CN101688007A - Improvements in or relating to brake and clutch discs - Google Patents
Improvements in or relating to brake and clutch discs Download PDFInfo
- Publication number
- CN101688007A CN101688007A CN200880010466A CN200880010466A CN101688007A CN 101688007 A CN101688007 A CN 101688007A CN 200880010466 A CN200880010466 A CN 200880010466A CN 200880010466 A CN200880010466 A CN 200880010466A CN 101688007 A CN101688007 A CN 101688007A
- Authority
- CN
- China
- Prior art keywords
- prefabrication
- carbon
- densification
- brake
- silication
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 230000006872 improvement Effects 0.000 title description 2
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 44
- 238000001764 infiltration Methods 0.000 claims abstract description 37
- 230000008595 infiltration Effects 0.000 claims abstract description 37
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 33
- 239000000835 fiber Substances 0.000 claims abstract description 33
- 239000000126 substance Substances 0.000 claims abstract description 19
- 239000007788 liquid Substances 0.000 claims abstract description 17
- 239000011226 reinforced ceramic Substances 0.000 claims abstract description 8
- 238000005470 impregnation Methods 0.000 claims abstract description 4
- 238000000034 method Methods 0.000 claims description 37
- 238000009417 prefabrication Methods 0.000 claims description 31
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 22
- 229910052710 silicon Inorganic materials 0.000 claims description 22
- 239000010703 silicon Substances 0.000 claims description 22
- 238000000280 densification Methods 0.000 claims description 19
- 239000000178 monomer Substances 0.000 claims description 13
- 239000002131 composite material Substances 0.000 claims description 10
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 10
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 9
- 239000004917 carbon fiber Substances 0.000 claims description 9
- 238000009736 wetting Methods 0.000 claims description 9
- 238000004519 manufacturing process Methods 0.000 claims description 7
- 238000006243 chemical reaction Methods 0.000 claims description 5
- 238000005255 carburizing Methods 0.000 claims description 3
- 239000004744 fabric Substances 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims description 3
- 150000001721 carbon Chemical class 0.000 claims description 2
- 230000003068 static effect Effects 0.000 claims description 2
- CREMABGTGYGIQB-UHFFFAOYSA-N carbon carbon Chemical compound C.C CREMABGTGYGIQB-UHFFFAOYSA-N 0.000 abstract 1
- 239000011203 carbon fibre reinforced carbon Substances 0.000 abstract 1
- 239000007795 chemical reaction product Substances 0.000 abstract 1
- 239000011347 resin Substances 0.000 description 13
- 229920005989 resin Polymers 0.000 description 13
- 230000008569 process Effects 0.000 description 9
- 238000003763 carbonization Methods 0.000 description 7
- 238000007598 dipping method Methods 0.000 description 7
- UFWIBTONFRDIAS-UHFFFAOYSA-N Naphthalene Chemical compound C1=CC=CC2=CC=CC=C21 UFWIBTONFRDIAS-UHFFFAOYSA-N 0.000 description 6
- 239000011159 matrix material Substances 0.000 description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 238000006116 polymerization reaction Methods 0.000 description 4
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 4
- 101100373011 Drosophila melanogaster wapl gene Proteins 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 210000004483 pasc Anatomy 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 229910010271 silicon carbide Inorganic materials 0.000 description 3
- CXWXQJXEFPUFDZ-UHFFFAOYSA-N tetralin Chemical compound C1=CC=C2CCCCC2=C1 CXWXQJXEFPUFDZ-UHFFFAOYSA-N 0.000 description 3
- QPUYECUOLPXSFR-UHFFFAOYSA-N 1-methylnaphthalene Chemical compound C1=CC=C2C(C)=CC=CC2=C1 QPUYECUOLPXSFR-UHFFFAOYSA-N 0.000 description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- 239000004215 Carbon black (E152) Substances 0.000 description 2
- 239000002841 Lewis acid Substances 0.000 description 2
- MWPLVEDNUUSJAV-UHFFFAOYSA-N anthracene Chemical compound C1=CC=CC2=CC3=CC=CC=C3C=C21 MWPLVEDNUUSJAV-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 230000004087 circulation Effects 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
- HYBBIBNJHNGZAN-UHFFFAOYSA-N furfural Chemical compound O=CC1=CC=CO1 HYBBIBNJHNGZAN-UHFFFAOYSA-N 0.000 description 2
- 230000004927 fusion Effects 0.000 description 2
- 229930195733 hydrocarbon Natural products 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- 150000007517 lewis acids Chemical class 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- YNPNZTXNASCQKK-UHFFFAOYSA-N phenanthrene Chemical compound C1=CC=C2C3=CC=CC=C3C=CC2=C1 YNPNZTXNASCQKK-UHFFFAOYSA-N 0.000 description 2
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 description 2
