COMPARISON
The manufacturing of Brake Pads involves forming the friction material into a solid and durable unit that adheres securely to a backing plate. Two primary methods are used: Hot Press and Cold Press, each with its advantages and disadvantages:
- Press Forming (Hot Press Method)
A mixture of friction materials is compressed at 1000 bar in a mold onto the metal backing plate. The molded pads are heated in a specialized oven at 150°C. This curing process binds the materials together into a single, solid unit. The high pressure and heat reduce the amount of resin required in the mixture, resulting in a denser and more robust brake pad. The final product exhibits greater thermal stability and resistance to glazing, creating better quality. The higher pressure and curing time make the hot press method more labor- and energy-intensive.
- Press Curing (Cold Press Method)
A mixture is pressed at a 400 bar in a mold onto the backing plate. Molds including pads are heated up to 150 C. Although this is a quick production process, more resin is needed. This results in a lower quality pad and a higher risk of glazing. That’s why ABS Brake Pads are made according to the hot press method, called Press Forming. Where applicable, they comply with European ECE-R90 regulations for friction materials.
SPECIAL TREATMENTS
To ensure the best performance, ABS Brake Pads go through additional treatments. Each step is designed to enhance specific aspects of the pad’s functionality:
- Scorching
During the scorching process, the top layer of resin on the brake pad’s surface is burned off. It accelerates the bedding-in process, allowing the pads to work effectively in less time. It also reduces the likelihood of brake fading during high-temperature operation, ensuring consistent performance. Scorching also helps the pads achieve better initial friction, improving safety.
- Chamfering
Chamfering involves cutting the edges of the pad’s friction surface at an angle, leading to quicker run-in, meaning that the pads make smoother initial contact with the brake disc. It also reduces noise as it minimizes vibration and reduces noise during braking, especially in high-stress scenarios.
- Milling Grooves
Grooves are milled into the friction surface of the pads to improve heat distribution during braking, which helps maintain consistent performance and extends the lifespan of the pads. It also reduces tension in the friction material, preventing cracks or damage under heavy use.
- Mounting Shims, Clips, and Indicators
Additional components like shims and clips are mounted onto the brake pads to reduce noise and vibration and provide wear indicators for the drivers.