Brake Pads Manufacturer

Brake pads are key braking components in modern cars. They help to decelerate or stop the wheels, which makes them crucial to safe driving. If you are a car owner, enthusiast, or auto parts seller looking to know more about these components, read on. This brake pad guide has what you are looking for.

What are brake pads?

To answer that question, we need to first look at how brakes work in a motor vehicle. The braking system in a car or truck is usually a mechanism that pushes a frictional material toward a surface.

Two methods are commonly used; drum brakes and disc brakes. In drum brakes, a hydraulic system thrusts a brake shoe toward the inner surfaces of drums.

Disc brakes involve pads squeezing a circular component called brake rotor or disc. With that information, we can now define brake pads.

Brake Pad Definition

Brake pads in car braking systems are components that make contact with brake rotors to stop the wheels or reduce their speed. Usually a rectangular shape, the pads stride a rotor on either side. Some people also call them brake disc pads.

A typical brake pad comprises a piece of friction material mounted on a metal backing plate for structural support. Behind the backing plate, a piece of insulating material is usually installed to reduce vibrations.

You can actually see the pads in most vehicles without even removing the wheels. They are the pieces held in the brake calipers, as can be seen in this brake rotor and brake pad diagram.

Most cars have two brake pads at each wheel. A few of them have more than two. These are mostly heavy duty or performance vehicles that need large stopping forces. It’s also common for brake pads to be in the front axle only, and drum brakes the rear.

Brake pads come in different types, each having unique braking characteristics. When selecting the kind to use in your vehicle, these properties play an important role, as you will find out shortly. Before that, let’s see how brake pads stop a vehicle.

Brake Pad Function

Brake pads provide the frictional force to decelerate or stop a vehicle. They work by converting the kinetic energy of the moving car or truck into thermal energy, thereby reducing its speed. The thermal energy dissipates into the air as heat, and brake pads are designed to ensure the process happens efficiently.

To produce the stopping power, brake pads are equipped with a surface called brake pad liner or lining. The lining consists of a special type of frictional material that can withstand the harsh conditions caused by brake pads rubbing against surfaces of the brake rotor. The working of brake pads follows a simple procedure, as explained below:

When you step on the brake pedal, the pressure exerted by your foot transmits in a brake fluid through the master cylinder, brake hoses, brake lines, and to the pistons at the brake calipers of each wheel. The system multiplies the foot pressure to about 30 times.

The pressure applied to the pistons forces them to move forward. Because brake pads are mounted on these pistons, they also move. The distance between the pads and the brake disc is only a few millimeters, and small movements cause them to press firmly against the rotating rotor.

The rotor is made of a harder material than the pad. This causes some of the pad’s friction material to rub off, forming a thin layer on the two surfaces. The layer leads to the pad and rotor sticking together. The resulting friction opposes the rotor’s motion, causing the vehicle to decelerate or come to a stop.

Brake Pad Efficiency

Brake pads and rotors work together to generate the braking friction. However, the friction when the pads squeeze brake disc must not cause the wheels to lock. Instead, it should result in a gradual but firm deceleration. A lot of research, therefore, goes into formulating the materials to use for the friction block.

For proper operation and driving safety, brake pad materials must satisfy these requirements:

• Provide a friction coefficient that’s high enough to stop a vehicle but low enough to prevent the wheels from locking
• Resist brake fade even when operating in high-temperature levels
• Maintain effectiveness or recover quickly enough in moisture or water conditions
• Be hard enough to resist wear and extend the brake pad useful life, but soft enough not to wear the rotor too quickly
• Operate sufficiently quiet and prevent annoying brake pad sound but without sacrificing stopping power
• Produce low brake pad dust
• Offer uniform wear during the entire brake pad’s lifetime
• Be lightweight enough for the application and required fuel economy

To ensure safe braking, researchers have, over the years, come up with different brake pads material formulations. The pads used in today’s car normally has between 20 and 20 different components, with each serving a specific purpose.

Although their exact proportions vary across manufacturers and brake pad types, the materials usually include the following.