- BBEAQIROQSPTKN-UHFFFAOYSA-N pyrene Chemical compound C1=CC=C2C=CC3=CC=CC4=CC=C1C2=C43 BBEAQIROQSPTKN-UHFFFAOYSA-N 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 1
- GVEPBJHOBDJJJI-UHFFFAOYSA-N fluoranthrene Natural products C1=CC(C2=CC=CC=C22)=C3C2=CC=CC3=C1 GVEPBJHOBDJJJI-UHFFFAOYSA-N 0.000 description 1
- 239000002783 friction material Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 229910021397 glassy carbon Inorganic materials 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 239000000543 intermediate Substances 0.000 description 1
- 230000003137 locomotive effect Effects 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- 230000003204 osmotic effect Effects 0.000 description 1
- 125000005575 polycyclic aromatic hydrocarbon group Chemical group 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000000197 pyrolysis Methods 0.000 description 1
- 230000035484 reaction time Effects 0.000 description 1
- 229920003987 resole Polymers 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 229910021332 silicide Inorganic materials 0.000 description 1
- FVBUAEGBCNSCDD-UHFFFAOYSA-N silicide(4-) Chemical compound [Si-4] FVBUAEGBCNSCDD-UHFFFAOYSA-N 0.000 description 1
- 238000005475 siliconizing Methods 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 125000001424 substituent group Chemical group 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 238000007669 thermal treatment Methods 0.000 description 1
- 230000010415 tropism Effects 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
- C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
- C04B35/573—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide obtained by reaction sintering or recrystallisation
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/52—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
- F16D69/02—Composition of linings ; Methods of manufacturing
- F16D69/023—Composite materials containing carbon and carbon fibres or fibres made of carbonizable material
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/52—Constituents or additives characterised by their shapes
- C04B2235/5208—Fibers
- C04B2235/526—Fibers characterised by the length of the fibers
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/608—Green bodies or pre-forms with well-defined density
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/74—Physical characteristics
- C04B2235/77—Density
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D2200/00—Materials; Production methods therefor
- F16D2200/0034—Materials; Production methods therefor non-metallic
- F16D2200/0039—Ceramics
- F16D2200/0047—Ceramic composite, e.g. C/C composite infiltrated with Si or B, or ceramic matrix infiltrated with metal
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Braking Arrangements (AREA)
- Mechanical Operated Clutches (AREA)
Abstract
Carbon fibre-reinforced ceramic brake and clutch discs are manufactured by siliconising incompletely densified carbon-carbon fibre preforms produced by only a single liquid infiltration step. Such useof only a single step to densify the preform substantially reduces processing times and costs whilst yielding highly effective siliconised end products, which may optionally then be subjected to a further carbon impregnation step, e.g. by a single chemical vapour or liquid infiltration step, to optimise their structural and frictional properties, particularly in terms of stability at high temperatures.
Description
Technical field
The present invention relates to a kind of method of making brake and clutch disc, for example be used for automotive lannd-going machine or flyer, and relate to new brake and clutch disc that it obtains.Especially, the present invention relates to comprise the brake and the clutch disc of carbon fibre reinforced ceramics material, the acquisition mode that this brake and clutch disc are passable is: utilize liquid infiltration technology (liquid infiltration) to form carbon base body around enhanced carbon fiber, use molten silicon impregnated carbon matrix afterwards.
Background technology
The use of carbon fibre reinforced ceramics brake facing is subjected to extensive concern, especially the carbon-to-carbon fibre composite of silication, because they have high strength, under elevated operating temperature, can keep good physics and rubbing characteristics, and with tinsel weight/power ratio is lower mutually, for example reduce 50-60% with respect to the cast iron sheet weight of standard.The reduction of this weight is for improving performance and fuel economy is extremely important; By reducing the non-springload weight of vehicle, also can improve road holding, processing property and comfortableness.Motor vehicle can use the high friction materials of low weight from clutch disc too and be benefited.
