Brake shoe

Abstract

In a brake shoe ( 1 ) comprising a carrier plate ( 2 ) having arranged thereon first a dampening and noise-reducing intermediate layer ( 4 ) and then a friction lining ( 6 ), it is provided that the intermediate layer ( 4 ), on the side thereof facing towards the friction lining ( 6 ), comprises a three-dimensional surface structure, and that the friction lining ( 6 ) on the carrier-plate side is adapted to the surface contour ( 5 ) of the intermediate layer ( 4 ).

1 . A brake shoe ( 1 ) having friction lining stiffness adapted to different braking requirements comprising a carrier plate ( 2 ), a three-dimensional intermediate layer ( 4 ) and a friction lining ( 6 ); said three-dimensional intermediate layer ( 4 ) being located between said carrier plate ( 2 ) and said friction lining ( 6 ), said three-dimensional intermediate layer ( 4 ) being formed of binding material which is soft relative to the friction lining ( 6 ) and being highly dampening and noise-reducing; said three-dimensional intermediate layer ( 4 ) including on a first side surface thereof a plurality of three-dimensional contoured surface portions ( 5 ) projecting in a direction away from said carrier plate ( 2 ); and said friction lining ( 6 ) having a first side surface including three-dimensional contoured surface portions complementary contoured to and mating with the plurality of three-dimensional contoured surface portions ( 5 ) of said three-dimensional intermediate layer ( 4 ) thereby adapting the stiffness of the friction lining ( 6 ) to different braking requirements.  
   
   
       2 . The brake shoe as defined in  claim 1  wherein the carrier plate ( 2 ) the three-dimensional intermediate layer ( 4 ) and the friction lining ( 6 ) are bonded to each other only by hot press bonding the binding material of the three-dimensional intermediate layer ( 4 ) to each of the carrier plate ( 2 ) and the friction lining ( 6 ).  
   
   
       3 . The brake shoe as defined in  claim 1  wherein said three-dimensional intermediate layer ( 4 ) is preformed to include the three-dimensional contoured first surface portions ( 5 ) prior to hot press bonding thereof to the carrier plate ( 2 ) and the friction lining ( 6 ).  
   
   
       4 . The brake shoe as defined in  claim 1  wherein the three-dimensional intermediate layer ( 4 ) is press-molded to the three-dimensional shape thereof.  
   
   
       5 . The brake shoe as defined in  claim 1  wherein the friction layer ( 6 ) first side surface is bonded to the contoured surface portions ( 5 ) of the three-dimensional intermediate layer ( 4 ).  
   
   
       6 . The brake shoe as defined in  claim 1  wherein the three-dimensional intermediate layer ( 4 ) is preformed by press-molding the binding material thereof.  
   
   
       7 . The brake shoe as defined in  claim 1  wherein the three-dimensional intermediate layer ( 4 ) is preformed by press-molding the binding material thereof, and the friction material and the intermediate layer material are pressed into the friction lining ( 6 ) on the carrier plate ( 2 ).  
   
   
       8 . The brake shoe as defined in  claim 1  wherein three-dimensional contoured first surface portions ( 5 ) of said three-dimensional intermediate layer ( 4 ) are bonded to said three-dimensional complementary contoured surface portions of said friction lining ( 6 ) absent a boundary member between said complementary contoured surface, the three-dimensional contoured surface portions ( 5 ) of said three-dimensional intermediate layer ( 4 ) being defined by projections ( 8 ,  8 ′,  8 ″,  8 ′″), and the three-dimensional intermediate layer ( 4 ) being bonded to the entirety of a surface of the carrier plate ( 2 ) absent mechanical attachment therebetween.  
   
   
       9 . The brake shoe as defined in  claim 1  wherein the carrier plate ( 2 ) is devoid of any openings formed therethrough.  
   
