Method for producing an automotive friction material with optimized multi dimensional construction

Abstract

A method for producing an automotive friction material with optimized multi-dimensional construction includes receiving a base friction-disc material, cutting the base friction-disc material to a predetermined size and shape, assembling the sized and shaped cut base friction-disc material, bonding the base friction-disc material to a base friction plate, and utilizing a multi nozzle printing array to deposit friction enhancing materials overtop a reaction surface of the base friction-disc material.

What is claimed is: 
     
         1 . A method for producing an automotive friction material with optimized multi-dimensional construction comprises:
 receiving a base friction-disc material;   cutting the base friction-disc material to a predetermined size and shape;   assembling the cut, sized, and shaped base friction-disc material;   bonding the base friction-disc material to a base friction plate; and   utilizing a multi nozzle printing array to deposit friction enhancing materials overtop a reaction surface of the base friction-disc material.   
     
     
         2 . The method of  claim 1  wherein receiving the base friction-disc material further comprises receiving a continuous roll or flattened stock forming the base friction-disc material. 
     
     
         3 . The method of  claim 1  wherein the base friction-disc material is a woven material. 
     
     
         4 . The method of  claim 1  wherein the base friction material is a composite material. 
     
     
         5 . The method of  claim 1  wherein cutting the base friction-disc material further comprises utilizing a die to cut interlocking arcuate segments or annular rings of base friction-disc material from the base friction-disc material. 
     
     
         6 . The method of  claim 5  wherein assembling the sized and shaped cut base friction-disc material further comprises connecting interlocking arcuate segments to form complete annular rings of base friction-disc material. 
     
     
         7 . The method of  claim 1  wherein bonding the base friction-disc material to the base friction plate further comprises injecting a bonding material between the base friction-disc material and the base friction plate. 
     
     
         8 . The method of  claim 1  wherein utilizing a multi nozzle print array further comprises providing a supply of a plurality of friction enhancing materials to nozzles of the print array, wherein the plurality of friction enhancing materials include friction modifiers and resins. 
     
     
         9 . The method of  claim 1  wherein utilizing a multi nozzle print array further comprises depositing structural resin to precise predetermined locations on the base friction-disc material in a high density linear printing process or a translational printing process. 
     
     
         10 . The method of  claim 1  further comprising dynamically adjusting material properties of the friction enhancing materials as the multi nozzle print array deposits the friction enhancing materials on the reaction surface of the base friction-disc material. 
     
     
         11 . The method of  claim 10  wherein dynamically adjusting material properties of the friction enhancing materials further comprises actively and dynamically controlling a duration of deposition, a viscosity, a density, and a flow speed or flow rate of the friction enhancing materials through the multi nozzle print array. 
     
     
         12 . The method of  claim 1  wherein utilizing a multi nozzle print array to deposit friction enhancing materials overtop a reaction surface of the base friction-disc material further comprises dynamically adjusting a depth of the friction enhancing materials as the friction enhancing materials are deposited on the base friction-disc material. 
     
     
         13 . A method for producing an automotive friction material with optimized multi-dimensional construction comprises:
 receiving a continuous roll or flattened stock base friction-disc material composed of a woven carbon material or a composite material;   cutting the base friction-disc material to a predetermined size and shape, the predetermined size and shape being interlocking arcuate segments or annular rings of base friction-disc material cut from the base friction-disc material stock; and   utilizing a multi nozzle printing array to deposit friction enhancing materials overtop a reaction surface of the base friction-disc material.   
     
     
         14 . The method of  claim 13  further comprising assembling the annular rings or assembling the interlocking arcuate segments to form annular ring, and utilizing a bonding material between the annular rings of base friction-disc material and a base friction plate to permanently bond the annular rings of base friction-disc material to the base friction plate. 
     
     
         15 . The method of  claim 13  wherein utilizing a multi nozzle print array further comprises providing a supply of a plurality of friction enhancing materials to nozzles of the print array, wherein the plurality of friction enhancing materials include friction modifiers and resins. 
     
     
         16 . The method of  claim 13  wherein utilizing a multi nozzle print array further comprises depositing a structural resin at precise predetermined locations on the base friction-disc material in a high density linear printing process or a translational printing process, and dynamically adjusting a duration of deposition, a viscosity, a density, a flow speed or flow rate, and a material composition of the friction enhancing materials as the multi nozzle print array deposits the friction enhancing materials on the base friction-disc material. 
     
     
         17 . The method of  claim 13  further comprising dynamically adjusting a depth of the friction enhancing materials as the friction enhancing materials are deposited on the base friction-disc material. 
     
     
         18 . The method of  claim 13  wherein utilizing a multi nozzle print array further comprises depositing a structural resin into joints between interlocking arcuate segments of base friction-disc material. 
     
     
         19 . A method for producing an automotive friction material with optimized multi-dimensional construction comprises:
 receiving a continuous roll or flattened stock base friction-disc material composed of a woven carbon material or a composite material;   cutting the base friction-disc material to a predetermined size and shape, the predetermined size and shape being interlocking arcuate segments or annular rings of base friction-disc material cut from the base friction-disc material;   bonding the annular rings to a base friction plate, or assembling the interlocking arcuate segments to form annular rings and bonding the resulting annular rings to the base friction plate by utilizing a bonding material between the annular rings of base friction-disc material and the base friction plate to permanently bond the annular rings of base friction-disc material to the base friction plate;   providing a supply of a plurality of friction enhancing materials to nozzles of a multi nozzle print array, wherein the plurality of friction enhancing materials include friction modifiers and resins;   utilizing the multi nozzle printing array to deposit a structural resin at precise predetermined locations on the base friction-disc material in a high density linear printing process or a translational printing process, and dynamically adjusting a duration of deposition, a viscosity, a density, a flow speed or flow rate, and a material composition of the friction enhancing materials as the multi nozzle print array deposits the friction enhancing materials on the base friction-disc material; and   dynamically adjusting a depth of the friction enhancing materials as the friction enhancing materials are deposited on the base friction-disc material,   wherein the multi nozzle printing array deposits friction enhancing materials overtop a reaction surface of the base friction-disc material.   
     
     
         20 . The method of  claim 19  wherein utilizing a multi nozzle print array further comprises depositing a structural resin into joints between interlocking arcuate segments of base friction-disc material.