The existing carbon silicide fiber reinforced ceramic brake facing that can buy mainly is " resin carbonation " method, in the method, but enhanced carbon fiber and carbide resin (for example pitch or resol) obtain desired shape by hot-moulded together, the molded prefabrication that is obtained carries out carbonization (for example being heated to 1000 ℃ Celsius in inert atmosphere or vacuum), and can select greying (for example, being heated to＞2000 ℃).The base substrate that is obtained can be shaped and/or link together subsequently, and can carry out siliconizing, for example immerse in fused silicon bathes to small part, perhaps hip treatment, in vacuum vessel, encapsulate, handle with waiting in the static pressure at high temperature afterwards with excess silicon.
The advantage of resin carbonation program is that operation is simple relatively, but also has a lot of shortcomings.Therefore, mould is filled with the fiber of random orientation usually, and mean length typically is less than 30mm, is more generally as to be less than 25mm.Fiber can be cut from the match rod-shaped material of the carbon fiber of pre-soaked resin, for example uses felted terxture, and wherein resin injects mould respectively.The random orientation of staple fibre preferably can limit the reproducibility of utilizing the product that the resin carbonation program obtained.
Another shortcoming is that resin may shrink, and carbon fiber is exposed to the outside in carbonization process.The integrity of these exposed fibers may be destroyed with pasc reaction in ensuing silicide step.Need use mould also make on the program restricted because any change of shape of product must cause expensive processing charges again.
In the prior art, can adopt chemical vapor infiltration to replace resin carbonation to form the carbon-to-carbon fibre composite, though be considered to usually for the special purposes carbon-to-carbon fiber composite brake facing of flyer for example, too complicated and expensive.The manufacturing of these brake facings generally includes and generates initial carbon fibre preform, and this prefabrication enters the chemical vapor infiltration step subsequently, for example adopts methane as the pyrolysis carbon source.Need a series of step, because deposit carbon stops up the aperture between the fortifying fibre easily, thus and the absorption of obstruction carbon.Usually after 10-14 days, occur initially saturated; At this moment, the density of prefabrication is approximately 1.4-1.5g/cm
3, and will not have enough intensity or integrity to be used as brake facing.Therefore, way is to remove the prefabrication of part densification from stove usually, and processes its surface to reopen the aperture that gets clogged, and continues chemical vapor infiltration afterwards.Usually need to also have a procedure of processing and the 3rd chemical vapor infiltration step at least, to obtain to have the about 1.8-1.9g/cm of density
3Brake facing; Treatment time is typically about 150 days altogether.U.S. Patent number 6,878,331 have proved that chemical vapor infiltration needs triplicate to five usually, to obtain required density.
The brake facing of Huo Deing does not have silication like this, and can be as the flyer brake.However, they are not suitable for ground vehicle, because its frictional behaviour at room temperature is relatively poor, can not be used to the slight brake that provides unexpected.
Up to now, even the brake facing that has had idea to think that chemical vapor infiltration produces will carry out silication subsequently, also need at least two chemical vapor infiltration steps.Therefore, U.S. Patent number 6,030 only uses chemical vapor infiltration one time if described each process in 913, at sedimentary high temperature carbon-coating tiny crack is arranged so, and has allowed the infiltration of undesired silicon in silicatization process.As seen, be quite expensive for the multistage infiltration that overcomes this problem.
Simultaneously, U.S. Patent number 6,110,535 have described a kind of technology that is used for the molten silicon composition is infiltrated the porous matrix of carbon composite, this porous matrix obtains by the compaction of utilizing chemical vapor infiltration, this is the first step of two-stage densification process normally, and then is the resin carbonation densification, thereby forms coke granule after chemical vapor infiltration in aperture.
Another approach that obtains the carbon-to-carbon fibre composite is that wetting monomer infiltration method (wetting monomerinfiltration) is as WO-A-9964361 and 6,756,112 descriptions of U.S. Patent number.In the method, carbon fibre preform is immersed in one or more liquid monomers, for example polycyclic aromatic hydrocarbons such as naphthalene, and preferably have for example Lewis acid (Lewis acid) of polymerizing catalyst.Be heated after the prefabrication behind the dipping, to promote monomeric polymerization, the polymer that is obtained further is heated carbonization subsequently.
