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Title:
BRAKE PAD WITH FIBER-REINFORCED FRICTION PAD
Document Type and Number:
WIPO Patent Application WO/2018/014117
Kind Code:
A1
Abstract:
A brake pad includes (a) a backing plate having an attachment surface and a plurality of piercing members protruding from the attachment surface; and (b) a fiber-reinforced friction pad having an array of glass fibers in a cured matrix material. The friction pad is impaled on the piercing members to secure the friction pad to the backing plate, with the piercing members penetrating into the array of glass fibers.

Inventors:
ARBESMAN, Ray (42 Burton Road, Toronto, Ontario M5P 1V2, M5P 1V2, CA)
PHAM, Nghi (100 Prairie Dunes Place, Concord, Ontario L4K2E4, L4K2E4, CA)
Application Number:
CA2017/050851
Publication Date:
January 25, 2018
Filing Date:
July 14, 2017
Export Citation:
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Assignee:
NUCAP INDUSTRIES INC. (3370 Pharmacy Avenue, Scarborough, Ontario M1W 3K4, M1W 3K4, CA)
International Classes:
F16D65/04; F16D65/092
Foreign References:
US20100170758A12010-07-08
US6479413B12002-11-12
US20050145454A12005-07-07
US9360067B12016-06-07
US20150053517A12015-02-26
Attorney, Agent or Firm:
BERESKIN & PARR LLP/S.E.N.C.R.L., S.R.L. (40 King Street West, 40th FloorToronto, Ontario M5H 3Y2, M5H 3Y2, CA)
Download PDF:
Claims:
We Claim:

1 A brake pad comprising: a) a backing plate having an attachment surface and a plurality of piercing members protruding from the attachment surface; and b) a fiber-reinforced friction pad having an array of glass fibers in a cured matrix material, the friction pad impaled on the piercing members to secure the friction pad to the backing plate, the piercing members penetrating into the array of glass fibers.

2. The brake pad of claim 1 , wherein the piercing members comprise integral backing plate barbs, each barb extending generally perpendicular to the attachment surface of the backing plate and having a pointed tip directed away from the attachment surface for piercing into the friction pad.

3. The brake pad of claim 2, wherein the friction pad has a friction surface and an opposed underside surface adjacent the attachment surface of the backing plate, and wherein the barbs penetrate through a penetration thickness of the friction pad measured from the underside surface, the array of glass fibers extending throughout the penetration thickness.

4. The brake pad of any one of claims 1 to 3, wherein the glass fibers extend across the friction pad.

5. The brake pad of any one of claims 1 to 4, wherein the glass fibers extend generally parallel to the attachment surface of the backing plate.

6. The brake pad of any one of claim 1 to 4, wherein the glass fibers extend generally perpendicular to the attachment surface of the backing plate.

7. The brake pad of any one of claims 1 to 6, wherein the array comprises a plurality of layered fiberglass panels.

8. The brake pad of claim 7, wherein the fiberglass panels are generally parallel to the attachment surface of the backing plate, and the piercing members penetrate through at least some of the fiberglass panels.

9. The brake pad of any one of claims 1 to 8, wherein the glass fibers make up at least 35% of the friction pad by mass.

10. The brake pad of claim 9, wherein the glass fibers make up at least 50% of the friction pad by mass.

1 1 . A kit for assembling a brake pad, the kit comprising: a) a backing plate having an attachment surface and a plurality of piercing members protruding from the attachment surface; and b) a fiber-reinforced friction pad having an array of glass fibers in a cured matrix material, the friction pad securable to the backing plate by impaling the friction pad on the piercing members to penetrate the array of glass fibers with the piercing members.

12. The kit of claim 1 1 , wherein the piercing members comprise integral backing plate barbs, each barb extending generally perpendicular to the attachment surface of the backing plate and having a pointed tip directed away from the attachment surface for piercing into the friction pad.

13. The kit of claim 12, wherein the friction pad has a friction surface, an opposed underside surface for impalement on the barbs, and a penetration thickness measured from the underside surface, the array of glass fibers extending throughout the penetration thickness, and wherein the barbs have a height measured from the attachment surface of the backing plate, the penetration thickness of the friction pad generally corresponding to the height of the barbs.