Abrasives- metal oxides, metallic chips, quartz, and others to provide the frictional properties

Binding materials- fiberglass, resin, carbon fiber, and several others to hold everything together.

Structural materials- ceramic, mineral fibers, and other materials

Fillers– examples include scrap rubber, sea coal powder, steel wool, and more.

These determine the brake pad lifespan, performance, and other properties. We will have these materials for brake pads explained later. First, let’s see about a brake pad’s structure.

Brake Pad Parts

Car brake pads are designed more or less the same way, save for a few differences. Generally, they usually look identical. Their structure, as already mentioned, consists of a friction lining, backing plate, shim, and a few other components. The brake pad diagram above illustrates the main parts, which include:

Friction Block- this is the main section of brake pads; and the most important. It consists of materials that produce friction when the pad makes contact with the brake rotor.

Underlayer- this is part underneath the friction block that adds to the block’s thickness. Although made of fictional materials, the underlayer does not normally come into contact with the rotor. The underlayer often contains the brake pad wear indicator.

Adhesive Layer– the brake pad adhesive layer contains the materials that bind the pad to the base plate. Different manufactures use different adhesives for this layer to provide a permanent attachment. Some brake pads do not have this part and instead attach to the backing plate mechanically.

Base Plate- Usually made from steel, the plate secures the brake pad’s friction block, helping to guide it when braking. The plate also dissipates heat.

Shim- many brake pads have a shim attached to the back surface of the backing plate. Often made from metal or a combination of rubber and metal, a brake pad shim helps to dampen vibrations and reduce brake pad rattle.

Slots- most brake pads come with a slot cut on the friction block. The slot allows gases and debris to escape. It also helps to prevent brake pad vibration noise. The number of slots can one or several, depending on the specific brand and design.

Chamfers- brake pads come with chamfers (the beveled ends) for several reasons. These include to guide the pad to the rotor, help with brake pad break in, and reduce vibrations.

Abutment tab- also known as abutment ear, this part protrudes on either side of the pad assembly. It provides a means to attach the brake pad to the caliper bracket, securing it to prevent lateral movements when braking.

Other Parts- a brake pad kit contains installation accessories. These include fasteners and other components. Brake pad pins and clips help to secure the pad firmly, reduce vibrations, and conduct heat away.

Brake Pad Design Differences

Most of the pads used in motor vehicle brakes may look similar. However, that changes when you examine them closely. The main brake pad differences include:

Underlayer Attachment- many manufacturers attach the friction block by means of adhesive. Others are mechanically installed using high pressures or molded into the base plate under high temperature and pressure.

Wear Sensor- some pads come with wear groove on the friction block. When the groove disappears, the brake pad is worn out. Others feature a piece on metal inserted in the pad’s friction block.

A worn brake pad exposes the metal, producing noise and alerting you on the need for replacement. The brake pad sensor can also be an attached metal strip that scrapes the rotor when the pad wears down. The resulting noise acts a warning of excessive wear.

Another way to help detect brake pad wear involves the use of a metal tab to close a circuit. Embedded in the friction material, the metal causes a brake pad warning light on the dashboard to come up.

Thickness- brake pad thickness varies across brands and models, with the standard depth being around 10mm-12mm. Different manufacturers also have different values for the brake pad minimum thickness before replacement. Usually, you should not allow the friction material to wear below 3mm.

Finish- some brake pads have their base plates painted to protect them from corrosion. Others are galvanised or plated for the same reason. When plated, a brake pad requires no paint except for visual appeal.

Types of Brake Pads

Manufacturers usually classify brake pad types according to the material used to make them. In that regard, the following are the different brake pads in today’s auto parts market.

Organic Brake Pads

These pads are also called NAO. They are organic for being asbestos free as well as metal free. To make them, manufacturers use plant fiber, glass, rubber, and resin as the binding material. Kevlar is also added, especially if the application requires some bit of performance.

NAO brake pads offer the benefits of quiet, soft braking. But then, their softness causes them to wear too quickly, making them among the most short-lived. They are also quite dusty, producing black dust that settles on wheel rims and other components. Organic brake pads are the cheapest in the market. They mostly fit compact cars that are used in street driving.

