CN100424376C - 整体垫片 - Google Patents

整体垫片 Download PDF

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CN100424376C
CN100424376C CNB2004800058399A CN200480005839A CN100424376C CN 100424376 C CN100424376 C CN 100424376C CN B2004800058399 A CNB2004800058399 A CN B2004800058399A CN 200480005839 A CN200480005839 A CN 200480005839A CN 100424376 C CN100424376 C CN 100424376C
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annular
carbon
shim elements
piece shim
compressing tablet
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CN1756913A (zh
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肯尼·张
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Safran Landing Systems SAS
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Messier Bugatti SA
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Abstract

一种由一碳材料制成的整体或其他形式的单件环形垫片元件用于在诸如压实的一制造过程中维持堆叠的环形压片之间的一空间。所述整体结构有利地简化所述压片在一处理腔室中的排列且在所述压片中引起较少变形。所述碳组合物还提供改进所述压实处理的有益的热效应。在所述环形垫片元件上提供一剥离涂层，以促进所述环形压片与所述垫片元件的分离。

Description

整体垫片
技术领域
本发明涉及在生产过程中用于使堆叠多孔衬底间隔分开的垫片元件。本发明的一个特定实例涉及尤其在压实过程(诸如化学气相渗透(CVI))中用于使堆叠的环形复合材料压片间隔分开的碳环形垫片元件。
背景技术
所述复合材料压片尤其可为用于制造刹车盘或其它摩擦元件的环形压片。
举例来说，在2003年8月14日申请的第10/468,031号美国专利申请案中揭示了一种用于压实制造刹车盘等的环形压片的装置；在图1中对其表示进行了说明。
图1是一处理腔室的高度图解说明，所述处理腔室中具有一包裹体10，所述包裹体包含由碳纤维制成的环形压片或衬底20的负载。所述负载呈一堆叠的衬底的形式，所述衬底各自具有通常垂直对准的中心通道。所述堆叠可由由一个或一个以上的中间支撑板12分离的复数个叠加的堆叠部分构成。
所述堆叠的衬底通过隔板30而彼此分离。如图2中所示，隔板30可径向安置，且其数量可变化，所述隔板30在整个堆叠中在相邻衬底之间提供大体上恒定高度的间隙22，同时允许如由所述衬底的通常对准的中心通路所组成的堆叠的内部体积24与位于所述堆叠外部且在包裹体10内部的外部体积26相连通。
在图1的实例中，包裹体10包含单一堆叠的衬底。在其它实例中，复数个堆叠的衬底可并排安置在同一包裹体中。
包裹体10通过一感受器14(例如由石墨制成)而加热，所述感受器14用于界定包裹体10，且与位于一包围所述感受器的外壳17外部的感应线圈16感应耦接。可使用其它的加热方法，例如，电阻加热(焦耳效应)。