14. The kit of claim 13, wherein the array comprises a plurality of layered fiberglass panels, the fiberglass panels extending generally parallel to the underside surface within the penetration thickness.

15. A brake pad comprising: a) a backing plate having an attachment surface and a plurality of piercing members protruding from the attachment surface; and b) a fiber-reinforced friction pad having an array of fibers in a cured matrix material, the friction pad impaled on the piercing members to secure the friction pad to the backing plate, the piercing members penetrating into the array of fibers.

16. A method of manufacturing a brake pad, the method comprising: a) positioning a preformed fiber-reinforced friction pad against a backing plate, the backing plate having an attachment surface and a plurality of piercing members protruding from the attachment surface, and the friction pad having an array of glass fibers in a cured matrix material; and b) impaling the friction pad on the piercing members to secure the friction pad to the backing plate, the impaling step including forcing the piercing members to penetrate into the array of glass fibers.

17. The method of claim 16, wherein the array comprises a plurality of layered fiberglass panels, the fiberglass panels generally parallel to the attachment surface of the backing plate, and wherein the impaling step includes forcing the piercing members to penetrate through at least some of the fiberglass panels.

18. The method of any one of claims 16 to 17, wherein the positioning step includes positioning the backing plate and the friction pad in a press, and the impaling step includes operating the press to impale the friction pad on the piercing members.

19. The method of any one of claims 16 to 18 further comprising, prior to step (a), driving a plurality of blade teeth across the attachment surface of the backing plate to gouge the piercing members from the attachment surface.

20. The method of claim 19, wherein the piercing members are formed as integral backing plate barbs, each barb extending generally perpendicular to the attachment surface of the backing plate and having a pointed tip directed away from the attachment surface for piercing into the friction pad.

21 . The method of any one of claims 16 to 20 further comprising, prior to step (a), forming the friction pad using a pultrusion process, the pultrusion process including pulling the glass fibers and uncured matrix material through a forming die and subsequently curing the matrix material.

22. A method of manufacturing a brake pad, the method comprising: a) positioning a preformed fiber-reinforced friction pad against a backing plate, the backing plate having an attachment surface and a plurality of piercing members protruding from the attachment surface, and the friction pad having an array of fibers in a cured matrix material; and b) impaling the friction pad on the piercing members to secure the friction pad to the backing plate, the impaling step including forcing the piercing members to penetrate into the array of fibers.

Description:
BRAKE PAD WITH FIBER-REINFORCED FRICTION PAD

FIELD

[0001 ] The disclosure relates generally to brake pads. More specifically, the disclosure relates to brake pads having fiber-reinforced friction pads and methods for joining such brake pads to a brake backing plate.

BACKGROUND

[0002] U.S. Patent No. 6,910,255 (Arbesman) discloses 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.

[0003] U.S. Patent No. 5,690,770 (Booher) discloses a composite friction unit including a three dimensional composite body formed of a substantially uniform array of predominately glass strands of primary reinforcing fibers in matrix of phenolic resin material, the reinforcing fibers distributed throughout the body in a predetermined uniform distribution and orientation, and a substantially uniform array and distribution of secondary fibers extending transverse to the primary fibers thereby forming a friction unit having a predetermined size and configuration and uniform distribution and alignment of fibers throughout.

[0004] U.S. Patent No 8,974,621 (Booher) discloses a composite friction unit of a three dimensional composite body formed of a substantially uniform array of predominately glass strands of primary reinforcing fibers in a matrix of phenolic resin material, the reinforcing fibers in the form of fabric distributed throughout the body forming a friction unit having a predetermined size and configuration and uniform distribution and alignment of fibers throughout. An alternate friction unit includes a substantially rigid or rigid backing co-pultruded in forming the unit. The units are produced in a pultrusion process wherein the reinforcing fibers and matrix are pulled through a forming die.

SUMMARY

[0005] The following summary is intended to introduce the reader to various aspects of the disclosure, but not to define or delimit any invention.

