CN101282795B - 双金属盘式制动器转子及其制造方法 - Google Patents
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Abstract
本发明提供了一种制造摩擦阻尼盘式制动器转子的方法,包括以下步骤:(A)在嵌件上提供陶瓷涂层,其中所述嵌件具有主体,该主体具有从其上延伸出的用于将所述嵌件固定在铸模内的所需位置处的突出部;(B)洗掉所述突出部上的陶瓷涂层;(C)将所述嵌件定位到铸模中;(D)在铸模中围绕所述嵌件浇铸盘式制动器转子的转子颊板,以便使得每个突出部的一部分都与转子颊板相结合,并且使得涂层大体上与转子颊板不相结合由此涂层在主体与颊板之间提供了适当的阻尼界面边界,并且每个突出部与转子颊板间的所述至少部分地结合防止导致发生腐蚀的外部元素在摩擦阻尼盘式制动器转子处于使用状态时到达界面边界。
Description
技术领域
本发明涉及一种双金属盘式制动器转子和制造双金属盘式制动器转子的方法,其中一个嵌件铸入制动器转子中,以提供更好的噪音阻尼而不使转子受到腐蚀。
背景技术
机动车辆盘式制动系统在每个车轮上采用盘式制动器转子,其中,盘式制动器转子通常包含可用于连接至机动车辆可旋转轴的轴毂的转子帽子部,和连接到该转子帽子部上的至少一个环形转子颊板,其中至少一个转子颊板具有一对彼此相对的制动表面,在要求制动时,制动垫片可以有选择地作用于制动表面上。典型地,转子颊板结构可以是实心的,在这种情况下,单个转子颊板在其上具有相对的制动表面,或者也可以是开口的,此时,一对转子颊板通过网状开口叶片彼此相互分开,并且每个转子颊板设有各自的制动表面以便共同提供两个彼此相对的制动表面。
盘式制动系统通常还包含一个卡钳,卡钳支撑一对彼此相对的制动垫片,一个制动垫片叠置于相应的转子颊板制动表面,其中,卡钳,制动垫片,以及其它相关的制动器部件一起构成″制动组件(brake corner)″。通常,卡钳可以使制动垫片从一个或多个转子颊板的制动表面脱离。机动车辆制动发生在制动组件,由卡钳将制动垫片压在一个或多个转子颊板的制动表面之上。在一个或多个旋转转子颊板和非旋转式制动垫片之间的摩擦相互作用致使机动车辆制动发生,制动效率取决于制动垫片相对制动表面的压力。
当制动发生时在制动组件产生不期望的刹车声响。这种刹车声响是盘式制动器转子(通常由铸铁组成)由制动垫片的摩擦材料所模态激励的结果。在以前的工艺中刹车声响通过减少盘式制动器转子由刹车垫片的摩擦材料引起的模态激励来处理(即降低摩擦系数),经过改变转子颊板的模态特性来改变制动组件的模态激励反应(即通过含碳量较高的一个或多个转子颊板和/或增加盘式制动器转子数量,或用特殊、昂贵的材料来改变共振频率、幅态、结构阻尼),以及通过例如经由制动垫片底板上放置的薄垫片通过引入额外的阻尼。
对大多数制动组件而言上述刹车声响的解决对策是相对有效的,但是为了获得好的效果它们需要大量的测试和分析。不幸的是,由于来自制动垫片的摩擦材料所致的强烈的模态激励,对于测试的机动车辆的制动组件,或有着高摩擦衬垫材料的机动车辆,是和先前的刹车声响的解决对策相矛盾的。
与本发明共同转让且在此作为参考被引用的2004年10月8日申请的美国专利申请No.10/961813教导了在转子内配置具有嵌件以提供提高的阻尼的Coulomb摩擦阻尼盘式制动器转子。
发明内容