将含有一种或一种以上碳的前体(通常为诸如甲烷和/或丙烷的碳氢化合物气体)的气体容纳于包裹体10中。在所示的实例中，通过所述包裹体的底部10a实现容纳。气体穿过在所述包裹体的底部部分中彼此叠加放置的一个或一个以上穿通板形成的预热区18，在板11之下支撑所述衬底的堆叠。由预热板加热的气体(其升高到包裹体内的温度)自由地流动到所述包裹体中，同时进入到内部体积24中，进入到外部体积26中且进入到间隙22中。剩余气体通过抽空经由形成于盖子10b中的出口而被从包裹体中抽出。
隔板30为单独放置的块状元件，通常由氧化铝制成。然而，一旦形成，所述氧化铝块元件极其易碎，且从破裂处的损耗非常高。实际上，在正常使用的情况下，常规氧化铝块常常维持不会超过2或3个压实循环。因为必须更换氧化铝块，所以这也自然地提高了制造成本。
此外，每个压片层之间的单独氧化铝块元件的适当手动放置极为耗时。在图2中以说明性实例的方式展示了六个所述块状元件，且在实际实践中，使用多达12个的块体。处理易碎的块体而不会使其破裂所需要的极大细心更加重了时间负担。一般来说，根据常规方法，包含七盘压片(每一盘具有十二到十四个压片堆叠)的完全压实过程可花费长达一个或两个工作日来设置。
与使用单独隔板元件30相关的另一个问题是其倾向于在压片中引起变形(即，凹痕)，此由堆叠于其上的压片(和隔板)的重量引起。如可从图2中了解到，存在以圆周方式在隔板元件30之间的压片的较大未受支撑的面积。因为所述压片材料通常易弯曲，且因为氧化铝形成的隔板元件30不会变形，所以在对应于隔板元件30的位置中的压片的表面中出现压痕。这些变形尽管微小，但是必须在额外的精整步骤中将其机械加工除去，以获得适用于摩擦应用的所要的平坦表面。结果，预期在已知的方法中会发生变形，且预期最终的机械加工步骤以移除那些变形，每个压片的厚度均厚于最终产品所要的厚度。经机械加工除去的材料意味着经济上的浪费。
发明内容
鉴于上述内容，本发明涉及一种用于使堆叠的环形压片间隔分开的整体或单件环形垫片元件。
根据本发明的一垫片元件具有一通常为平整的环形形状，其具有相对的第一和第二表面。所包括表面的至少一个表面被加工成形以至少部分地界定用于使所述垫片元件的内部空间与一外部相连通的径向延伸的气流路径。
根据本发明的一垫片元件优选在径向尺寸上与跟其相邻的环形压片类似。也就是说，所述垫片元件优选具有与所述环形压片类似的内直径和类似的外直径。如果所述垫片元件在尺寸上与所述环形压片通常不相等，那么优选使所述垫片元件略微较小(即，具有大于所述环形压片的内直径和/或小于所述环形压片的外直径)，而不是所述垫片元件大于(即，径向较宽)所述环形压片。
在本发明的一个实例中，所述垫片元件由一具有其上形成有剥离涂层的碳材料(诸如，石墨或碳/碳复合物)制成。
附图说明
参考附图将更好地理解本发明，其中：
图1说明用于压实堆叠的环形压片的处理腔室；
图2说明用于将图1中说明的堆叠环形压片间隔分开的单独隔板元件的排列；
图3a-3c说明根据本发明的整体垫片元件的第一实例；
图4a-4c说明根据本发明的整体垫片元件的第二实例；和
图5a-5c说明根据本发明的整体垫片元件的第三实例。
特别强调，本文的图式仅用于说明本发明的实例，且无意解释为以任何方式限制本发明的定义。还请注意，本文的图式一般来说或在相关视图中没有必要按比例绘制。
具体实施方式
一般来说，根据本发明的垫片元件具有某些根本有用的特征。
与在堆叠中的每一环形压片之间使用数个单独隔板元件相比，一整体或单件构造大大促进了将一处理腔室装载有堆叠的环形压片的操作。如上文注意到，上文参考图2所描述的常规排列需要手动放置每个常规隔板元件。此外，因为常规隔板元件通常由高度易碎的材料(诸如氧化铝)制成，所以在本来已经够冗长且乏味的手动过程期间必须非常小心地处理每个隔板元件以努力避免破裂。所述隔板元件又相对较小且非常薄(例如，1″x4″x0.1″)，这也使对其进行处理较困难。