[0006] According to some aspects, a brake pad includes: (a) a backing plate having an attachment surface and a plurality of piercing members protruding from the attachment surface; and (b) a fiber-reinforced friction pad having an array of glass fibers in a cured matrix material. The friction pad is impaled on the piercing members to secure the friction pad to the backing plate, and the piercing members penetrate into the array of glass fibers.

[0007] In some examples, the piercing members may be in the form of integral backing plate barbs. Each barb may extend generally perpendicular to the attachment surface of the backing plate and have a pointed tip directed away from the attachment surface for piercing into the friction pad.

[0008] In some examples, the friction pad has a friction surface and an opposed underside surface adjacent the attachment surface of the backing plate. The barbs may penetrate through a penetration thickness of the friction pad measured from the underside surface. The array of glass fibers may extend throughout the penetration thickness.

[0009] In some examples, the glass fibers may extend across the friction pad. In some examples, the glass fibers may extend generally parallel to the attachment surface of the backing plate. In some examples, the glass fibers may extend generally perpendicular to the attachment surface of the backing plate. [0010] In some examples, the array may include a plurality of layered fiberglass panels. In some examples, the fiberglass panels may be generally parallel to the attachment surface of the backing plate, and the piercing members may penetrate through at least some of the fiberglass panels.

[001 1 ] In some examples, the glass fibers may make up at least 35% of the friction pad by mass. In some examples, the glass fibers may make up at least 50% of the friction pad by mass.

[0012] According to some aspects, a kit for assembling a brake pad includes: (a) a backing plate having an attachment surface and a plurality of piercing members protruding from the attachment surface; and (b) a fiber- reinforced friction pad having an array of glass fibers in a cured matrix material. The friction pad is securable to the backing plate by impaling the friction pad on the piercing members to penetrate the array of glass fibers with the piercing members.

[0013] In some examples, the piercing members may be in the form of integral backing plate barbs. Each barb may extend generally perpendicular to the attachment surface of the backing plate. Each barb may have a respective pointed tip directed away from the attachment surface for piercing into the friction pad.

[0014] In some examples, the friction pad may have a friction surface, an opposed underside surface for impalement by the barbs, and a penetration thickness measured from the underside surface. The array of glass fibers may extend throughout the penetration thickness. The barbs may have a height measured from the attachment surface of the backing plate, and the penetration thickness of the friction pad may generally correspond to the height of the barbs.

[0015] In some examples, the array includes a plurality of layered fiberglass panels. The fiberglass panels may extend generally parallel to the underside surface within the penetration thickness. [0016] According to some aspects, a brake pad includes: a) a backing plate having an attachment surface and a plurality of piercing members protruding from the attachment surface; and (b) a fiber-reinforced friction pad having an array of fibers in a cured matrix material. The friction pad is impaled on the piercing members to secure the friction pad to the backing plate. The piercing members penetrate into the array of fibers.

[0017] According to some aspects, a method of manufacturing a brake pad includes: (a) positioning a preformed fiber-reinforced friction pad against a backing plate. The backing plate has an attachment surface and a plurality of piercing members protruding from the attachment surface. The friction pad has an array of glass fibers in a cured matrix material. The method further includes (b) impaling the friction pad on the piercing members to secure the friction pad to the backing plate. The impaling step includes forcing the piercing members to penetrate into the array of glass fibers.

[0018] In some examples, the array includes a plurality of layered fiberglass panels. The fiberglass panels may be generally parallel to the attachment surface of the backing plate. The impaling step may further include forcing the piercing members to penetrate through at least some of the fiberglass panels.

[0019] In some examples, the positioning step may include positioning the backing plate and the friction pad in a press, and the impaling step may include operating the press to impale the friction pad on the piercing members.

[0020] In some examples, the method may further include, prior to step (a), driving a plurality of blade teeth across the attachment surface of the backing plate to gouge the piercing members from the attachment surface.

[0021 ] In some examples, the piercing members may be formed as integral backing plate barbs. Each barb may extend generally perpendicular to the attachment surface of the backing plate and have a pointed tip directed away from the attachment surface for piercing into the friction pad.

[0022] In some examples, the method may further include, prior to step (a), forming the friction pad using a pultrusion process. The pultrusion process may include pulling the glass fibers and uncured matrix material through a forming die and subsequently curing the matrix material.

