Patent Application
20130306415
The present invention relates to a disc for disc brake, and more particularly to a disc for disc brake, comprising a support (called a bell) and a braking band suitable to cooperate with disc brake calipers in order to exert a braking action on a vehicle. The braking band comprises a body extending around a symmetry axis and being laterally defined by braking surfaces. The body can be obtained by the interaction of a mixture comprising filament rovings essentially consisting of carbon, with silicon at a temperature which is sufficient to cause the melting of the silicon.
With the term “filaments essentially consisting of carbon” is meant to include fibrous materials obtained by means of pyrolysis of different products either of synthetic origin, for example, polyacrylonitrile (PAN) and polysiloxane, or of natural origin, for example pitch, cellulosic natural resources such as the vegetable fibers and wood.
The term “filament rovings” is meant to connote sets of filaments which range from 3000 to 50000 units and having a diameter ranging between 2 and 3 μm, associated to one another and impregnated with a resin, for example polyurethane. Then, the rovings are broken, such as to have a length which is lower than 30 mm, and finally they are randomly arranged within the mixture.
These randomly-arranged filament rovings are usually defined based on the number of the units forming the roving, for example with 3K, 10K, 50K, etc.
The use of these ceramic composite materials is known in various applications where a high resistance to impact, compression, and friction-generated temperature is required, and these characteristics may not be ensured by simple ceramic materials due to the inherent brittleness thereof. Particularly, ceramic composite materials for braking applications are known which are obtained by the interaction of silicon with a mixture comprising carbon filament rovings, optionally reinforcing fibers, and additives at a temperature in which the silicon is at the molten state.
In accordance with the prior art, the preparation of these composite materials may be carried out as follows: the filament rovings are mixed with a binding resin, pitch and other additives and the mixture is set in a mold where it is molded with the aid of heating and the application of a pressure, thus obtaining a shaped preform.
The preform is then subjected to a first baking at such a temperature as to cause either the carbonization or pyrolysis of the resin.
Due to this baking, the preform acquires a certain porosity because of the loss of volatile material at the temperatures of the carbonization or pyrolysis.
Then, the baked preform is subjected to a second baking in the presence of silicon at such a temperature as to cause the melting of the silicon and the infiltration thereof into the pores of the preform.
The silicon infiltration allows the cohesion of the carbon filament rovings to be increased whereas, at the same time, the melted silicon, in the conditions of the second baking, partly reacts with the carbon of the preform thus forming silicon carbides having the effect of improving the cohesion characteristics of the material.
The composite material prepared with the above-mentioned method is often used in the manufacturing of brakes and clutches components for vehicles, particularly for manufacturing braking bands for brakes, due to its good characteristics of resistance to compression, friction-generated temperature and wear.
Despite the above-mentioned good characteristics the known braking bands for disc brake in the composite material have the serious drawback that incidental cracks or breaks may be formed thereon. Following thermal and/or compressive stresses, the cracks quickly tend to spread all over the structure of this material thus causing the total disintegration of the same.
Therefore, it is understood that the use of the known braking bands for vehicle disc brakes involves considerable risks to user safety.
The problem addressed by the present invention is to provide a disc for disc brake, which has such structural and functional characteristics as to overcome the drawbacks mentioned with reference to the prior art.
This problem is solved by a disc for disc brakes as described below.
The present invention relates to a disc for disc brakes, comprising a support and a braking band suitable to cooperate with brake calipers in order to exert a braking action on a vehicle, the braking band comprising a shaped body extending around a symmetry axis and being laterally defined by braking surfaces, the band being made of composite material which can be obtained by the interaction of a mixture, comprising filament rovings, essentially consisting of carbon, randomly arranged and having sizes which are not larger than 30 mm, with silicon at a temperature which is sufficient to cause the melting of the silicon, characterized in that it comprises at least one strengthening ring in a carbon-carbon material located near or at the cracking point.
With cracking point is meant the inner circumference/edge of the braking band and, more particularly, is meant the part of braking band which is operatively connected to the support, after the disc has been assembled.