由于使用根据本发明的一整体垫片元件，定位所述垫片元件的单一动作代替根据常规方法定位单独隔板元件的数次放置动作。与以上述常规方式装载处理腔室的一到两天相比，使用根据本发明的一整体垫片可(在相等基础上)将装载时间减少到两到四个小时。
另外，与如图2中所说明的单独隔板元件的常规使用相比，根据本发明的整体垫片元件的结构在一较大面积上更好地支撑堆叠于其上的一个或一个以上的环形压片的重量。具体地说，所述环形整体垫片元件的径向宽度应该约等于或稍微窄于所述环形压片的径向宽度。结果，每个环形压片在从所述处理腔室移除之后较不易变形。这意味着在压实处理之后想要获得有效未变形的表面需要较少的补救的机械加工。
如刚刚提及的，所述整体垫片元件优选具有约与所述环形压片相同的径向宽度，或较其略微较窄(例如，相对于其外直径和/或内直径窄约5mm)。如果所述整体垫片元件比所述环形压片宽，那么暴露的部分将倾向于具有从压实气体的分解的形成于其上的剩余物(诸如热解碳)。这会减少所述垫片元件的使用寿命或者有需要额外的整修程序来移除所述形成物。另外，如果所述垫片元件向外径向延伸越过所述环形压片的外部边缘，那么为了同时处理，在处理腔室中定位数个环形压片堆叠会产生问题(如经常出现的)。因为处理腔室内的间隔问题，会负面影响生产效率，到可同时处理较少堆叠的程度。
一般来说，根据本发明的整体垫片元件包括在其一个表面或两个表面上径向延伸的通道或其它特征，此在实际效果中至少部分地界定了使整体垫片元件的径向内侧与其径向外侧相连通的气流路径。在此提及“部分地”界定的气流路径是因为在某些情形下，所述气流路径还由与所述整体垫片元件的结构合作的一个所述环形压片的相对表面而部分地界定。使用整体垫片的气流路径的的横截面面积在实际效果中可与现有技术的排列中呈现的横截面面积优选相比较。然而，根据个别情况可改变此考虑。
应了解，例如，可通过调整每一通道的大小等或通过提供多个通道等来影响所呈现的气流路径的全部横截面面积。在这个方面，一个确定因素是维持对叠加的环形压片的支撑的所要水平。
通常，根据本发明的整体垫片元件应该由可经受住高达约1100℃且优选(为安全目的)高达约1200℃到1400℃温度的材料制成。所选择的材料优选在所提及的操作温度下与压片反应最小。
适用于所预期的整体垫片元件的材料的实例包括(不限于)：碳材料，诸如石墨、碳/碳、和编织碳纤维纱；模制陶瓷；和金属材料，诸如不锈钢、铬镍铁合金、钛、钼、钽和钨。
图3a-3c、图4a-4c和图5a-5c说明了根据本发明的基于碳的整体垫片的实例几何结构。组成材料可为(例如)碳/碳材料，或其可为非常导热的石墨。在后者情况中，可在诸如PGX、UCAR和MKU-S等品名下购买适当的石墨。
可将碳/碳材料以已知方式从2-D或3-D压片(可为针缝的)或从多层的碳纤维编织物层压制成根据本发明的环形垫片，且接着使用CVI或树脂填充方法进行压实。
可以已知方式将碳/基于碳的原始材料模制和/或机械加工成形，且可以已知方式将用作原始材料的石墨从坯料机械加工成所要的几何结构。
在图3a-3c中，图3a是根据本发明的一环形垫片元件300的平面图。图3b是环形垫片元件300的透视图。图3c是在垂直于环形垫片元件300所处平面的平面中的垫片元件300的横截面正视图。
环形垫片元件300具有在其一个侧面上与其间相对下降部分(其中一些在304b处表示)交替的复数个间隔分开的通常规则形状的凸起部分(其中一些在304a处表示)。同样，环形垫片300的另一侧面具有与其间相对下降部分(其中一些在302b处表示)交替的相应的间隔分开的通常规则形状的凸起部分(其中一些由302a处的虚线表示)。
在这个实例中，凸起部分302a、304a的边缘部分重叠于环形垫片元件300的另一侧面上的相应凸起部分的边缘。例如，参看图3c。其共同提供了比上文提及的常规隔板元件30大的重量支承面积。因此，堆叠的重量在较大面积上扩展，且负载不会集中，不会引起对应于常规隔板元件30的位置的常规方法中相对严重的压印。