Ceramic Brake Pads

Ceramic brake pads are made by combining stacks of ceramic fibers, metal fibers, fillers, and binding materials to make a friction material. These pads offer many advantages, including quiet operation, consistent performance, and low wear rate. They are also less dusty, plus their dust does not show or remain on rims.

Because of their moderate hardness, ceramic pads do not wear the rotor aggressively, allowing a longer lifespan for both components. One of the downsides of ceramic pads is their cost. They are the most expensive of all types, mostly due to their superior characteristics. You will, therefore, mostly find them installed in high-end cars.

Semi-Metallic Brake Pads

These are among the most used types of brake pads. They are built from a combination of metal fibers (copper, iron, and other metals), graphite, glues, and lubricants. Semi-metallic pads usually contain between 30% to 65% metal material, which makes them longlasting. They also offer excellent heat transfer and excellent braking force.

The disadvantages of semi-metallic pads include their excessive hardness, which takes a toll on the brake rotor, causing it to wear rapidly. They also not work efficiency in low temperatures, plus they are dusty, producing a characteristic brown dust.

Low Metallic Brake Pads

As the name implies, low metallic pads contain low amounts of copper and steel. They offer moderate hardness and fair stopping power in a range of conditions. Because the pads contain metallic materials, they also dissipate heat quickly enough.

Despite the good sides, low metallic pads have their disadvantages. They produce a considerable amount of brake dust, which makes the rims look unsightly. They are also among brake pads that produce noise during braking. The performance of low-metallic brake pads can be said to be between that of ceramic and semi metallic types.

Sintered Brake Pads

Sintered brake pads are also called metallic brake pads. To make them, manufacturers use extreme heat and pressure to cause metal particles to fuse together. This produces a hard frictions block that performs excellently in a wide array of conditions.

Sintered brake pads maintain friction and stopping power even when red hot, which is one of their greatest attributes. They are also not affected by water or moisture. Their disadvantage is that they wear the brake rotor too quickly. They are usually suitable for racing cars whose brakes generate a lot of heat. You will also find them commonly utilized in motorcycles and ATVs.

Brake Pad Material Comparison

How do the different types of brake pads compare? Here, we take a look at the advantages of one type over another.

Ceramic Vs. Organic Brake Pads

Ceramic brake pads are costly components, wat costly than any other type. However, they perform excellently when compared to organic pads. Ceramics are long lasting, produce less dust, and operate consistently over a wide range of conditions.

Organic brake pads are the most affordable of all. But then, they are also the least effective. Compared to the ceramic types, they are less durable, produce a lot of brake dust, and do not offer large stopping forces. Despite that, they are the most used pads in factory cars, mainly due to their low cost.

Ceramic Vs Semi Metallic/Low Metallic

As we have seen, ceramic brake pads provide a good enough stopping force, last a long time and operate quietly. However, these characteristics do not surpass those of pads that contain metal materials. Metal makes brake pads hard and increases the friction coefficient, making their grip on the rotor better.

Semi-metallic and low-metallic pads offer better stopping power than ceramic pads. However, they are too aggressive on the rotor, causing it to wear quickly. They also produce more dust than ceramic pads and are noisier.

Brake Pad Wear Patterns

Brake pads are meant to wear uniformly. However, that does not always happen. Improper brake pad installation, wrong friction material for the application, and bad brake components all cause wear problems.

Driving with brake materials that are irregularly or completely worn can be a safety risk. You may not stop on time or at all. Below is a brake pad wear chart showing different wear patterns and their meaning.

Braked Pads Vs. Brake Shoes

Brake pads and shoes are both parts that help to stop a vehicle. And while friction characterizes their working, there are several differences between the two. Brake pads are used in disc brake systems, brake shoes in drum brakes. The main differences between the two components are in their:

Location- brake pads are positioned in the brake calipers and moved by pistons, while brake shoes and located in brake drums.

Performance– brake discs cool faster than brake shoes, making them perform better in terms of grip and consistency.

Application- brake shoes are mostly used in the rear wheels where less braking power is needed. Front wheels are usually equipped with brake pads that can stand up to the aggressive braking involved.