In the case of an axial-symmetrical structure such as a disc for disc brake, as a result of functional calculus the crack propagation paths have higher probability of being radially located to the body, thus spreading from the inside to the outside of the braking band until they cause the burst thereof. This is due to the fact that the point of the braking band suffering the higher thermal and mechanical stresses during the braking is the inner edge thereof and particularly the part of band which is operatively connected to the support, after the disc has been assembled. Therefore, in this point, the cracks are formed which radially spread over the band structure thus causing the disintegration of the latter.
Therefore, in a disc for disc brake the crack propagation is hindered by positioning the strengthening ring at or near the inner edge of the braking band, i.e. exactly where the cracks start and spread.
Advantageously, the at least one strengthening ring is either located near or at the inner edge of the braking band at the level of at least one braking surface or embedded within the ceramic material that forms the braking band. Preferably, the ring is located at the level of at least one braking surface and is operatively connected to the support, after the disc has been assembled.
Therefore, the present invention is based on having surprisingly found that by positioning at least one strengthening ring, made of carbon-carbon material characterized by a very high mechanical resistance and low brittleness, at the inner edge of the braking band of a disc for disc brake, without changing the band original composition, the problem is solved of preventing the cracks from being formed and spreading over the whole shape during the use of this disc.
In a further embodiment, the braking body also comprises reinforcing fibers, besides the “filaments essentially consisting of carbon”, which preferably consist of carbon, or other materials, such as SiC, Si3N4, TiC, or metal materials, such as platinum, suitable to resist the temperatures of the interaction with silicon. While the “filaments essentially consisting of carbon” are randomly arranged within the mixture providing the braking body, the reinforcing fibers are located such as to extend along the shape of the body, preferably they are radially arranged. In other words, the reinforcing fibers are incorporated into the material such as to take fixed and predetermined positions.
The incorporation may be carried out in different ways. For example, the reinforcing fibers may be ordered in a plurality of rovings which are arranged according to predetermined directions.
These directions may be, for example, filling and warp directions, the rovings providing a fabric.
Alternatively, the reinforcing fibers may provide a nonwoven, for example a felt.
It is important that the reinforcing fibers should have satisfactory cohesion characteristics with the other components of the composite material providing the braking band in order to avoid that the whole structure may disintegrate during the use even in the absence of cracks or breaks.
Moreover, the reinforcing fibers have to be substantially inert relative to the components of the composite material and to have a sufficient resistance to the pyrolysis and silicon infiltration temperatures in order to avoid that they may be degraded during the preparation of the material forming the disc.
For an example of disc for disc brakes comprising the reinforcing fibers see EP 1 124 071 of the same Applicant.
Further characteristics and the advantages of the disc for disc brake according to the invention will be understood from the description of preferred embodiments thereof as set forth herein below, which are given by way of indicative and non-limiting example, with reference to the annexed figures, in which:
With reference to
Advantageously, the strengthening ring comprises 5 ring sectors that are connected to one another according to the joint modes described above.
Alternatively, the strengthening ring is provided as one piece without a gap.
The braking band 5 has a body 6 being laterally defined by two braking surfaces 3 and 4 suitable to cooperate with disc brake calipers in order to exert a braking action on a vehicle. The surfaces 3 and 4 are parallel to each other and define a body thickness therebetween, which has been indicated with P in
The braking surfaces 3 and 4 have holes 7 allowing the air passing therethrough and hence disc cooling during the braking.
With reference to
Each tooth 8 has at least one through hole 10. The teeth 8 and through holes 10 are uniformly arranged near the inner edge of the braking band 5 with the same angular pitch of the radial recesses 14 being present on the support 15 in order to be aligned with these recesses and hence to house coupling means 16 for anchoring the braking band 5 to the support 15 (
With reference to
The ring 2b comprises one or more through holes 10 which are used for housing the coupling means 16 required for anchoring the band 5 to the support 15 as explained above.
With reference to
The support 15 is coupled with the braking band so that the peripheral ring 18 is operatively connected to the strengthening ring 2b and the recesses 14 are aligned with the through holes 10, after the disc has been assembled, thus allowing the introduction of the coupling means 16.