[0023] According to some aspects, method of manufacturing a brake pad includes: (a) positioning a preformed fiber-reinforced friction pad against a backing plate. The backing plate has an attachment surface and a plurality of piercing members protruding from the attachment surface. The friction pad has an array of fibers in a cured matrix material. The method further includes (b) impaling the friction pad on the piercing members to secure the friction pad to the backing plate. The impaling step includes forcing the piercing members to penetrate into the array of fibers.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:

[0025] Figure 1 is a perspective view of an example brake pad;

[0026] Figure 2 is a perspective view of the backing plate of the brake pad of Figure 1 ;

[0027] Figure 3 is an enlarged perspective view of a portion of the backing plate of Figure 3;

[0028] Figure 4 is a schematic cross-sectional view of the brake pad of Figure 1 , taken along line 4-4 of Figure 1 ;

[0029] Figure 5 is an enlarged view of a portion of Figure 4; [0030] Figure 6 is a schematic cross-sectional view of the brake pad of Figure 1 , taken along line 6-6 of Figure 4;

[0031 ] Figure 7 is a flow chart illustrating an example method for manufacturing the brake pad of Figure 1 ;

[0032] Figure 8A is a schematic representation of a step of the example method of Figure 7;

[0033] Figure 8B is a schematic representation of a step subsequent to that of Figure 8A of the method of Figure 7;

[0034] Figure 9 is a schematic representation of a portion of an alternative fiber panel for a brake pad like that of Figure 1 ;

[0035] Figure 10 is a schematic cross-sectional view like that of Figure 5 of an alternative brake pad; and

[0036] Figure 1 1 is a schematic cross-sectional view of the brake pad of Figure 10, taken along line 1 1 -1 1 of Figure 10.

DETAILED DESCRIPTION

[0037] Various apparatuses or processes will be described below to provide an example of an embodiment of the claimed subject matter. No embodiment described below limits any claim and any claim may cover processes or apparatuses that differ from those described below. The claims are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an embodiment of any exclusive right granted by issuance of this patent application. Any subject matter described below and for which an exclusive right is not granted by issuance of this patent application may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim, or dedicate to the public any such subject matter by its disclosure in this document.

[0038] Disclosed herein are brake pads having a backing plate and a fiber- reinforced friction pad secured to the backing plate. The friction pad can include an array of fibers in a cured matrix material. The matrix material can include resins, such as, for example, phenolic resin, and can further include friction material filler. The fibers of the array can be embedded within the matrix material in a predetermined arrangement. For example, the fibers of the array may be arranged to extend at predetermined angles with respect to one another. For further example, some of the fibers of the array may extend parallel to one another, a first plurality of fibers of the array may be offset from a second plurality of fibers of the array by a predetermined angle, and/or some of the fibers of the array may be arranged in one or more fiber panels, such as, for example, woven, stitched, braided, roving, and/or chop-strand panels.

[0039] It has presently been determined that fiber-reinforced friction pads as described herein can be joined to a brake backing plate by impalement. For example, as will be described in further detail below with respect to the drawings, the backing plate can include a plurality of piercing members (e.g. barbs) extending from a face thereof. These piercing members can be generally pointed and sharp, and can also be referred to as barbs. The friction pad can be secured to the backing plate by impaling the friction pad on the piercing members, and penetrating the array of fibers of the friction pad with the piercing members. It is believed that the array of fibers provides structural support to the surrounding cured matrix material, which may allow for piercing of the friction pad by the piercing members without necessarily excessively cracking or excessively crumbling the cured matrix material. This can be the case even where the matrix material may be otherwise considered to be generally friable (i.e. too friable to be joined to the backing plate by piercing). Such examples can allow for a friction pad to be pre-formed (i.e. formed separately from a backing plate), and to be subsequently secured to the backing plate by impalement. This can in turn allow for ease of manufacture, without necessarily requiring excess energy, and without necessarily increasing the weight of the brake pad.