下降部分302a、304b界定径向延伸的通道或气流路径，压实气体可经由所述径向延伸的通道或气流路径从堆叠的环形压片的内部流动到外部。如上文所提及，这些通道存在用于压实气流的全部横截面面积一般来说可根据特定处理情形而改变。然而，一般来说，所述横截面面积通常应与当使用如上提及的常规隔板元件30时存在的横截面面积可比较。
在图4a-4c中，图4a是根据本发明的环形垫片元件400的平面图。图4b是环形垫片元件400的透视图。图4c是在垂直于环形垫片元件400所处平面的平面中的垫片元件400的横截面正视图。
环形垫片元件400具有类似于环形垫片元件300的结构，因为其两个侧面具有与相对下降部分402b、404b相交替的相对凸起部分402a、404a。在此，同样，相对下降部分402b、404b界定了径向延伸的通道或气流通路，所述压实气体可经由所述径向延伸的通道或气流通路从堆叠的环形压片的内部流通到其外部。
在图3c中可见，相对于组成材料306的中心平面厚度界定环形垫片元件300的结构。因此，可围绕环形垫片元件300的外部边缘追踪一直的圆周路径。
相反，因为环形垫片元件400相对于环形垫片元件300来说较薄，所以其中不存在组成材料的均等平面厚度。因此，仅可能沿环形垫片元件400的外部边缘追踪一起伏路径(对应于交替的凸起和下降部分)。(例如，参看图4c。)
在图5a-5c中，图5a是根据本发明的环形垫片元件500的平面图。图5b是环形垫片元件500的透视图。图5c是在垂直于环形垫片元件500所处平面的平面中的垫片元件500的横截面正视图。
最一般的说，环形垫片元件500不同于环形垫片元件300与400，因为环形垫片元件500的相对侧面上的凸起部分502a、504a相对对准，下降部分502b、504b也一样。特别参看图5c。如前面，下降部分502b、504b至少部分地界定数个通道，所述压实气体可经由所述数个通道在所述堆叠的环形压片的内部与其外部之间流通。
在一个实例中，可考虑从在碳(如，石墨)坯料的相对表面上的形成对应通道502b、504b的透视中的环形垫片元件500的制造，所述碳坯料具有至少约为凸起部分502a、504a对应的位置处的环形垫片元件500的厚度的初始厚度。
如上文所提及，可通过任何已知且适当的处理(尤其(但不仅)为机械加工或模制，或两者)来获得前述几何结构。
当使用碳材料制造用于复合碳环形压片的根据本发明的垫片元件时，有时会存在垫片元件在压实处理后粘附到压片的问题。为解决这个问题，预期在垫片元件的表面上提供一剥离涂层，以有助于避免所述粘附。
有用的剥离涂层的一个实例包括形成于垫片元件上的由MoSi2制成的第一层，和形成于第一层上的由Al2O3制成的第二层。这些层(例如)可通过使用已知的等离子喷涂方法来形成。MoSi2层充当桥接层以改进Al2O3层到所述结构的粘附。
应注意到，提供基于碳的垫片元件(尤其是石墨垫片元件)在制造期间具有额外的益处。一般来说，将石墨垫片元件提供到环形压片堆叠上增加了所述堆叠的热质量，从而促进加热，且又促进压实。因为其相对较难单独升高压片的温度，所以这是有益的。(在常规方法中，压片的堆叠的顶部和底部具有最高水平的压实，因为与所述堆叠中的中间压片相比较，其较大暴露于加热。)同样，因为碳垫片元件的良好的热传导性，所以可在邻近的环形压片的径向宽度上提供较均匀的温度分布。
虽然已相对于认为是本发明最实用的实施例描述了本发明，但请特别注意，这仅仅是举例，且在所附权利要求书的精神和范畴内对其进行适当的修改和变化是可能的。

Claims (22)

1. 一种具有相对的第一和第二表面的环形单件垫片元件，其中所述环形单件垫片元件由一碳材料制成，具有一形成于所述碳材料上的剥离涂层，所述环形单件垫片元件包括形成于所述第一和第二表面的至少一个表面上的复数个径向延伸的通道。
2. 根据权利要求1所述的环形单件垫片元件，其中复数个径向延伸的通道形成于所述第一和第二表面两者上。
3. 根据权利要求2所述的环形单件垫片元件，其中形成于所述第一表面上的所述复数个通道与形成于所述第二表面上的所述复数个通道相对准。