Lifespan- brake pads last longer than brake shoes, due to their operating conditions that allow for heat to dissipate and water, gases, dust, debris, and other contaminants to escape. In reality, though, brake shoes appear to be more durable because of their position in the rear where there is little wear.

Brake Pad FAQs

Do you still have questions about the brake pads used in today’s motor vehicles? We answered the most common.

Q1. What is brake pad bedding in?

A. It refers to the conditioning of new brake pads to establish or initiate their optimal performance. During the process, a uniform layer of friction material gets deposited on the pads and brake.

Q2. What is brake pad glazing

A. When you have brake pads glazed, it means the friction material has overheated and crystallized on both the rotor and pad surfaces. The problem usually occurs when you allow higher braking temperatures than those specified by the manufacturer. Improper bedding in can also cause it. Signs include reduced braking power, judder when you press the brake pedal, and cracked friction blocks.

Q3. What causes brake pads to fail?

A. Many things can cause brake pad failure such as contamination on the pad surface (oil, dirt, and debris), excessive heat, and worn or damaged brake rotor. Some of the symptoms to look for are unusual brake pad noise like grinding, screeching, the car pulling to one side when braking, and judder or vibrations.

Q4. How long do brake pads last?

A. It depends on the brake pads quality, type, and your unique driving habits. Assuming moderate conditions, expect 30 000 to 70 000 miles. To extend the lifespan of these components, it’s necessary to observe these tips; avoiding high speeds, keeping your foot off the brakes, avoiding unnecessary loads, and observing distance with the vehicle in front.

Q5. How often should brake pads replacement be done?

A. You should carry out brake pads change before the friction material wears completely. We recommend regular inspections as opposed to only relying on brake pad wear sensor warnings, which often come when the friction material is almost ineffective

Q6. What is the brake pad cost?

A. Brake pad price varies depending on the brand, material type, quality, and other factors. Ceramic brake pads are the most expensive, organic types the cheapest. Some brake pad brands, especially from established companies, cost more than those that are just emerging. Prices vary between $30 and $100 or slightly more for the most costly.

Q7. What is the brake pad replacement replacement cost?

A. Brake pad change cost revolves around $150 for pads on both wheels on the same axle. Some car owners choose to change the parts themselves, only incurring the cost to buy them. However, it’s usually more advisable to opt for professional brake pad services when it comes to replacement.

Q8. Can one use racing brake pads in the regular car?

A. You could, but the performance would be dismal. Racing brake pads are designed to be effective at certain temperature levels. You cannot achieve these heat ranges with street driving. Furthermore, the pads are made from very hard materials and would consume the brake rotors in your car within no time.

Q9. What is the best brake pad?

A. It boils down to individual factors such as best material for brake pads, best brand, and best design. Your preferences also matter, such as if you are looking for performance, durability, or minimal braking noise and brake pad dust.

While you can scour through the brake pads on sale to find the most appropriate for your specific needs, it’s ideally almost impossible to find one that fits all situations. A brake pad that offers exceptional bite wears the rotor pretty quickly, in addition to producing a lot of noise.

A soft one grips the rotor quietly, but with a less firm grip. It will also produce a lot of dust. As you can see, you can only get one or the other. To answer the questions, we recommend going for what works for you.

If you drive a compact car or sedan, go for organic pads. They are quiet and inexpensive, plus you do not need excessive friction to stop the wheels. If looking for brake pads to install in an SUV or truck, go for semi or low-metallic types. They offer excellent stopping power. The sintered types too. Sport cars can use either ceramic or semi-metallic pads.

Q10. Are OEM brake pads better than aftermarket options?

A. It depends. OEM brake pads offer moderate performance but can be the best bet in most situations. However, aftermarket brake pads provide more options. They allow you to choose low-performance alternatives for less demanding rides, average pads, or costly designs that perform better than OEM.

Conclusion

Brake pads are safety components, seeing that they are directly involved in stopping a vehicle. Finding the right types for your vehicle is, therefore, the first step in ensuring driving safety. With virtually every vehicle today using disc brakes, the components are also one of the most important to know about.