[0040] In some examples, the fibers of the array are glass fibers. In some examples, the array may include various types of fibers, such as, for example, glass, rock, ceramic, carbon, graphite, aramid, nomex, wool, and/or cotton fibers in selected proportions and distributions to alter certain characteristics of the friction pad. Various metallic fibers, such as copper and/or aluminum, for example, may also be utilized in various proportions with non-metallic fibers. The fibers of the array may be in the form of a plurality of individual fibers, a plurality of fiber bundles, one or more types of fiber panels in the same or different orientations, and/or combinations thereof.

[0041 ] Referring to Figure 1 , a schematic representation of an example brake pad 100 is shown. The brake pad 100 includes a backing plate 102 and a fiber-reinforced friction pad 104 secured to the backing plate 102. Referring to Figure 2, the backing plate 102 has a friction-pad attachment surface 106, an opposed caliper-facing surface 108, and a plurality of piercing members 1 10 protruding from the attachment surface 106.

[0042] Referring to Figure 3, in the example illustrated, the piercing members 1 10 are in the form of integral barbs 1 10. The barbs 1 10 can be formed by texturing the attachment surface 106 using blades having a plurality of blade teeth. The blade teeth can be driven across the attachment surface 106 to gouge the piercing members (barbs) 1 10 from the attachment surface 106. For example, the blade teeth can carve grooves 1 14 into the backing plate 102 from which the piercing members 1 10 are raised. A plurality of first blades having respective blade teeth can be driven across the attachment surface 106 in a first direction to form a first plurality of the barbs 1 10, and a plurality of second blades having respective blade teeth can be simultaneously driven across the attachment surface 106 in a second direction opposite the first direction to form a second plurality of the barbs 1 10.

[0043] In the example illustrated, the barbs 1 10 of the backing plate 102 are relatively straight, and extend generally perpendicular to the attachment surface 106. Each barb 1 10 has a generally sharp, pointed tip 1 12 directed away from the attachment surface 106 for piercing into the friction pad 104.

[0044] Referring to Figure 5, in the example illustrated, the piercing members 1 10 have a height 1 16 measured from the attachment surface 106 of the backing plate 102. In some examples, the height 1 16 of the piercing members 1 10 may be between about 0.03 inches and 0.08 inches. In some examples, the height 1 16 of the piercing members 1 10 may be between about 0.04 inches and 0.06 inches. In some examples, the backing plate 102 may include between about 15 and 40 piercing members per square inch. In some examples, the piercing members 1 10 can be distributed over at least 60% of the attachment surface 106.

[0045] Referring to Figures 4 and 5, in the example illustrated, the friction pad 104 has an array 120 of glass fibers in a cured matrix material 124. The glass fibers of the array 120 may be in the form of a plurality of individual glass fibers, a plurality of glass fiber bundles, one or more types of fiberglass panels in the same or different orientations, and/or combinations thereof. In the example illustrated in Figures 4 to 6, the glass fibers of the array 120 are in the form of glass fiber bundles 122 woven into fiberglass panels 140. The array 120 is described in further detail below. The friction pad 104 is impaled on the piercing members 1 10 to secure the friction pad 104 to the backing plate 102, with the piercing members 1 10 penetrating into the array 120 of glass fibers.

[0046] Referring to Figure 4, in the example illustrated, the friction pad 104 includes a friction surface 130 and an opposed underside surface 132 adjacent the attachment surface 106 of the backing plate 102. The friction pad 104 has an overall friction pad thickness 134 between the friction surface 130 and the underside surface 132. The piercing members 1 10 penetrate the underside surface 132 and extend through a penetration thickness 136 of the friction pad 104 measured from the underside surface 132. The penetration thickness 136 is less than the overall friction pad thickness 134, and generally corresponds to the height 1 16 of the piercing members 1 10.

[0047] In the example illustrated, the array 120 of glass fibers extends throughout the penetration thickness 136 of the friction pad 104. In the example illustrated, the array 120 of glass fibers extends throughout the overall friction pad thickness 134. The array 120 may include a density of glass fibers suitable for facilitating piercing of the friction pad 1 104 by the piercing members 1 10. In some examples, the array 120 of glass fibers can make up at least 35% of the friction pad 104 by mass. In some examples, the array 120 of glass fibers can make up between about 35% and 70% of the friction pad 104 by mass, and the matrix material 124 can make up between about 30% and 65% of the friction pad 104 by mass. In some examples, the array 120 of glass fibers can make up at least 50% of the friction pad 104 by mass.