本发明提供一种制造摩擦阻尼盘式制动器转子的方法,包括以下步骤:(A)在嵌件上提供陶瓷涂层或其它适合的涂层,其中所述嵌件具有主体,该主体具有从其上延伸出的用于将所述嵌件固定在铸模内的所需位置处的突出部;(B)洗掉所述突出部上的陶瓷涂层;(C)将所述嵌件定位到铸模中;(D)在铸模中围绕所述嵌件浇铸盘式制动器转子的转子颊板,以便使得每个突出部的一部分都与转子颊板相结合,并且使得涂层大体上与转子颊板不相结合由此涂层在主体与颊板之间提供了适当的阻尼界面边界,并且每个突出部与转子颊板间的所述至少部分地结合防止导致发生腐蚀的外部元素在摩擦阻尼盘式制动器转子处于使用状态时到达界面边界。
突出部可以位于环形主体的内部(即从内径延伸出),也可以位于环形主体的外部(即从外径延伸出),或同时位于环形主体的内部和外部。嵌件材料优选是钢同时铸件材料为铸铁。陶瓷涂层优选为含有与有机粘结剂混合在一起的氧化铝和二氧化硅微粒的铸模涂料。此外,在施加所述涂层之前对所述嵌件进行喷砂处理。所述涂层被喷涂到所述嵌件上,并且在所述定位于铸模中之前,所述嵌件在大约500华氏度条件下被加热至少大约1小时。在所述嵌件已被加热后从所述突出部上局部地去除所述涂层。所述陶瓷涂层的厚度大约在50微米到300微米之间,所述嵌件的厚度大约在1.5毫米到2.0毫米之间。
另一种可选方式是,不是先将涂层施加到主体和突出部上然后洗掉所述突出部上的陶瓷涂层,而是可以在将涂层仅施加到主体上的时候将突出部盖住(遮蔽住)。同时,石墨涂层可被施加到突出部上以增强结合。
所述嵌件可设有沿径向进行延伸的或环形延伸的加强肋。另一种可选方式是,所述嵌件可包括沿所述环形嵌件主体的内径向下折弯的凸缘,和/或可包括便于铸模填料通过的通孔,以防止在充填铸型的过程中嵌件被抬起。
通过阅读下面对优选实施例进行的描述,本发明的这些和其它特征和优点中将会更加清晰。
附图说明
图1a是根据本发明的定位在铸模内的嵌件的侧剖示意图;
图1b是图1a中所示区域1b的局部放大视图;
图1c是图1a中所示根据本发明的在合模并且将熔融铁水注入到铸模中以便形成摩擦阻尼盘式制动器转子时图1a中的铸模和嵌件的侧剖示意图;
图1d是图1a中所示根据本发明的在开模并且摩擦阻尼盘式制动器转子从铸模中顶出时图1a中的铸模的侧剖示意图;
图2是图1a-d中所示嵌件的平面图,图中用虚线示出了其它可选的结构;
图3是根据本发明的另一可选实施例的嵌件的平面图,;
图3a是具有其它可选的加强凸起的嵌件的局部剖面示意图;
图3b是具有其它可选的向下折弯的加强凸缘的嵌件的局部剖面示意图;
图4是铸模处于闭合状态用于进行浇铸时,用于铸造具有开口的转子颊板的摩擦阻尼盘式制动器转子的定位在铸模内的嵌件的侧剖示意图。
具体实施方式
参见图1a,本发明的铸模10的上、下半模12、14之间形成一个用于铸造本发明的摩擦阻尼盘式制动器转子的空腔16。图1b示出了预定位在铸模10内并且其具有一置于下半模14的切除部22、24上的突出部20的嵌件18。如图1c所示,当上、下半模12、14合模时,突出部20被分别支撑在下半模14的切除部22、24和上半模12的平台26、28之间。
参见图2,图中示出了嵌件18的平面图。如图中所示,嵌件18具有大体上呈环状的主体30,该环状主体30具有从其上延伸出的突出部20。每个突出部包括远端部32和近端部34。如图1c所示,远端部32分别被截留在切除部22、24和平台26、28之间,而每个突出部20的近端部34暴露在型腔16内的熔融金属中。