Liquid monomer dipping, polymerization and carbonisation steps repeat several times usually, to obtain the densification of required degree.Therefore, four circulations were used for producing by a definite date the carbon-to-carbon fibre composite of the about 1.8g/cm of density in 4-5 days altogether; Typical density after first circulation is about 1.4g/cm.The product that is obtained it is said and is better than by scheduling to last individual month the resulting matrix material of multi-grade chemical gas-phase permeation technology of 6-8.
At our pct international patent application number: among the PCT/GB2006/002815, our beyond thought discovery has been described, only obtain not the prefabrication of densification fully through single chemical vapor infiltration step, this prefabrication carries out silication again, can obtain the brake of carbon-to-carbon fibre composite and the clutch-plate of efficient silication.Therefore, can reduce the treatment time of chemical vapor infiltration, for example reduce to 7 days from about 150 days or still less; This will reduce processing cost greatly, and make the manufacturing of brake and clutch-plate lower than the cost of resin carbonation processing.The reduction of cost makes product can buy from commercial, and is used for motor-driven ground vehicle, comprises racing car, motorcycle, lorry, truck, bus, passenger vehicle, military vehicle, locomotive engine, passenger train and railway freight-car.
Summary of the invention
The present invention is based on our discovery, after densified preform is not carried out preliminary densification through single liquid infiltration step (liquidinfiltration) fully, make this incomplete densified preform carry out silication, can obtain good product in very economical ground.
According to an aspect of the present invention, the manufacture method of a kind of carbon fibre reinforced ceramics brake or clutch disc is provided, comprise and make the carbon fibre preform that has corresponding to required brake facing shape, adopt carbon to make described prefabrication densification by a liquid infiltration step, by reacting the prefabrication silication that makes described densification with molten silicon.
Major advantage of the present invention is, by avoiding using mould, reduced the shape restriction of carbon fibre preform, can change as required, need not to process again, therefore makes the manufacture method can be general.
Equally, the length of carbon fiber without limits.Therefore, prefabrication preferably comprises long fiber, and for example mean length is 50mm at least, and preferably at least 75,100,125,150 or 250mm, because macrofiber has improved the intensity and the integrity of product.Do not wish to be subjected to the restriction of theoretical side, compare with the product that above-mentioned U.S. Patent number 6,030,913 described single-stage chemical vapor infiltrations produce, long stapled have to be beneficial to guarantee that product keeps not having textural defect, for example tiny crack.
Preferably, enhanced carbon fiber is a successive, and promptly average fiber length equals or exceeds the outer edge of brake facing and the radial distance between the inner boundary.A kind of simple manufacture method of successive fibre preforms product is from the continuous of carbon fibre fabric or volume cutting, for example to comprise the fabric or the non-woven felt of the cross-level of different angles (for example 0 ° and 90 °).Liquid infiltration can utilize wetting monomer infiltration to realize, as above-mentioned WO-A-9964361 and U.S. Patent number 6,756,112, at this as a reference.
Wetting monomer comprises furfural and polynuclear aromatics, for example contains common 2-4 condensed phenyl ring, and wherein a part of phenyl ring can be hydrogenated, and can be loaded with one or more ring substituents, for example C1-4 groups (for example methyl or ethyl).The exemplary of these hydrocarbon polymers comprises naphthalene, methylnaphthalene, tetraline, phenanthrene, anthracene and pyrene; The use of naphthalene is more favourable, handled easily, and cost is relatively low.Preferably, have the monomer of relatively low fluxing point, for example be no more than 225 ℃, preferably be no more than 175 ℃, the convenient processing is with the dipping prefabrication.The use of partially hydrogenated hydrocarbon polymer (being liquid when room temperature), for example 1,2,3,4-tetralin is more favourable equally.
The realization of dipping can be by making prefabrication dipping or be immersed in liquid state (the comprising fusion) monomer, enters in the prefabrication by kapillary up to the monomer of aequum.Dipping time is 2-10 hour, and for example 1-5 hour, this depended on some factors, for example the size of prefabrication, monomeric characteristic and temperature.
