Patent ID: 7234573

Claim:
A method of manufacturing a brake shoe ( 1 ) defined by a carrier plate ( 2 ) devoid of any openings formed therethrough and having arranged upon the entirety of a surface thereof a single intermediate layer ( 4 ) and a friction lining ( 6 ) upon the single intermediate layer ( 4 ), the single intermediate layer ( 4 ) being made of binding material which is soft as compared to material of the friction lining ( 6 ) and being highly dampening and noise-reducing, the single intermediate layer ( 4 ) including on a side surface facing the friction lining ( 6 ) a plurality of three-dimensional surface contours ( 5 ) projecting in a direction away from the carrier plate ( 2 ), the friction lining ( 6 ) on a side facing the carrier plate ( 2 ) having surface contours complementary to the surface contours ( 5 ) of the single intermediate layer ( 4 ), and the single intermediate layer surface contours ( 5 ) being bonded to the friction lining surface complementary contours absent a boundary member therebetween by performing the steps of: (a) placing a carrier plate ( 2 ) devoid of any openings formed therethrough into a first press mold, (b) pre-press molding intermediate layer material in the same first press mold to form a single pre-pressed intermediate layer ( 4 ) upon the entirety of a surface of the carrier plate ( 2 ) including the three-dimensional surface contours ( 5 ) thereof, (c) after the performance of step (b), introducing the friction lining material into the same first press mold upon the entire three-dimensional surface contours ( 5 ) of the single intermediate layer ( 4 ), and (d) in the same first press mold bonding the friction lining material to the single pre-pressed intermediate layer ( 4 ) along the three-dimensional surface contours ( 5 ) thereof by finish press molding the single pre-pressed intermediate layer ( 4 ) and the friction lining ( 6 ) in association with bonding the single pre-pressed intermediate layer ( 4 ) to an entire surface of the carrier plate ( 2 ) to complete the molding of the brake shoe ( 1 ) absent a boundary member between the surface contours and absent mechanical attachment between the single intermediate layer ( 4 ) and the carrier plate ( 2 ).