铸模10优选是砂型,嵌件18是在围绕整个主体30的两个相对的表面36、38(如图1b所示)上均有涂层的预制的钢构件。这些涂覆表面36、38在铸造过程中不与浇铸金属结合。沿着这些涂覆表面36、38的″润湿性″或亲合力的不足可产生预期的阻尼界面边界。然而,突出部20,尤其每个突出部20的近端部34被构造成与转子颊板的浇铸金属相结合。由于嵌件18的涂覆表面36、38不与转子颊板的浇铸金属结合,与颊板形成适当的阻尼界面边界。然而,突出部,尤其是其近端部34,与转子颊板浇注金属的结合防止外部因素引起的腐蚀到达涂覆表面36、38和转子颊板的浇铸金属之间的界面边界。这种结合可以通过如下方式实现,即首先在突出部20上涂布和形成主体30的涂覆表面36、38涂层相同的材料,然后清除突出部20的涂层以局部地移除涂层使突出部被微焊接至铸铁以便有效密封嵌件/铁界面的源自铸件外部的水或其它因素腐蚀而导致的缝隙。另外,除了先将涂层涂布到整个嵌件然后局部清洁突出部外,石墨涂层可施加于突出部20以强化和浇铸金属的结合。因此所谓突出部边缘的″湿润性″也可以通过在进行涂布前遮盖住突出部来实现。嵌件材料可以是任何熔点高于铸铁的且在铸造过程中不会被熔解的材料。
上面提及的涂覆表面36、38首先应当清理干净表面上的油、锈迹或污物。可使用脱脂剂去除油的薄膜,钢丝绒可用于除锈。最佳效果是当对钢制嵌件进行喷砂处理时表面没有油和锈迹。这样在使表面变粗糙的同时有利于涂层更好地进行附着。
优选的涂层材料是一种商标名称为IronKote且可从安大略省韦兰的加拿大维苏威耐火材料公司购买到的陶瓷铸模涂料。IronKote是氧化铝、二氧化硅微粒与有机粘结剂混合在一起的混合物。IronKote大约是47.5%的氧化铝和39.8%二氧化硅与有机粘结剂Lignisole(木素磺化盐(lignosulfanate))的混合物。该涂层的厚度优选大约在50微米到300微米之间。也可以使用熔点高于铸铁的其它陶瓷涂层。
一旦嵌件被清洗干净且不带油和锈迹,可以用IronKote进行浸蘸或在两个侧表面36、38上进行喷洒并且进行空气干燥。嵌件然后被放置在烘箱内,温度为500华氏度并持续45分钟。这样就最小限度地吸收水分和有机粘合剂,并提供了相对均匀的涂层。
一旦结束涂装工艺后,用钢丝绒从突出部上局部地去除涂层。随着涂层从突出部上被除去,在铸铁和嵌件的钢制突出部之间形成结合。
参见图1d,铸模10处于开启位置,摩擦阻尼盘式制动器转子40从型腔移出。如图所示,摩擦阻尼盘式制动器转子40具有帽子部42,该帽子部具有在其边缘周围延伸的转子颊板44,和设置在转子颊板44内的嵌件18。在摩擦阻尼盘式制动器转子40从铸模10取出后嵌件18的突出部20的远端32将被机械加工掉。
可以在内径、外径或者同时在两个位置使用定位突出部以便在金属铸造过程中稳定嵌件。例如,图2中嵌件18具有如部分剖视图所示的可选的内部突出部56。突出部的数量和位置取决于具体的转子几何形状和尺寸,以及钢制嵌件的厚度。突出部56和20可以一起使用或单独使用。
钢制嵌件的厚度优选在1.5毫米到2毫米之间,当然也可使用其它厚度。在厚度未达到使周围铸件“冷却”达到有害的碳化物析出点的同时,选择所述厚度以防止嵌件产生弯曲。
通过防止钢制嵌件在铸造过程中与铁发生反应,保持用于所需声阻尼的界面。通过增强突出部与铸钢之间的结合,消除突出部区域的缝隙以便使界面与铸件的外部环境隔离开从而消除在使用中存在的腐蚀问题。此外,多于一个嵌件可被铸造在转子内的适当位置处。
图2还以虚线示出了可选的通孔45,在使熔融金属移动嵌件18的动作呈最小程度的同时,有利于进行铸模填充。换句话说,当铸模如图1d所示通过浇口通道47被填充时,孔45防止熔融材料将嵌件抬起。通过在所述部分下面设置浇道并采用水平浇注工艺,金属不再过早冲到或溅到嵌件上面。另外,静止不动的铸模填充防止在充型过程中金属液滴与熔融金属接触之前溅到嵌件上,以避免铁的小液滴的过早凝固。
此外,熔融材料优选在浇口通道47处被过滤,如图1d所示,利用陶瓷过滤器以减少与渣相关的缺陷。
再看图3,图中示出了另一种可选的嵌件18A,所述嵌件包括环形加强肋41和径向加强肋43,其与突出部20同时存在。这些可选的肋41,43有助保持嵌件18A在充型过程中的位置和形状(即防止出现″土豆状碎片″)。优选地,所述肋040英寸厚,带有.060英寸(1.5毫米)厚的嵌件。
