This invention relates to a lining or a functional body or a friction lining for disk brakes, in particular for high-performance brakes for road and rail vehicles.
Friction linings for disk brakes according to the preamble of the claims 1 and 2 are known.
The aim of this invention is to create a lining or a functional body or a friction lining for disk brakes of the above mentioned type with which the strength properties of carrier plates, for example for brake linings, are economically improved and carrier plates are obtained, the mechanical/dynamical properties of which remain maintained even after the rough ground treatment. Furthermore, the rough ground is also to be inserted in case of sensitive carrier sheets without the strength properties of the friction lining carrier made of steel being modified after the rough ground treatment.
According to the invention, the lining or functional body according to the invention consists of a carrier in form of a ground plate, for example a carrier plate or a carrier sheet, of a thin-walled rough ground carrier made of a metal sheet or of another appropriate material placed on the carrier, of a rough ground made of a support base sintered on the surface of the rough ground carrier which is turned away from the lining carrier, this support base being made of single moulded bodies with undercuts, recesses or the like which are positively and frictionally connected with the rough ground carrier, and of a functional block fixed on the rough ground carrier with the rough ground, this functional block being made of a friction material, a synthetic material, in particular of such a synthetic material which is not appropriate to get glued or to be applied in another manner, for example of a polymer or a polytetrafluor ethylene, whereby the rough ground carrier is fixed on the lining carrier by means of a welded, riveted or glued joint or other connecting procedures, such as engraving.
A friction lining according to the invention consists of a friction lining carrier, of a thin-walled rough ground carrier placed on the friction lining carrier, of a rough ground made of a support base sintered on the surface which is turned away from the friction lining carrier, this support base being made of single moulded bodies with undercuts, recesses or the like which are positively and frictionally connected with the rough ground carrier, and of a friction lining block fixed on the rough ground carrier with the rough ground, whereby the rough ground carrier is fixed on the lining carrier by means of a welded, riveted or glued joint or other connecting procedures, such as engraving.
For this friction lining, the rough ground is not applied onto the actual friction lining carrier as for the known friction linings but on a separate rough ground carrier which is itself fixed with the friction lining carrier, i.e. the carrier plate or the carrier sheet. The rough ground carrier is preferably fixed on the friction lining carrier by means of a marginal welding running all around so that, on the one hand a fixed connection is obtained between the rough ground carrier and the friction lining carrier and on the other hand so that the penetration of moisture between the rough ground carrier and the friction lining carrier is avoided.
The procedure is so that a sheet is punched as a rough ground carrier according to the friction lining contour.
This sheet as a rough ground carrier is then provided with the rough ground and the coated rough ground carrier is then welded, riveted or glued onto the actual friction lining carrier or fixed by means of other appropriate connecting procedures. For the welding, the laser beam welding is convenient since with this method the contour all around can be tightly welded and any number of welding spots can be arranged and distributed on the surface. When punching, the rough ground carrier can be bulged or moulded in order to obtain a higher strength. Eventually constituted hollow spaces can be filled before welding with a damping material.
Besides a welding all around for the fixing of the rough ground carrier with the friction lining carrier, the fixing can also take place by spot welding, whereby the spot welding preferably takes place on rough ground free surfaces.
For saving weight, according to a further characteristic of the invention, the friction lining carrier is provided at least with a window-type cut, whereby it is also possible within this context to weld the rough ground carrier with the friction lining carrier in the edge area of the window-type cut.
A filling or insulating material, for example made of a synthetic material or of ceramics for damping preferably temperatures or sound, can be placed in the window-type cut of the friction lining carrier. For increasing or improving the heat flow, a metallic filling or insulating material can be used, for example copper, wrought alloys made of light metal. It is also possible to place a filling of ceramics in the window-type cut of the friction lining carrier in order to maintain a high strength of the friction lining carrier in spite of a slight weight.
Moreover, the rough ground carrier can also consist of a thin sheet made of a composite material made of copper, coppered steel plate and aluminum fittings, whereby both components of the composite material are welded together by ultrasonic or laser welding. The rough ground is then applied onto the uppermost component of the composite material.
In order to obtain a sufficient adherence between the friction lining block and the rough ground carrier with a simultaneous improvement of the protection against corrosion for the rough ground carrier as well as for the friction lining carrier, a metal electroplating, which consists of copper, silver, tin, cadmium, zinc, chromium or of another appropriate material, is applied before pressing-on the friction material onto the rough ground carrier, whereby a coating made of a high temperature resistant synthetic material such as, for example trifluorethylene, polytetrafluor ethylene, polysiloxane, silicone rubber can also be applied. The combined action of the rough ground, i.e. of the support base and the electroplating, results in a high protection against corrosion for the rough ground carrier, while the rough ground causes the bonding between the friction lining block and the rough ground carrier, since the electroplating follows the contour of the rough ground. An ecological method for manufacturing friction linings is created in this way.