   
       10 . The brake shoe as defined in  claim 1  wherein said three-dimensional contoured first surface portions ( 5 ) of said three-dimensional intermediate layer ( 4 ) are bonded to said three-dimensional complementary contoured surface portions of said friction lining ( 6 ) absent a boundary member between said complementary contoured surface portions, the three-dimensional contoured surface portions ( 5 ) of said three-dimensional intermediate layer ( 4 ) being defined by projections ( 8 ,  8 ′,  8 ″,  8 ′″), the three-dimensional intermediate layer ( 4 ) being bonded to the entirety of a surface of the carrier plate ( 2 ) absent mechanical attachment therebetween, and the carrier plate ( 2 ) is devoid of any openings formed therethrough.  
   
   
       11 . The brake shoe as defined in  claim 1  wherein the three-dimensional intermediate layer ( 4 ) is press-molded to the three-dimensional shape thereof, the friction layer ( 6 ) first side surface is bonded to the contoured first surface portions ( 5 ) of the three-dimensional intermediate layer ( 4 ), and the three-dimensional intermediate layer ( 4 ) is formed by press-molding the binding material thereof.  
   
   
       12 . The brake shoe as defined in  claim 1  wherein the three-dimensional contoured surfaces ( 5 ) of the three-dimensional intermediate layer ( 4 ) are oriented symmetrically to a radial axis of symmetry ( 10 ) of the carrier plate ( 2 ).  
   
   
       13 . The brake shoe as defined in  claim 1  wherein the three-dimensional contoured surfaces ( 5 ) of the three-dimensional intermediate layer ( 4 ) are arranged asymmetrically relative to a radial axis of symmetry ( 10 ) of the carrier plate ( 2 ).  
   
   
       14 . The brake shoe as defined in  claim 1  wherein the three-dimensional contoured surfaces ( 5 ) of the three-dimensional intermediate layer ( 4 ) are inclined relative to the carrier plate ( 2 ) and form a wedge-shaped intermediate layer ( 4 ).  
   
   
       15 . A brake shoe ( 1 ) having friction lining stiffness adapted to different braking requirements comprising a carrier plate ( 2 ), a single three-dimensional intermediate layer ( 4 ) and a friction lining ( 6 ); said three-dimensional intermediate layer ( 4 ) being located between said carrier plate ( 2 ) and said friction lining ( 6 ), said three-dimensional intermediate layer ( 4 ) being formed of binding material which is soft relative to the friction lining ( 6 ) and being highly dampening and noise-reducing; said three-dimensional intermediate layer ( 4 ) being preformed by premolding, prior to press-molding the three-dimensional intermediate layer ( 4 ) to the friction lining ( 6 ) and carrier plate ( 2 ), the binding material thereof into a premolded single substantially three-dimensional intermediate layer ( 4 ) including on a first side surface thereof a plurality of three-dimensional contoured surface portions ( 5 ) projecting in a direction away from said carrier plate ( 2 ); and said friction layer ( 6 ) having a first side surface press-molded against and to a surface configuration complementary contoured to the plurality of three-dimensional contoured surface portions ( 5 ) of said premolded single three-dimensional intermediate layer ( 4 ) formed during the press-molding of the friction lining ( 6 ) and the carrier plate ( 2 ) to the single three-dimensional intermediate layer ( 4 ) thereby adapting the stiffness of the friction lining ( 6 ) to different braking requirements.  
   
   
       16 . The brake shoe as defined in  claim 15  wherein said three-dimensional contoured first surface portions ( 5 ) of said premolded single three-dimensional intermediate layer ( 4 ) are bonded to said three-dimensional complementary contoured surface of said friction lining ( 6 ) absent a boundary member between said complementary contoured surfaces, the three-dimensional contoured surface portions ( 5 ) of said premolded single three-dimensional intermediate layer ( 4 ) being defined by projections ( 8 ,  8 ′,  8 ″,  8 ′″), and the premolded single three-dimensional intermediate layer ( 4 ) being bonded to the entirety of a surface of the carrier plate ( 2 ) absent mechanical attachment therebetween.  
   
