Brake Tech
B y T i m F r i t z
Understanding
Brake
Pad Construction
rake pads are wear
B items that can only
last so long. One of
the main concerns engi-
neers face is maintaining
the integrity of the lining
assembly for the service life
of the lining. The friction
lining on a disc brake pad is
mounted on a steel backing
plate. The plate provides
stiffness and rigidity, and
allows the caliper to
squeeze the pads against
the rotor.
New methods for mount-
ing the brake pad (friction
material) onto the steel
backing plate are constant-
ly being tested. Working in
an undercar service shop, Friction material must be able to maintain a firm hold way and some the oppo-
it’s important that you un- on the backing plate under high shear loads and extreme site way. The shape, distri-
derstand how parts work heat, while being placed in a corrosive environment for an bution and angle of the
and are aware of the re- extended amount of time.
search and development
that has gone into each product. The
more you know about what you are
selling, the better you can educate
your customers.
Methods used for mounting the
friction material to the backing
plate include:
•Rivets: Rivets are used to at-
tach the friction material to the
backing plate.
•Adhesive: Friction material is
bonded to the backing plate using
an adhesive.
•Molding: Molded pads are made
by pressing, heating and curing the
friction material to the backing
64 BRAKE & FRONT END • August 2004
eter, more durable com-
ponent.
•Mechanical locking:
Instead of using an adhe-
sive, the friction material
is mechanically locked to
the backing plate.
One of the newer forms
of mechanical locking is
known as NRS. Now used
by several brake pad sup-
p l i e r s, N R S r e l i e s o n
dozens of tiny curved
hooks that project from
the surface of the backing
plate, creating an incredi-
bly strong mechanical lock
between the backing plate
and friction material.
Some of the hooks face one
hooks provide adhesion be-
tween the plate and fric-
plate. In Integrally-Molded (I-M) ap- tion material.
plications, the friction material is The hooks only project about
extruded through, rather than rivet- 1/16th of an inch above the surface
ed or glued to, the metal backing of the plate, so the pads can wear
plate, forming an integrated, single- quite a bit before the tops of the
piece component. According to the hooks are exposed. Even when the
manufacturer, this design spreads hooks do become exposed, tests have
out and absorbs heat and energy shown that the hooks cause no dam-
over a larger surface area, resulting age to the rotor.
in quieter performance and longer Maintaining the integrity of the
pad life. brake lining assembly is something
A related term is “integrally that every brake technician is con-
molded insulator” (IMI). On these cerned about. It’s important to make
applications, the insulator is located sure that the brake parts that are in-
between the backing plate and fric- stalled on customers’ vehicles are
tion material. The result is a qui- well-built, reliable and trouble free. ■
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