[0048] Referring to Figures 4 to 6, in the example illustrated, the array 120 of glass fibers includes a plurality of layered fiberglass panels 140. The fiberglass panels 140 are generally parallel to the attachment surface 106 of the backing plate 102 (and the underside surface 132 of the friction pad 104). At least some of the fiberglass panels 140 extend within the penetration thickness 136 of the friction pad 104. In the example illustrated, the piercing members 1 10 penetrate through the fiberglass panels 140 extending within the penetration thickness 136. In the example illustrated, the fiberglass panels 140 are distributed generally uniformly throughout the friction pad 104.

[0049] In the example illustrated, each fiberglass panel 140 extends across the friction pad 104, and has a profile generally corresponding to a respective cross-section of the friction pad 104 (see Figure 6). In the example illustrated, each fiberglass panel 140 extends between opposed surfaces of the friction pad 104. Referring to Figure 6, the friction pad 104 includes opposed side surfaces 142, 144 extending between the friction surface 130 and the underside surface 132, a top surface 146 extending between the opposed side surfaces 142, 144 and the opposed friction and underside surfaces 130, 132, and a bottom surface 148 opposite the top surface 146 and extending between the opposed side surfaces 142, 144 and the opposed friction and underside surfaces 130, 132. In the example illustrated, each fiberglass panel 140 extends lengthwise between the opposed side surfaces 142, 144, and widthwise between the top and bottom surfaces 146, 148.

[0050] In some examples, the fiberglass panels 140 may be oriented in a different manner than shown in Figures 4 to 6. For example, the fiberglass panels 140 may be oriented perpendicular to the attachment surface 106 of the backing plate 102, and may extend across the friction pad 104 between the friction and underside surfaces 130, 132 of the friction pad 104.

[0051 ] The fiberglass panels 140 may include one or more types of panels. For example, the fiberglass panels 140 may include unidirectional fiberglass panels having glass fibers oriented generally parallel to one another; bidirectional fiberglass panels (e.g., woven cloth fabric) having a first plurality of glass fibers offset from a second plurality of glass fibers by a predetermined angle; and/or omni-directional fiberglass panels (e.g., chop strand mats) having glass fibers oriented at various angles relative to one another in a common plane (e.g., as shown in Figure 9).

[0052] Referring to Figure 6, in the example illustrated, the fiberglass panels 140 are bidirectional fiberglass panels having a first plurality of glass fibers offset from a second plurality of glass fibers by a predetermined angle. In the example illustrated, the fiberglass panels 140 are woven panels, with the first plurality of glass fibers (shown as fiber glass bundles 122a) and the second plurality of glass fibers (shown as fiber glass bundles 122b) offset from one another by approximately 90 degrees. The first plurality of glass fibers extend across the friction pad 104 between the opposed side surfaces 142, 144 of the friction pad 104, and the second plurality of glass fibers extend across the friction pad 104 between the opposed top and bottom surfaces 146, 148 of the friction pad 104. In some examples, one or more of the fiberglass panels 140 may have glass fibers oriented at an oblique angle relative to other glass fibers of the same or a different fiberglass panel 140, and/or the surfaces of the friction pad 104.

[0053] The matrix material 124 can include any suitable resin, such as, for example, phenolic resin, and can further include friction material filler. The friction material filler can include, for example, milled and/or chopped fibers of glass, ceramic, kevlar, steel, wool, or cotton; powdered ceramics and non-ferrous metals; and/or mineral filler.

[0054] Referring to Figure 7, an example method 300 for manufacturing the brake pad 100 is shown. At step 310a, the piercing members 1 10 are gouged from the attachment surface 106 of the backing plate 102 by driving a plurality of blade teeth across the attachment surface 106, as described above.

[0055] At step 310b, the friction pad 104 is formed using a pultrusion process. The pultrusion process includes pulling the glass fibers and uncured matrix material through a forming die, and subsequently curing the matrix material. The cured matrix material may then be cut to a desired shape to form the friction pad 104. Suitable pultrusion processes for forming the friction pad 104 are described in, for example, U.S. Patent No. 5,690,770 and U.S. Patent No 8,974,621 , and will not be described in detail herein for brevity.

