a) in such a way that a second press chamber area (211d) for receiving the pressing compound for the intermediate layer (22a) is formed; and e) introducing the pressing compound (22a) into the pressing chamber area (212d); f) Step 4 A: By applying a pressure plate (220) to the opening of the bale chamber area (212 d) or by immersing the pressure plate (220) into the opening of the bale chamber area (212 d) by lifting the pressure plate (220) at simultaneous counter-movement of the ram (211 a) precompression of the molding compound (22 a); g) Step 5 A: By applying the upper tool (215 a) to the opening of the pressing chamber area (212 d) or by immersing the upper tool (215 b) into the opening of the pressing chamber area (212 d), the pressing masses (21 a, 22 a), with simultaneous counter-movement of the ram (211 a), the 1st compression and reaction phase; h) Step 6 A: Placing the first press ram (211a) in such a way that a third press chamber area (212c) for receiving the first subset of duroplastic molding compound (10a) is formed. At the same time, the second press ram (211b) is placed in such a way that a further press chamber area (212b) is formed for receiving the second subset of duroplastic molding compound (10a); and i) introducing the pressing compound (10a) into the pressing chamber areas (211b and 211c); j) Step 7 A: By applying the upper tool (215 a) to the opening of the bale chamber areas (212 b, 212 c) or by immersing the upper tool (215 b) into the opening of the bale chamber areas (212 b, 212 c), the Pressing compounds (10a, 21a, 22a), with simultaneous counter-movement of the ram (211a, 211b), pressed in an integrated process; k) Step 8 A: To remove the pressed brake pad (100), the first press ram (211a) and the second press ram (211b) are placed in the home position, ie in the zero position of the press tool (200). Brake pad (100) according to one of the preceding claims, characterized in that that the friction lining block (20b), according to step 4 C, 5c , consisting of a friction lining segment (21b) and an intermediate layer (22b) as a preform, produced in an external process, placed in the compression chamber area (212a, 212d) and then pressed with the duroplastic molding compound (10a) to form a brake lining (100) or became. Brake lining (100) according to one of the preceding claims, characterized in that the friction lining block (20b), according to step 4 C, 5c , consisting of a friction lining segment (21b) as a preform, produced in an external process, inserted in the compression chamber area (212a) and subsequently pressed with the duroplastic molding compound (10a) to form a brake lining (100). Brake pad (100) according to one of the preceding claims, characterized in that the intermediate layer (22), according to step 4 B, 5b , consisting of a semi-finished product (22b), produced in an external process, placed in the compression chamber area (212d) and subsequently pressed with the friction lining material (21a, 21b) and the duroplastic molding compound (10a) to form a brake lining (100). Brake lining (100) according to one of the preceding claims, characterized in that according to steps 6B to 7B, 5d , the addition of material to the duroplastic molding compound (10a) takes place in two steps, so that a structural element (23) can be positioned within the carrier plate contour; a) Step 6 B: Placing the ram (211a, 211b) in such a way that the compression chamber areas (212b, 211c) are formed to receive the duroplastic molding compound (10a), and b) introducing the molding compound (10a) into the bale chamber areas (212b, 212c); c) Step 6 C: By immersing the upper tool (215 b) into the opening in the opening of the pressing chamber areas (212 b, 212 c), the pressing masses (10 a), with the counterforce applied to the pressing ram (211 a, 211 b) , pre-pressed. The pressing chamber areas (212 b, 212 c) are partially filled with molding compound (10 a); d) Step 6 D: The upper tool (215 b) gives access to the free pressing chamber areas (212 b, 212 c), the structural element (23) can be positioned on the pre-pressed mass (10 a); e) Step 6E: The rams (211a, 211b) remain in the position assumed in step 6B. The pressing compound (10a) is placed in the free pressing chamber areas (212b, 212c); f) Step 7 B: By immersing the upper tool (215 b) into the opening of the pressing chamber areas (212 b, 212 c), the pressing masses (10 a, 21 a, 22 a) are pressed with simultaneous counter-movement or by applying the counter-force by the ram (211 a, 211 b), pressed in an integrated process. Brake lining (100) according to one of the preceding claims, characterized in that steps 6B to 7B, 5d , following steps 6A and 7A in Figs 5b and 5c can substitute. Pressing tool (200) for pressing at least two molding compounds, in particular at least one molding compound for forming a friction lining block (20) and a duroplastic pressing compound for forming a carrier plate (10), which together form a brake lining (100), characterized in that the pressing tool (200 ) has at least one press chamber, comprising the press chamber areas (212 a, 212 b, 212 c, 212 d), and several press rams (211 a, 211b) assigned to this press chamber, the individual press rams (211a, 211b) being individually controllable. Press tool (200) according to claim 28 , characterized in that the pressing tool (200) for pressing the molding compounds (10 a, 21 a, 22 a) and for pressing the semi-finished products or pre-pressed parts (20 b, 21 b, 22 b) for the production of a brake pad (100) according to the Claims 1 until 27 is trained. Press tool (200) according to claims 28 and 29 , characterized in that the pressing tool has at least one individually controllable pressing mandrel (211 c) which acts in the pressing chamber area (212 b) as a placeholder for cavities in the carrier plate (10). Press (300) with a pressing tool (200) for pressing at least two molding compounds, in particular at least one molding compound for forming a friction lining block (20) and a duroplastic pressing compound for forming a carrier plate (10), which together form a brake lining (100), characterized in that that the pressing tool (200) according to one of claims 28 until 30 is trained.

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