Particularly, after the disc has been assembled, the strengthening ring 2b is operatively connected to the peripheral ring 18 of the support 15. In other words, the strengthening ring 2b has thickness R which is greater than the thickness T of the peripheral ring 18 of the support 15.
The connection area between two teeth is the part of braking band suffering the higher thermal and mechanical stresses during the braking and, for this reason, it is the portion in which the cracks have higher probability of being formed and spreading. The positioning of at least one strengthening ring in this area either avoids or considerably reduces the cracking and propagation thereof.
Such as illustrated in
Alternatively, the air ducts may be obtained by means of processing to be carried out either after the molding of the preform or after the pyrolysis.
However, the strengthening ring of the invention may also be used in the braking bands which are not provided with air ducts, i.e. in the non-ventilated braking bands.
The strengthening ring according to the invention is in carbon-carbon material. For the objects of the invention, with “carbon-carbon material” is meant a material comprising graphitic carbon fibers immersed in an amorphous carbon matrix.
The graphitic carbon fibers are obtained from a precursor material which is, preferably, polyacrylonitrile.
The solution of polyacrylonitrile is transferred to the die such as to obtain filaments which are subjected to protracted heating at 220° C. in an oxidizing atmosphere. Consequently, the fibers are carbonized at 1000-1500° C. in an inert atmosphere and hence graphitized at 2000-3000° C. During these processes the fibers are tensioned such as to orientate the graphitic crystals and increase the resistance.
Preferably, the thus-obtained fibers are joined in rovings of either parallel or twisted fibers. A certain amount of filaments may also be twisted as a strand and, therefore, the strands may be woven together to provide a bi-dimensional fabric.
The thus-formed bi-dimensional fabric is impregnated with a binding resin, preferably a polymeric phenolic resin. Therefore, a stack of alternated layers of fabric with impregnation resin is formed, which is subjected to inert-atmosphere heating. The heating causes the polymerization of the resin which consequently acts as a bonding agent among the layers. The pyrolysis of the stack of bonded layers and, subsequently, a second impregnation with liquid resin and a polymerization autoclave treatment are then carried out. Finally, the preform is subjected to a final pyrolysis treatment. Optionally, the impregnation step of the stack of bonded layers, the autoclave treatment and pyrolysis can be repeated either once or several times.
At the end of this process the carbon-carbon material is obtained, being advantageously of a tri-dimensional-sheet shape. This material has a good mechanical resistance and good specific elastic modulus which is maintained unchanged up to about 2300° C. Furthermore, it does not have a melting point because it sublimes at about 3300° C.
The carbon-carbon material and the manufacturing process thereof are known in the art. To the purpose of the present invention any carbon-carbon material available on the market may be used. For example, the carbon-carbon material available from Schunk is used.
The panel of carbon-carbon material is then cut in the shape which is adapted to be subsequently used in the braking band for disc brakes of the invention, as discussed above.
The present invention also relates to a method for manufacturing a disc for disc brakes, comprising the steps of:
a) Inserting a strengthening ring into the empty mold for the disc;
b) Inserting a part of the mixture obtained by blending a predetermined amount of filament rovings essentially consisting of carbon and having a length which is not higher than 30 mm into the mold, with a predetermined amount of an organic binder;
c) Inserting means for obtaining the air ducts into the mold, when the product is finished;
d) Inserting the second part of the mixture obtained by blending a predetermined amount of filament rovings essentially consisting of carbon and having a length which is not higher than 30 mm into the mold, with a predetermined amount of an organic binder;
e) Forming a preform by means of molding;
f) Subjecting the preform to a first baking at such a temperature as to substantially cause either the carbonization or pyrolysis of the organic binder;
g) Subjecting the baked preform to a second baking in the presence of silicon at such a temperature as to substantially cause the melting of the silicon and the infiltration of the latter into the preform.
When the strengthening ring is desired to be embedded within the material forming the braking band, the following process will be carried out: the mixture of point b) is inserted into the mold, then the strengthening ring and finally the mixture of point d). Therefore, the subsequent molding and baking steps will be carried out according to points e)-g). In other words, the step c) will not be carried out in this case and hence the finished band will not be provided with air ducts.