[0056] In some examples, adhesives (e.g., chemical bonding agents) can optionally be provided between the backing plate 102 and the friction pad 104 to help strengthen the bond therebetween. The adhesive can be applied over the attachment surface 106 of the backing plate 102 and/or the underside surface 132 of the friction pad 104 at step 315. [0057] At step 320, the preformed friction pad 104 is positioned against the backing plate 102. Referring to Figure 8A, in the example illustrated, the backing plate 102 and the friction pad 104 can be positioned in a fixture of a press 150. The friction pad 104 can be aligned with and positioned against the backing plate 102, with the underside surface 132 of the friction pad 104 adjacent the tips 1 12 of the piercing members 1 10.

[0058] At step 330, the friction pad 104 is impaled on the piercing members 1 10 to secure the friction pad 104 to the backing plate 102, such that the piercing members 1 10 are forced to penetrate into the array 120 of glass fibers. Referring to Figure 8B, in the example illustrated, the press 150 can be engaged to press the friction pad 104 against the piercing members 1 10 so that the friction pad 104 is impaled onto the piercing members 1 10. The press 150 can force the piercing members 1 10 to penetrate into the friction pad 104 and through at least some of the fiberglass panels 140. As described above, it has been determined that fiber-reinforced friction pads can be pierced by piercing members of a backing plate, without necessarily excessively cracking or crumbling of the friction pad.

[0059] When the underside surface 132 of the friction pad 104 is adjacent the attachment surface 106 of the backing plate 102, the press 150 can be released.

[0060] Referring to Figures 10 and 1 1 , an alternative brake pad 1 100 is illustrated. The brake pad 1 100 is similar to the brake pad 100, and like features are identified by like reference characters, incremented by 1000.

[0061 ] The brake pad 1 100 includes a backing plate 1 102 and a friction pad 1 104 secured to the backing plate 1 102. The backing plate 1 102 has an attachment surface 1 106 and a plurality of piercing members 1 1 10 protruding from the attachment surface 1 106. The friction pad 1 104 has an array 1 120 of glass fibers in a cured matrix material 1 124. The friction pad 1 104 is impaled on the piercing members 1 1 10 of the backing plate 1 102 to secure the friction pad 1 104 to the backing plate 1 102, with the piercing members 1 1 10 penetrating into the array 1 120 of glass fibers.

[0062] In the example illustrated, the piercing members 1 1 10 penetrate an underside surface 1 132 of the friction pad 1 104, and extend through a penetration thickness 1 136 of the friction pad 1 104. The array 1 120 of glass fibers extends throughout the penetration thickness 1 136.

[0063] In the example illustrated, the glass fibers extend across the friction pad 1 104, between opposed surfaces of the friction pad 1 104. In the example illustrated, the glass fibers extend generally perpendicular to the attachment surface 1 106 of the backing plate 1 102 across the friction pad thickness 1 134, between the underside surface 1 132 and an opposed friction surface 1 130 of the friction pad 1 104. In the example illustrated, the array 1 120 of glass fibers includes a plurality of glass fiber bundles 1 122 distributed generally uniformly throughout the matrix material 1 124.

[0064] In some examples, the glass fibers may be oriented in a different manner than shown in Figures 10 and 1 1 . For example, the glass fibers may be oriented generally parallel to the attachment surface 1 106 of the backing plate 1 102 (and the underside surface 1 132 of the friction pad 1 104).

[0065] While the above description provides examples of one or more processes or apparatuses, it will be appreciated that other processes or apparatuses may be within the scope of the accompanying claims.

[0066] To the extent any amendments, characterizations, or other assertions previously made (in this or in any related patent applications or patents, including any parent, sibling, or child) with respect to any art, prior or otherwise, could be construed as a disclaimer of any subject matter supported by the present disclosure of this application, Applicant hereby rescinds and retracts such disclaimer. Applicant also respectfully submits that any prior art previously considered in any related patent applications or patents, including any parent, sibling, or child, may need to be re-visited.