Furthermore, it is proposed for a friction lining of the above mentioned type to provide that the support base constituting the rough ground consists of a material mixture made of a fraction (A) with a lower melting point and a fraction (B) with a higher melting point.
By using this mixture for constituting the support base in form of a structure made of positively and frictionally connected moulded elements moulded from the mixture which have undercuts, recesses and the like, it is possible that the surface of the structure has a completely bizarre and irregular structure, in the macrostructure as well as in the microstructure with respect to the single sintered particles so that each single moulded body sintered on the base has a bigger surface compared with a spherical surface, however without possessing a spherical configuration. A very high mechanical strength and a high temperature stability are thus achieved, what results in a high adhesive property and mounting safety of the friction lining block on the rough ground carrier. A further advantage results in that rough ground carriers made of a very thin steel can be used without the bonding between the friction lining block and the rough ground of the rough ground carrier or the rough ground carriers being impaired.
According to an advantageous embodiment, it is provided that the low melting point fraction (A) is a low melting metal such as tin, soft braze or quick solder or the like or a low melting alloy such as bronze, brass or the like and that the higher melting point fraction (B) is made of iron, sand, ceramics powder or the like, whereby the melting point of the higher melting point fraction (B) should lie under the melting point of the rough ground carrier. The rough ground carrier is made of steel, stainless steel, ceramics, aluminum or of other appropriate materials, whereby the actual friction lining carrier can also be configured in the same way. While the fraction (A) is low melting, the melting points of fraction (B) and also of the material of the rough ground carrier must be high; they can be different or also the same.
In spite of the electroplating, a direct force and heat transfer from the friction lining block to the sintered material base and thus to the rough ground carrier is possible. An additional connecting layer can preferably be omitted. A rust formation under the base and a begin of rust are additionally avoided in particular by using bronze so that the service life is improved and the corrodibility even under extreme environmental conditions is reduced.
Add to this that, due to the use of a composite material and in particular due to the used rough ground carrier, such a friction lining has optimal emergency running properties in the area of the sintered support base. Due to the bizarre structure of the surface in the brake disk contact area, a composite material made of a friction material and of a sintered material always has contact with the brake disk so that a braking can still be carried out with the residual friction material fraction.
Simultaneously, there is a brake disk protection since, due to the used compound material, a destruction of the brake disk can be avoided. Thus, due to this structure, there is a high bonding and friction to the end so that emergency running properties do exist. A shearing-off of the rest lining is not possible because of the existing gearing between the bizarre structure of the surface of the structure with the friction lining block, whereby the safety is still additionally increased by the fact that a rust formation underneath can be safely avoided.
Furthermore, it has been proved that the used surface of the structure for the rough ground still has the additional advantage that there are no air inclusions between the friction lining block and the sintered support base, the undercuts and recesses being filled to a large extent by the friction material, whereby such inclusions make it possible for the materials to expand into the thus resulting caverns so that occurring heat tensions are reduced. Thus, there results an additional careful treatment of the friction lining and an improvement of the service life.
According to a preferred embodiment, the low melting fraction (A) consists of approximately 30% bronze and the high melting fraction (B) of a 70% iron powder, whereby the bronze used should have a percentage of 10% tin. By using such a mixture, the result is optimal with respect to all the properties wished such as the capacity of resistance to wear, silencing and protection against corrosion.
Preferably it is provided that the sintered support base is made of a ground layer which covers the rough ground carrier in the area of the friction material receiving surface on the whole surface or on part of the surface, this ground layer being made of single moulded elements positively and frictionally connected with each other, which have undercuts, recesses or the like. The gripping elements can be configured as cylindrical columns, as truncated columns, as a true truncated cone or even in form of a pyramid in a triangular, square or polygonal basic surface, whereby the single gripping elements are arranged respectively at a distance from each other. The selection of the type of the gripping elements used depends on the wished properties of the friction lining. While a column-type configuration of the gripping elements results in the fact that the fraction between the support base material and the friction material remains relatively constant in the contact area even in case of increasing wear, when using other gripping elements the fraction of the support material increases so that a reduced wear can be achieved here so that the brake properties remain maintained even for a strong stress of the friction lining between two examinations.