   
       17 . The brake shoe as defined in  claim 15  wherein said three-dimensional contoured first surface portions ( 5 ) of said premolded single three-dimensional intermediate layer ( 4 ) are bonded to said three-dimensional complementary contoured surface of said friction lining ( 6 ) absent a boundary member between said complementary contoured surfaces, the three-dimensional contoured surface portions ( 5 ) of said premolded single three-dimensional intermediate layer ( 4 ) being defined by projections ( 8 ,  8 ′,  8 ″,  8 ′″), the premolded single three-dimensional intermediate layer ( 4 ) being bonded to the entirety of a surface of the carrier plate ( 2 ) absent mechanical attachment therebetween, and the carrier plate ( 2 ) is devoid of any openings formed therethrough.  
   
   
       18 . The brake shoe as defined in  claim 15  wherein the three-dimensional contoured surfaces ( 5 ) of the three-dimensional intermediate layer ( 4 ) are oriented symmetrically to a radial axis of symmetry ( 10 ) of the carrier plate ( 2 ).  
   
   
       19 . The brake shoe as defined in  claim 15  wherein the three-dimensional contoured surfaces ( 5 ) of the three-dimensional intermediate layer ( 4 ) are arranged asymmetrically relative to a radial axis of symmetry ( 10 ) of the carrier plate ( 2 ).  
   
   
       20 . The brake shoe as defined in  claim 15  wherein the three-dimensional contoured surfaces ( 5 ) of the three-dimensional intermediate layer ( 4 ) are inclined relative to the carrier plate ( 2 ) and form a wedge-shaped intermediate layer ( 4 ).  
   
   
       21 . A brake shoe ( 1 ) having friction lining stiffness adapted to different brake requirements comprising a carrier plate ( 2 ) devoid of any openings formed therethrough and having thereon a single intermediate layer ( 4 ) and a friction lining ( 6 ) upon the single intermediate layer ( 4 ), the single intermediate layer ( 4 ) being formed of binding material which is soft relative to the friction lining ( 6 ) and is highly dampening and noise-reducing, said single intermediate layer ( 4 ) including on a first side surface opposing a first side surface of the friction lining ( 6 ) a plurality of three-dimensional contoured surface portions ( 5 ) projecting in a direction away from the carrier plate ( 2 ), the first side surface of the friction lining ( 6 ) opposing the single intermediate layer ( 4 ) having a three-dimensional contoured surface complementary to the three-dimensional contoured surface portions ( 5 ) of the single intermediate layer ( 4 ), said three-dimensional contoured surface portions ( 5 ) of said single intermediate layer ( 4 ) being bonded to said three-dimensional complementary contoured surface of said friction lining ( 6 ) absent a boundary member between said complementary contoured surfaces, the three-dimensional contoured surface portions ( 5 ) of said single intermediate layer ( 4 ) being defined by projections ( 8 ,  8 ′,  8 ″,  8 ′″), and the intermediate single layer ( 4 ) being bonded to the entirety of a surface of the carrier plate ( 2 ) absent mechanical attachment therebetween thereby adapting the stiffness of the friction lining ( 6 ) to different braking requirements.  
   
   
       22 . The brake shoe as defined in  claim 21  wherein said projections( 8 ,  8 ′,  8 ″,  8 ′″) define a complementary surface of said single intermediate layer ( 4 )and said friction lining ( 6 ).  
   
   
       23 . The brake shoe as defined in  claim 22  wherein said projections ( 8 ,  8 ′,  8 ″,  8 ′″) have one of a bar, cylindrical, conical and sinusoidal cross-sectional shape.  
   
   
       24 . The brake shoe as defined in  claim 23  wherein said projections have a cylindrical cross-sectional shape.  
   
   
       25 . The brake shoe as defined in  claim 24  wherein the three-dimensional contoured surface ( 5 ) of the single intermediate layer ( 4 ) facing the friction lining ( 6 ) are inclined relative to one of a radial axis of symmetry ( 10 ) of the carrier plate ( 2 ) and an axis which is orthogonal to the radial axis of symmetry ( 10 ) and parallel to the carrier plate ( 2 ).