Polymer based backing plates for railway brake shoes and disc pads

Abstract

A lightweight backing plate for use with at least one of a railway brake shoe and a disc brake pad. Such lightweight backing plate being formed from a predetermined polymeric material selected from a group consisting of unsaturated polyester, polyphenylene sulfide, glass epoxy, phenolic polymers and various combinations thereof.

I claim:  
     
         1 . A lightweight backing plate for use with at least one of a railway brake shoe and a disc brake pad, said lightweight backing plate being formed from a predetermined polymeric material selected from a group consisting of unsaturated polyester, polyphenylene sulfide, glass epoxy, phenolic polymers and various combinations thereof.  
     
     
         2 . A lightweight backing plate, according to  claim 1 , wherein said lightweight backing plate further includes a predetermined reinforcing material.  
     
     
         3 . A lightweight backing plate, according to  claim 2 , wherein said predetermined reinforcing material is glass fiber.  
     
     
         4 . A lightweight backing plate, according to  claim 1 , wherein said predetermined polymeric resin contains preselected mineral fillers.  
     
     
         5 . A lightweight backing plate, according to  claim 1 , wherein said predetermined polymeric material is an unsaturated polyester.  
     
     
         6 . A lightweight backing plate, according to  claim 5 , wherein said unsaturated polyester contains styrene.  
     
     
         7 . A lightweight backing plate, according to  claim 1 , wherein said backing plate is used for a railway brake shoe.  
     
     
         8 . A lightweight backing plate, according to  claim 1 , wherein said backing plate is used for a disc brake pad.  
     
     
         9 . A composition brake shoe for use with at least one of railway vehicle brakes and automotive brakes, said brake shoe comprising: 
 (a) a lightweight backing plate member, said backing plate member being formed from a predetermined polymeric material selected from a group consisting of unsaturated polyester, polyphenylene sulfide, glass epoxy, phenolic polymers and various combinations thereof; and    (b) a preselected friction type composition material having a predetermined shape, said predetermined friction type composition material being bonded to said lightweight backing plate member.    
     
     
         10 . A composition brake shoe, according to  claim 9 , wherein said preselected friction type composition material is bonded to said lightweight backing plate member during molding.  
     
     
         11 . A composition brake shoe, according to  claim 9 , wherein said lightweight backing plate member includes means for securing said composition brake shoe to a brake beam disposed on a railway vehicle.  
     
     
         12 . A composition brake shoe, according to  claim 11 , wherein said means for securing said composition brake shoe to such brake beam is a keybridge.  
     
     
         13 . A composition brake shoe, according to  claim 9 , wherein said predetermined polymeric material includes a glass fiber reinforcing.  
     
     
         14 . A composition brake shoe, according to  claim 9 , wherein said predetermined polymeric material includes mineral fillers.  
     
     
         15 . A composition brake shoe, according to  claim 9 , wherein said predetermined polymeric material is an unsaturated polyester.  
     
     
         16 . A composition brake shoe, according to  claim 15 , wherein said unsaturated polyester contains styrene.  
     
     
         17 . A method of manufacturing an improved brake block for use with at least one of railway brake shoes and disc brake pads, said method comprising the steps of: 
 (a) selecting a composition friction material;    (b) molding said composition friction material selected in step (a), at a predetermined temperature and a predetermined pressure, to form a predetermined shape for use as at least one of a brake shoe and a brake pad;    (c) selecting a polymeric material from a group consisting of unsaturated polyester, polyphenylene sulfide, glass epoxy, phenolic polymers and various combinations thereof;    (d) forming a backing plate from said polymeric material selected in step (c) to a predetermined configuration; and    (e) bonding said composition friction material molded to said predetermined shape in step (b) to said backing plate formed in step (d).    
     
     
         18 . A method of manufacturing an improved brake block, according to  claim 17 , wherein said method further includes a step of forming said backing plate in situ during molding of said friction type composition material.  
     
     
         19 . A method of manufacturing an improved brake block, according to  claim 17 , wherein said preselected polymeric material contains glass fiber reinforcing.  
     
     
         20 . A method of manufacturing an improved brake block, according to  claim 17 , wherein said polymeric material contains mineral fillers.  
     
     
         21 . A method of manufacturing an improved brake block, according to  claim 17 , wherein said polymeric material is an unsaturated polyester.  
     
     
         22 . A method of manufacturing an improved brake block, according to  claim 21 , wherein said unsaturated polyester contains styrene.