In the step c), the means for obtaining the air ducts, when the product is finished, are known. An example of the means is described in the application PCT/IT01/00412 of the same Applicant.
During the pyrolysis and silicon infiltration steps, such as described in points f) and g) the strengthening ring, since it is of very compact material due to the repeated resin and pyrolysis infiltration treatments which tend to fill all the cavities, does not suffer substantial changes. Particularly, a least silicon infiltration occurs into the ring, but which does not entail substantial changes in the composition of the carbon-carbon material. On the contrary, the melted silicon reacts with the carbon contained in the mixture of filaments essentially consisting of carbon and binder, thereby providing SiC.
Therefore, the finished band comprises a braking band made of C/SiC material and a strengthening ring made of carbon-carbon material. Advantageously, the strengthening ring is placed in the mold, at point a) of the process, so that it is at or near the band inner edge or circumference, when the band is finished.
In a preferred embodiment of the invention, before the preform molding step e), a second strengthening ring is inserted.
In a further preferred embodiment, a plurality of reinforcing fibers is incorporated into the mixture comprising filaments essentially consisting of carbon and binders.
The incorporation of the reinforcing fibers into the mixture may be carried out in different ways.
According to a preferred embodiment, the reinforcing fibers are incorporated after step b), then the means for obtaining the air ducts and hence the second part of the mixture (step d)) are inserted. Thereby, the plurality of reinforcing fibers is completely covered before the subsequent steps e)-g).
The reinforcing fibers can be added to the mixture in the form of a plurality of rovings which are arranged according to predetermined directions.
These predetermined directions can be filling and warp directions, the rovings providing a fabric.
The fabric may comprise 2 to 30 fibers per cm, preferably 5-8 fibers/cm.
Alternatively, the reinforcing fibers may form a nonwoven fabric, for example a felt.
The number of reinforcing fibers incorporated into the mixture is a function of the desired fiber content in the final composite material, the content ranging between 4-30% by volume on the volume of the material, preferably 10-20%.
In the method according to the invention, the filament rovings may have a diameter 0.1 to 2 mm, preferably 0.3 to 0.5 mm.
The filament rovings content in the mixture may vary from 50% to 80% by volume on the volume of the mixture and preferably ranges between 60%-70%.
Advantageously, the filament rovings and/or the reinforcing fibers can be previously covered with a protective resin, preferably polyurethane, before they are employed in accordance with the method of the invention.
Alternatively, the filament rovings and the reinforcing fibers can be previously covered with the same organic binder used for preparing the mixture.
Thereby, a higher cohesion of the material and a more compact product are obtained.
During the first baking of the preform, the resin and the organic binder carbonize, thus creating a protective layer on the filament rovings and the reinforcing fibers, and thus preventing a possible disintegration or even a dissolution thereof in the subsequent silicon treatment.
Thereby, the filament rovings and the reinforcing fibers maintain the original shape throughout the process, thus obtaining a material with good cohesion and resistance characteristics.
The organic binder is a traditional binder which may be selected from the group comprising phenolic and acrylic resins, paraffin, pitch, polystyrenes etc.
Preferably, the binder is selected from the group comprising pitch and phenolic resins.
The binder can be added to the mixture in any desired form for example at the solid, semi-liquid, liquid or solution state.
For example, the phenolic resin may be added in the form of pellets, powder or grains.
The organic binder content in the mixture may vary from 5% to 30% by volume on the volume of the mixture and preferably ranges between 20%-26% by volume.
The mixture can also contain other traditional additives used as fillers and, indirectly, in order to adjust the porosity and density of the desired composite material.
These additives consist of inorganic material particles such as preferably powdered graphite, silicon carbide, metal carbides and nitrides.
The additive content in the mixture may vary from 0.7% to 23% by volume on the volume of the mixture and preferably ranges between 9%-15%.
The mixing can be traditionally carried out and with traditional equipment and the filament rovings will be accidentally arranged in the different directions.
In the molding step of the inventive method, the mixture optionally comprising the reinforcing fibers, is heated in the mold at a temperature from 80° C. to 180° C., preferably 100-120° C. and a pressure ranging between 0.1 N/cm2 and 5 N/cm2, preferably 0.5-1 N/cm2 is applied thereon.