Flood monomeric polymerization and can realize that for example temperature is at 300-500 ℃ by heating; Reaction times is approximately 2-6 hour, for example 4 hours.By further heating carbonization, for example Heating temperature is at 700-1400 ℃ subsequently for the polymeric matrix that is obtained, and the time is 6-24 hour, for example 10-18 hour.Wetting monomer infiltration process promptly comprises dipping, polymerization and carburising step, about 12-36 of treatment time altogether hour, preferred 20-30 hour, more preferably from about 24 hours.
As selection, prefabrication can preferably have lower molecular weight and (for example be less than 5 directly with liquid (comprising fused) polymkeric substance or resin impregnation, 000, preferably be less than 3,000 or 2,500), and corresponding lower viscosity, pass through as above-mentioned heating carbonization after this.
The density of prefabrication is generally 0.9-1.4g/cm after liquid infiltration and carbonization
3
If desired, the prefabrication of part densification can be before silication greying, for example by 2000 ℃ or more than, for example 2400 ℃, and in non-oxygenated environment, for example at rare gas element for example in argon gas or the vacuum, for example about 96 hours of thermal treatment under top temperature.
Silication can prior art in any appropriate form realize.For the ease of operating, preferably have to immerse and handle or the hot isotatic pressing processing, in described immersion was handled, the prefabrication of part greying, part densification immersed in the molten silicon bath at least in part.The density of silication product can be 1.9-2.4g/cm
3, for example about 2.0g/cm
3
Product can be processed into required last size before or after silication.Preferably before silication, process, because the intermediates hardness of pre-silication is less, than the easier processing of the finished product after the silication.
If desired, the product after the silication can be once more through a carbon impregnation step.This processing will help strengthening the life-span and the performance of flyer brake facing, for example antiwear characteristic and frictional behaviour.This flyer brake facing can reach very high working temperature when landing, surpass the fusing point (1410 ℃) of silicon sometimes.In this case, the free silica in the carbon-to-carbon fibre composite sheet of silication may be in the surf zone fusion, and wherein silicon may react and form silicon carbide or be frozen into thin slice.The possibility of front can cause the wearing and tearing of the braking components that cooperates to increase, and this is because the higher abrasive characteristic of silicon carbide, and the latter jeopardizes the security of brake facing rubbing characteristics simultaneously.
Infiltration can be eliminated this problem according to carbon according to the present invention, by with residual free pasc reaction and/or the free silicon of covering, perhaps in the brake facing structure, retained carbon, when brake facing during above the fusing point of silicon, carbon and free silica react with in use.Equally also can adopt control carbon/silicon and carbon/silicon carbide ratio, to obtain the optimum balance of hardness, wear resistance and abrasive characteristic.
This carbon infiltration preferably realizes by single-stage, by chemical gas phase mentioned above or liquid infiltration.
Brake of carbon fibre reinforced ceramics that the method according to this invention obtained and clutch disc are new and useful product.The product of handling acquisition with traditional resin carbonation is different, and the carbon base body of product of the present invention shows very high tackiness for increasing fiber.Therefore, these fibers are protected, and avoid in silicatization process and pasc reaction, and compared with prior art, the intensity and the integrity of this product are improved.
In through the silication sheet after the last carburizing treatment, because this osmotic treated, any contents of free si is locked in the brake facing effectively, and this can be when working temperature surpasses the fusing point of silicon, and restriction silicon moves to the brake facing surface.
Provide a kind of brake of carbon-to-carbon fibre composite or clutch disc of silication according to another characteristic of the invention, it is characterized in that containing carburizing, these carbon cover on the silicon composition.
The carbon base body of resin carbonation product mainly comprises amorphous glassy carbon in the prior art, and the matrix carbon content of product of the present invention is relatively regular, is generally with the thin slice tropism, coarse or smooth sheet form.This makes that during silication more all even in check with the reaction of silicon, more all even reproducible product is made in permission.
Claims (20)
1. the manufacture method of carbon fibre reinforced ceramics brake or clutch disc, it is characterized in that, comprise: make the carbon fibre preform that has corresponding to required brake or clutch disc shape, adopt carbon, make described prefabrication densification, by reacting the prefabrication silication that makes described densification with molten silicon by single-stage liquid infiltration step.
2. method according to claim 1 is characterized in that: the mean length of the described carbon fiber in the described prefabrication is 50mm at least.