另一种可选方式是,加强肋41可以是如图3a中嵌件18B的局部剖面示意图所示的加强脊41A。参见图3b,在进一步可选的实施例中,如图3所示嵌件18的环形主体的内径49可包括如图3b中嵌件18C的局部剖面示意图所示的向下折弯的凸缘41B。这些不同的加强肋有助保持嵌件18,18A,18B,或者18C在充型过程中的位置和形状。
图3还示出了由虚线所示的隆起区域71,以表示在如附图1c中的切除部和平台22,26,24和28区域中形成的模腔中设置的间隙。铸模10中的这些隆起区域71使得当熔融金属加热嵌件时嵌件可以扩展而不发生变形。
本发明提供了减弱了的盘式制动器噪音和尖叫声,并且限制了在机械加工后所暴露的嵌件发生腐蚀。
上述过程也可以用于开口型转子颊板结构,应当注意的是:在转子颊板中的两个或者可选择的一个设置一个或者多个嵌件。例如,图4示出了铸模60,该铸模具有上、下半模62、64,在其间形成型腔66,用于形成配置有开口型颊板的摩擦阻尼盘式制动器转子。具有辐板结构68和嵌件70的预先制造的型芯被支撑在型腔66内并且铸造。具有辐板结构的型芯形成了颊板的开口形状。嵌件70具有支撑在切除部74和平台76之间的突出部72。参见图1a-d中实施例的描述,在嵌件的主体被涂布并且不与铸造金属相结合以形成适当的阻尼界面边界的同时,突出部72被用于结合铸造金属。突出部的结合可防止发生腐蚀。
对于本发明所属技术领域的技术人员而言,以上所述的优选实施例可以进行改变或修改。在不偏离本发明范围的情况下可以进行所述改变和修改,所述范围仅由所附权利要求书的范围进行限定。
Claims (23)
1.一种制造摩擦阻尼盘式制动器转子的方法,所述方法包括以下步骤:
在嵌件上提供陶瓷涂层,其中所述嵌件具有主体,该主体具有从其上延伸出的用于将所述嵌件固定在铸模内的所需位置处的突出部;
洗掉所述突出部上的陶瓷涂层;
将所述嵌件定位到铸模中;以及
在铸模中围绕所述嵌件浇铸盘式制动器转子的转子颊板,以便使得每个突出部的一部分都与转子颊板相结合,并且使得涂层与转子颊板不相结合由此涂层在主体与颊板之间提供了适当的阻尼界面边界,并且每个突出部与转子颊板间的所述至少部分地结合防止导致发生腐蚀的外部元素在摩擦阻尼盘式制动器转子处于使用状态时到达界面边界。
2.如权利要求1所述的方法,其中所述嵌件包含钢并且所述铸件包含铸铁。
3.如权利要求1所述的方法,其中所述陶瓷涂层包括含有与有机粘结剂混合在一起的氧化铝和二氧化硅微粒的铸模涂料。
4.如权利要求1所述的方法,其中在施加所述涂层之前对所述嵌件进行喷砂处理。
5.如权利要求4所述的方法,其中所述涂层被喷涂到所述嵌件上,并且在所述定位于铸模中之前,所述嵌件在大约500华氏度条件下被加热至少大约45分钟。
6.如权利要求5所述的方法,其中在所述嵌件已被加热后从所述突出部上局部地去除所述涂层。
7.如权利要求1所述的方法,其中所述陶瓷涂层的厚度大约在50微米到300微米之间。
8.如权利要求1所述的方法,其中所述嵌件的厚度大约在1.5毫米到2.0毫米之间。
9.如权利要求1所述的方法,其中所述突出部位于所述主体的内部和外部。
10.如权利要求1所述的方法,其中所述嵌件具有在其中形成的便于铸模填料通过的通孔。
11.如权利要求1所述的方法,其中从嵌件的下面填充所述铸模,从而防止熔融金属过早地接触嵌件。
12.一种摩擦阻尼盘式制动器转子,包括:
具有定位在其中的嵌件的至少一个转子颊板,所述嵌件具有大体上呈环状的主体,该主体具有多个从其上延伸出的突出部,并且每个突出部的一部分与转子颊板相结合,同时主体通过陶瓷涂层与转子颊板隔开,从而使得所述主体提供与颊板的适当的阻尼界面边界,同时突出部与转子颊板的结合防止导致发生腐蚀的外部元素到达界面边界。