The thus-obtained shaped and compact preform is extracted from the mold, following the removal of the means for providing the air ducts, and hence is subjected to a first baking such as to carbonize the organic binder (step f, pyrolysis).
This baking is carried out in a traditional furnace at a temperature substantially dependent on the type of binder used and generally ranging between 900-1200° C.
The baking is carried out in the presence of an inert gas flow such as nitrogen or argon and in an overpressure of 10-100 mbar, preferably 20-30 mbar.
The inert gas flow also advantageously allows the gases which are released from the pyrolysis of the organic binder to be removed.
During this step of the process, the preform acquires a higher porosity which is important in the subsequent baking because it allows the melted silicon to infiltrate thereinto. On the other hand, as explained above, the strengthening ring does not suffer any substantial change either during the pyrolysis step f), or during the subsequent silicon infiltration step, because the carbon-carbon material by which it is formed is a very compact and highly resistant material at very high temperatures.
According to an embodiment of the invention, the method may further comprise a finishing step of the surface of the preform from the first baking of step f.
This advantageously allows possible surface deformations of the preform to be removed by traditional equipment such as to produce the desired shape of the latter.
The finishing operation is preferably carried out by dry process, for example with diamond, because the preform, which has acquired a certain porosity after the baking, could disadvantageously absorb liquid substances if the finishing is carried out by wet process.
The pyrolized preform in accordance with step f) is subjected to a second baking in the presence of silicon (step g).
In order to carry out the second baking, the preform, baked and optionally subjected to finishing, is inserted into the chamber of a container the volume of which is about double relative to the volume of the preform, thus filling the gap being formed between the preform and the container with silicon that envelopes the preform. Therefore, the amount of silicon used is the required one, or little larger, for filling the preform porosity.
In order to fill the gap, pure silicon is used, or an aluminum-silicon or copper alloy, either in grains or powder.
The chamber may be in communication with the outside by means of suitable holes allowing the gases released during the baking to leak out.
After the silicon has been loaded, the container is inserted into a suitable furnace, which is traditional per se, heated at a temperature of 1400-1700° C.
At such temperatures, the silicon melts and infiltrates into the pores of the preform (Silication). The silicon only partially infiltrates into the strengthening ring.
This baking is carried out by the vacuum method by reducing the pressure from 900 mbar to 300 mbar, preferably from 800 to 500 mbar.
At the end of the baking the material is cooled for example with argon or, preferably, with nitrogen, such that the residual silicon solidifies in small balls to be easily recovered by the container.
Optionally, the thus-obtained braking band according to the invention may be subjected to finishing operations, for example surface finishing, which can be traditionally carried out either by dry or wet process.
It is understood that the baking steps, i.e. pyrolysis and silication, could be carried out in a single furnace, thus allowing to reduce the time and complexity of the manufacturing equipment.
The finishing operations, in accordance with an embodiment, may be provided following any of the above-mentioned treatments.
In accordance with a further embodiment, the method for manufacturing a disc for brakes comprises, before step a), the following steps:
a1) providing a sheet of carbon-carbon material manufactured as described above;
a2) cutting two or more circle-arc-shaped sectors 1 as described above,
a3) joining the two or more sectors of point a2) such as to obtain the strengthening ring.
In step a3), the junction between the sectors 1 is carried out with a joint mode as described above in detail. Preferably, five sectors 1 are cut and hence joined together.
Alternatively, in step a2) a single ring-shaped piece is cut without gap, which is directly inserted into the mold. In this case, step a3) is not carried out.
The disc according to the invention is provided with a braking band which is distinguished for the excellent characteristics of friction, hardness and resistance to bending, wear, friction-generated temperature, impact and compression and at least one strengthening ring, which is located at the point from which the cracks start, in carbon-carbon material characterized by high hardness and stress resistance. The position of the strengthening ring and the inherent characteristics of the carbon-carbon material minimize the formation of cracks and particularly the propagation thereof in the disc.
This causes a high use safety of the disc of the invention, because possible cracks or breaks which may occur thereon during the use do not involve the total structure disintegration because the propagation thereof is avoided by the provision of the strengthening ring.