For this embodiment, the bizarre structure of the sintered particles is particularly advantageous for the manufacturing of the rough ground, whereby each sintered compact has a bigger surface than a spherical surface, however without having the configuration of a sphere. Thus, a high mechanical strength and temperature stability and a high adhesive property are achieved.
In particular by using a rough ground carrier provided with a rough ground for receiving the friction lining block, it is achieved that for a rough rough manufacturing according to the methods known until now, the actual friction lining carrier is in no way impaired in its mechanical and chemical properties. Add to this that rough ground carriers made of a very thin material can be used and that the actual friction lining carrier can also have a lower thickness, since the total strength is obtained by the adhesion of the rough ground carrier with the friction lining carrier.
Further advantageous configurations and further developments of the invention are characterized in the subclaims.
The lining or functional body according to the invention can be used instead of the friction lining described above everywhere where a coating is to be applied onto a carrier, whereby the functional block can have any configuration and material composition.
Embodiment examples of the invention will be explained below in more detail with reference to the attached drawings.
In the embodiment shown in
In
The rough ground carrier 15 is fixed on the friction lining carrier 11 by means of welded, riveted or glued connections 30, whereby other connecting means and connecting procedures can also be used.
The marginal welding 30a represents in
Preferably the rough ground carrier 15 with its rough ground 20 and its friction lining block 25 is fixed on the friction lining carrier 11 by means of a marginal welding 30a running all around (
Accordingly, the friction lining block 25 is not placed directly on the friction lining carrier 11 but on the rough ground carrier 15 placed between the friction lining block and the friction lining carrier.
The marginal welding 30a for fixing the rough ground carrier 15 on the friction lining carrier 11 takes laces by laser beam welding. It is also possible to fix the rough ground carrier 15 on the friction lining carrier 11 by spot welding 31, whereby the spot welding 31 is made on rough ground free surfaces 20a (
For the embodiments according to
As
For the noise attenuation, for the friction lining 10 a friction lining carrier 11 with a window-type cut 40 can also be inserted, whereby the cut 40 is filled with a filling or insulating material 45 (
The window-type cut 40 in the friction lining carrier 11 can also be closed with a filling 46 of ceramics. This configuration has the advantage that in spite of a light weight of the friction lining carrier 11, this friction lining carrier has a high strength and inherent rigidity.
For the embodiment represented in
According to
For the embodiment shown in
Besides a plating 150 made of metallic materials, a synthetic material having the same properties can also be used as a coating. Such a coating is indicated by 150′ in
The friction material mixture is pressed onto the rough ground carrier 15 provided with the support base 21 with the aid of a corresponding moulded element in such a way that during the pressing procedure the friction material mixture flows into the gaps between the single moulded bodies and into the spaces which are formed by the undercuts, recesses and the like 23. In this way, an intimate connection is created between the deforming friction lining block 25 and the support base 21 which joggle and indent into each other. Thus, the friction material receiving surface on the rough ground 20 is filled up so that there does not result here any free surface or free space or only a very low number of free surfaces or free spaces.
According to a further embodiment according to the invention, the rough ground 20 on the rough ground carrier 15 can be formed by a wire grating which is placed on the rough ground carrier 15 by means of a welded, a soldered or another connection. With this configuration, a positive frictional connection with the friction lining block 25 is also obtained. This wire grating consists of rods with a circular, elliptic, triangular cross-section or with another geometrical cross-section form by configuring undercuts, recesses or the like.
In
The friction lining according to the invention 10 has the advantage that, in spite of a temperature treatment, there is no material softening or any loss of strength with respect to the friction lining carrier 11. “Friction lining carrier” 11 designates the carrier sheet or the carrier plate which carries the rough ground carrier 15 with the rough ground 20 and the friction lining block 25 placed on this rough ground.
The invention is not exclusively limited to friction linings such as those described above and represented in the drawings. All possible composite bodies with the most different materials fall under lining or functional body.
Number | Date | Country | Kind |
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200 11 435.2 | Jul 2002 | DE | national |
The present application is a continuation of U.S. application Ser. No. 10/312,666, filed Jun. 27, 2003, which is a National Phase of PCT/EP01/07644, filed Jul. 4, 2001, which claims priority of German application DE 200 11 435.7, filed Jul. 5, 2000, the entire contents of which are incorporated herein by reference.
Number | Date | Country | |
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Parent | 10312666 | Jun 2003 | US |
Child | 12075515 | US |