Heavy-duty vehicle brake assembly with sealing interface

Abstract

A heavy-duty vehicle brake assembly with a sealing interface includes a brake shoe, which includes a shoe table mounted on a web and a brake lining mounted on the shoe table. The shoe table is coated with a zinc-rich coating to form the sealing interface between the brake lining and the shoe table. The sealing interface resists the formation of corrosion cells on the brake shoe table, which in turn reduces the build-up of significant rust between the brake shoe table and the brake shoe lining, thereby preventing cracking and potential dislodging of the lining, while also facilitating replacement of linings when they eventually wear. A method of constructing a heavy-duty vehicle brake assembly with a sealing interface is also provided.

What is claimed is: 
     
         1 . A method of forming a heavy-duty vehicle brake assembly with a sealing interface, comprising the steps of:
 providing a brake shoe table;   applying a pre-treatment to said shoe table to optimize the adhesion of a coating to the shoe table;   applying a zinc-rich coating to said shoe table; and   mounting a brake lining on said shoe table, whereby said zinc-rich coating forms said sealing interface between said brake lining and the shoe table to resist the formation of corrosion cells on said brake shoe table.   
     
     
         2 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 1 , further comprising the step of cleaning said shoe table to remove dirt from a top surface of the shoe table. 
     
     
         3 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 1 , wherein said step of applying a pre-treatment to said shoe table includes applying a phosphate pre-coat onto the shoe table, in which said phosphate pre-coat includes at least one of iron phosphate, zinc phosphate, zirconium phosphate, and manganese phosphate. 
     
     
         4 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 1 , wherein said step of applying a pre-treatment to said shoe table includes at least one of silane coating, shot blasting, and cleaning. 
     
     
         5 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 1 , wherein said step of applying said zinc-rich coating to said shoe table includes spraying a powder coating onto the shoe table. 
     
     
         6 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 5 , wherein said step of applying said zinc-rich coating to said shoe table includes electrostatic spraying a powder coating onto the shoe table. 
     
     
         7 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 5 , wherein said step of applying said zinc-rich coating to said shoe table includes applying the zinc-rich coating to the shoe table in a thickness of about at least one point zero mils dry film thickness. 
     
     
         8 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 7 , wherein said step of applying said zinc-rich coating to said shoe table includes applying the zinc-rich coating to the shoe table in a thickness of from about one point five to about two point zero mils dry film thickness. 
     
     
         9 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 1 , wherein said step of applying said zinc-rich coating to said shoe table includes at least one of spraying a liquid or suspension coating onto the shoe table and dipping said shoe table into a bath of said liquid or suspension coating. 
     
     
         10 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 9 , wherein said step of applying said zinc-rich coating to said shoe table includes applying the zinc-rich coating to the shoe table in a thickness of about at least one point zero mils wet film thickness. 
     
     
         11 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 10 , wherein said step of applying said zinc-rich coating to said shoe table includes applying the zinc-rich coating to the shoe table in a thickness of from about two to about six mils wet film thickness. 
     
     
         12 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 11 , wherein said step of applying said zinc-rich coating to said shoe table includes applying the zinc-rich coating to the shoe table in a thickness of from about two point two to about five mils wet film thickness. 
     
     
         13 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 12 , wherein said step of applying said zinc-rich coating to said shoe table includes applying the zinc-rich coating to the shoe table in a thickness of from about two point four to about four point five mils wet film thickness. 
     
     
         14 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 1 , wherein said step of applying said zinc-rich coating to said shoe table includes a composition of zinc and at least one of micaceous iron oxide, cadmium, aluminum, stainless steel, tin, brass, and manganese. 
     
     
         15 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 14 , wherein said step of applying said zinc-rich coating to said shoe table includes applying a liquid or suspension coating to the shoe table in a thickness of from about six to about fourteen mils wet film thickness. 
     
     
         16 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 15 , wherein said step of applying said zinc-rich coating to said shoe table includes applying a liquid or suspension coating to the shoe table in a thickness of from about six point five to about thirteen point five mils wet film thickness. 
     
     
         17 . The method of forming a heavy-duty vehicle brake assembly with a sealing interface of  claim 16 , wherein said step of applying said zinc-rich coating to said shoe table includes applying a liquid or suspension coating to the shoe table in a thickness of from about seven to about thirteen mils wet film thickness.