A further advantage of the composite material according to the invention is also that it can be carried out in a simple and cost-effective manner, such that considerable extra charges and very expensive equipment are not required.
In fact, it shall be noted that the disc according to the invention can be manufactured with the aid of the traditional technologies applied to the manufacturing of the corresponding known discs.
The characteristics and the advantages of the present invention will be better understood from the following description of an exemplary preparation of a shaped composite material according to the invention, the description being given by way of indicative and non limiting example.
A mixture containing, by volume percentage on the volume of the mixture, 65% of carbon filament rovings having a diameter 0.3 mm to 0.5 mm and a length 5 mm to 10 mm, 23% of dry phenolic resin and 12% of silicon carbide powder is traditionally prepared in a mixer, known as the Erigh mixer.
The mixing causes a random distribution of the filament rovings.
From a panel of carbon-carbon material of the firm Schunk 5 circle-arc shapes having a protuberance and a recess at the opposite ends, respectively, are cut, the latter being of a shape which is complementary to the protuberance and adapted to house the latter. The 5 circle arcs are joint connected to one another such as to provide the strengthening ring, having 241×217 mm in size.
The strengthening ring is inserted into an annular mold of 150 mm in inner diameter, 380 mm in outer diameter and 210 mm in height, centered relative to the axis, and located so that it is near the inner edge of the braking band and, particularly, at 1 mm distance from the inner edge, when the band is finished.
A portion of the mixture is then placed in the mold cavity.
About 30 pins are inserted into the mold, in a radial position, spaced from one another by 40 mm.
Therefore, a second portion of mixture is added up to fill the mold and, finally, a second strengthening ring, obtained as the first ring from the junction of 5 circle arcs, but having 241×176 mm in size.
The second ring is positioned centered relative to the axis and such that the inner edge thereof coincides and form the band inner edge.
Then, the shaping is carried out by heating the mold at a temperature of 120° C. and applying a pressure equal to 1 N/cm2, thus obtaining a ring-shaped blank body.
The blank band, after it has been extracted from the mold and after the pins have been removed, is subjected to baking in a furnace heated at a temperature of 1100° C. for a stopping time of 12 hours.
The baking is carried out at a pressure of 30 mbar and in an inert atmosphere due to the presence of argon, conveyed into the furnace with a flow of 30 liters/minute.
After baking, the band is traditionally subjected to a diamond finishing by dry process in order to remove surface deformations.
At this point, the blank band is placed in a container provided with holes in order to allow the gas leakage.
The container is loaded with grain silicon in the amount required for filling the hollow space formed between the band and the container.
The container is then transferred to a furnace which is heated at the temperature of 1500° C. and is caused to stop in this furnace for an 8-hour time.
The baking is carried out at a reduced pressure of 700 mbar to which a cooling in the furnace with a continuous nitrogen blowing is followed.
Therefore, a band which is traditionally subjected to diamond finishing after cooling such as to remove the surface deformations and to obtain the final shape, with the desired accuracy and tolerance is obtained.
The composite material composition of the disc braking band by volume percentage on the volume of the material is the following: 55% filament rovings, 10% additives, 15% reinforcing fibers and 20% of products deriving from the binder carbonization.
The disc comprising the thus-obtained braking band has been tested as a component of a disc brake for vehicles and exhibited excellent hardness, impact-resistance, wear, compression, friction-generated temperature characteristics during the braking
Particularly, the disc has not exhibited the presence of cracks.
To the preferred embodiment solution to the ceramic composite material described above, those skilled in the art, aiming at satisfying contingent and specific needs, will be able to carry out several modifications, adjustments and replacements of elements with others being functionally equivalent thereto, without departing from the scope of the claims below.
| Number | Date | Country | Kind |
|---|---|---|---|
| 05425912.2 | Dec 2005 | EP | regional |
This application is a continuation of copending application Ser. No. 11/610,306, filed Dec. 13, 2006. Priority is claimed under 35 USC 119 from European Patent application 05425912.2, filed Dec. 23, 2005.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11610306 | Dec 2006 | US |
| Child | 13766064 | US |