4. 根据权利要求2所述的环形单件垫片元件，其中形成于所述第一表面上的所述复数个通道在一圆周方向上从形成于所述第二表面上的所述复数个通道偏移。
5. 根据权利要求1所述的环形单件垫片元件，其中所述碳材料是一碳/碳纤维材料和一固体石墨材料中的一种。
6. 根据权利要求5所述的环形单件垫片元件，其中所述碳材料是碳/碳纤维材料，且所述碳/碳纤维材料是一编织碳纤维纱织物。
7. 根据权利要求1所述的环形单件垫片元件，其中所述剥离涂层包含形成于所述碳材料上的一第一MoSi2层和形成于所述第一MoSi2层上的一第二Al2O3层。
8. 一种制备用于一化学气相渗透处理的复数个环形碳纤维压片的方法，其包含：
堆叠所述复数个环形碳纤维压片，其中在每对所述环形碳纤维压片之间分别提供一由一碳材料制成的环形单件垫片元件，所述堆叠的复数个环形碳纤维压片和环形单件垫片元件在所述堆叠的复数个环形碳纤维压片内共同界定一内部空间，
其中每个环形单件垫片元件具有相对的第一和第二表面和形成于所述第一和第二表面的至少一个表面上的复数个径向延伸的通道，所述复数个径向延伸的通道用于使所述堆叠的复数个环形碳纤维压片所述内部空间与所述堆叠的复数个环形碳纤维压片的一外部相连通，每个环形单件垫片元件被提供有一形成于所述环形单件垫片元件上的剥离涂层，以用于防止所述环形碳纤维压片粘附至所述环形单件垫片元件。
9. 根据权利要求8所述的方法，其中每个环形单件垫片元件的所述第一和第二表面中的每个表面均具有各自的复数个形成于所述第一和第二表面上的通道。
10. 根据权利要求9所述的方法，其中形成于所述第一表面上的所述复数个通道与形成于所述第二表面上的所述复数个通道相对准。
11. 根据权利要求9所述的方法，其中形成于所述第一表面上的所述复数个通道在一圆周方向上从形成于所述第二表面上的所述复数个通道偏移。
12. 根据权利要求8所述的方法，其中所述碳材料是一碳/碳纤维材料和一固体石墨材料中的一种。
13. 根据权利要求12所述的方法，其中所述碳材料是碳/碳纤维材料，且所述碳/碳纤维材料是一编织碳纤维纱织物。
14. 根据权利要求8所述的方法，其中所述剥离涂层包含形成于所述碳材料上的一第一MoSi2层和形成于所述第一MoSi2层上的一第二Al2O3层。
15. 根据权利要求8所述的方法，其中在每对所述环形碳纤维压片之间分别提供由一碳材料制成的所述环形单件垫片元件增加了所述堆叠的复数个环形碳纤维压片的热质量，从而改进化学气相渗透处理的效率。
16. 根据权利要求8所述的方法，其中每个环形单件垫片元件具有一外直径，所述环形单件垫片元件的外直径小于所述环形碳纤维压片的外直径；每个环形单件垫片元件具有一内直径，所述环形单件垫片元件的内直径大于所述环形碳纤维压片的内直径。
17. 根据权利要求16所述的方法，其中每个环形单件垫片元件的所述外直径比所述环形碳纤维压片的所述外直径小约5mm，每个环形单件垫片元件的内直径比所述环形碳纤维压片的所述内直径大约5mm。
18. 一种用于由一碳材料制造一单件环形垫片的方法，所述方法包含：
由一碳材料形成一环形元件，所述环形元件具有相对的第一和第二表面和形成于相对的所述第一和第二表面中的至少一个表面上的一径向延伸的通道；和
在所述环形元件上形成一剥离涂层。
19. 根据权利要求18所述的方法，其中形成所述剥离涂层包含在所述碳材料上形成一第一MoSi2层和在所述第一MoSi2层上形成一第二Al2O3层。
20. 根据权利要求19所述的方法，其中形成所述剥离涂层包含使用浆液喷涂以在所述碳材料上形成所述第一MoSi2层和在所述第一MoSi2层上形成所述第二Al2O3层。
21. 根据权利要求18所述的方法，其中形成一环形元件包含对一石墨坯料进行机械加工。
22. 根据权利要求18所述的方法，其中所述碳材料是一碳/碳纤维材料和一编织碳纤维纱织物中的一种。
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