13.如权利要求12所述的摩擦阻尼盘式制动器转子,其中所述突出部位于所述主体内部。
14.如权利要求12所述的摩擦阻尼盘式制动器转子,其中所述突出部位于所述主体外部。
15.如权利要求12所述的摩擦阻尼盘式制动器转子,其中所述突出部位于所述主体内部和外部。
16.如权利要求12所述的摩擦阻尼盘式制动器转子,其中所述嵌件包含钢并且所述铸件包含铸铁。
17.如权利要求12所述的摩擦阻尼盘式制动器转子,其中所述陶瓷涂层包括含有与有机粘结剂混合在一起的氧化铝和二氧化硅微粒的铸模涂料。
18.如权利要求12所述的摩擦阻尼盘式制动器转子,其中所述陶瓷涂层的厚度大约在50微米到300微米之间。
19.如权利要求12所述的摩擦阻尼盘式制动器转子,其中所述嵌件的厚度大约在1.5毫米到2.0毫米之间。
20.如权利要求12所述的摩擦阻尼盘式制动器转子,其中所述嵌件主体呈环形并且上面具有直立的环形加强肋。
21.如权利要求12所述的摩擦阻尼盘式制动器转子,其中所述嵌件主体是环形的并且具有从其上径向延伸出的突出部,并且在其上具有多个与所述突出部共同延伸的直立的环形加强肋。
22.如权利要求12所述的摩擦阻尼盘式制动器转子,其中所述嵌件主体呈环形并且具有沿所述嵌件的内径向下折弯的凸缘。
23.一种制造摩擦阻尼盘式制动器转子的方法,所述方法包括以下步骤:
提供嵌件,所述嵌件具有主体,该主体具有从其上延伸出的用于将所述嵌件固定在铸模内的所需位置处的突出部,其中,在主体上而不是在突出部上提供陶瓷涂层;
将所述嵌件定位到铸模中;以及
在所述铸模中围绕所述嵌件浇铸盘式制动器转子的转子颊板,以便使得每个突出部的一部分都与转子颊板相结合,并且使得涂层与转子颊板不相结合由此涂层在主体与颊板之间提供了适当的阻尼界面边界,并且每个突出部与转子颊板间的所述至少部分地结合防止导致发生腐蚀的外部元素在摩擦阻尼盘式制动器转子处于使用状态时到达界面边界。
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- 2006-07-31 WO PCT/US2006/029687 patent/WO2007040768A2/en active Application Filing
- 2006-07-31 DE DE112006002490.6T patent/DE112006002490B4/de active Active
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Also Published As
Publication number | Publication date |
---|---|
US20070062768A1 (en) | 2007-03-22 |
US20110198169A1 (en) | 2011-08-18 |
WO2007040768A2 (en) | 2007-04-12 |
CN101282795A (zh) | 2008-10-08 |
DE112006002490T5 (de) | 2008-07-17 |
US7937819B2 (en) | 2011-05-10 |
DE112006002490B4 (de) | 2014-08-21 |
WO2007040768A3 (en) | 2007-05-24 |
US8820491B2 (en) | 2014-09-02 |
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