3. method according to claim 1 is characterized in that: the mean length of the described carbon fiber in the described prefabrication equals or exceeds the outward flange of described brake or clutch disc and the radial distance between the preglabellar field.
4. according to any described method of claim 1 to 3, it is characterized in that: described prefabrication cuts and gets from the serialgram or the volume of carbon fibre fabric.
5. method according to claim 4 is characterized in that: described serialgram is the non-woven felt.
6. according to any described method of claim 1 to 5, it is characterized in that: initial prefabrication density is 0.3-0.6g/cm
3
7. according to any described method of claim 1 to 6, it is characterized in that: the density of the prefabrication after the densification is 0.9-1.4g/cm
3
8. according to any described method of claim 1 to 7, it is characterized in that: described prefabrication amounts to maximum 12-36 hours densification by single wetting monomer infiltration step.
9. method according to claim 8 is characterized in that: the treatment time of described impregnation step amounts to 24 hours.
10. according to any described method of claim 1 to 9, it is characterized in that: before reacting with molten silicon, the prefabrication after the densification is machined to the size of required brake or clutch disc.
11. according to any described method of claim 1 to 10, it is characterized in that: carry out in the following way: the prefabrication after the densification is immersed in the molten silicon bath at least in part with the reaction of molten silicon, perhaps under high temperature and static pressure such as grade, in vacuum vessel, encapsulate with excessive silicon.
12. according to any described method of claim 1 to 11, it is characterized in that: the density of the prefabrication after the silication densification is 1.9-2.4g/cm
3
13. according to any described method of claim 1 to 12, it is characterized in that: the prefabrication after the silication densification is machined to the size of required brake or clutch disc.
14. according to any described method of claim 1 to 13, it is characterized in that: the prefabrication after the silication densification is again through a carburization step.
15. method according to claim 14 is characterized in that: described carburization step is single-stage chemical gas phase or liquid infiltration.
16. method according to claim 15 is characterized in that: the described chemical vapor infiltration treatment time amounts to 7-14 days.
17. method according to claim 15 is characterized in that: described liquid infiltration is wetting monomer infiltration, and this wetting monomer infiltration treatment time amounts to 12-36 hour.
18. method according to claim 17 is characterized in that: the described wetting monomer infiltration treatment time amounts to about 24 hours.
19. a carbon fibre reinforced ceramics brakes or clutch disc, it is characterized in that: obtain by any described method of claim 1 to 18.
20. brake of the carbon-to-carbon fibre composite of a silication or clutch disc, it is characterized in that: contain carburizing, this carbon covers on the silicon composition.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0701849.2 | 2007-01-31 | ||
| GBGB0701849.2A GB0701849D0 (en) | 2007-01-31 | 2007-01-31 | Improvements in or relating to brake and clutch discs |
| PCT/GB2008/000308 WO2008093078A1 (en) | 2007-01-31 | 2008-01-31 | Improvements in or relating to brake and clutch discs |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN101688007A true CN101688007A (en) | 2010-03-31 |
Family
ID=37891046
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN200880010466A Pending CN101688007A (en) | 2007-01-31 | 2008-01-31 | Improvements in or relating to brake and clutch discs |
Country Status (5)
| Country | Link |
|---|---|
| EP (1) | EP2109636A1 (en) |
| JP (1) | JP2010516617A (en) |
| CN (1) | CN101688007A (en) |
| GB (1) | GB0701849D0 (en) |
| WO (1) | WO2008093078A1 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2013171770A1 (en) * | 2012-05-16 | 2013-11-21 | Petroceramics S.P.A. | Shaped composite material |
| EP3000797B1 (en) | 2014-09-24 | 2019-11-27 | Rolls-Royce Corporation | Method for making ceramic matrix composite articles using gelling |
| US10017426B2 (en) | 2016-04-01 | 2018-07-10 | Honeywell International Inc. | High density carbon-carbon friction materials |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE19749462C1 (en) * | 1997-11-10 | 1999-03-04 | Deutsch Zentr Luft & Raumfahrt | Moulded body reinforced with carbon fibres |
| US6309703B1 (en) * | 1998-06-08 | 2001-10-30 | The United States Of America As Represented By The Secretary Of The Air Force | Carbon and ceramic matrix composites fabricated by a rapid low-cost process incorporating in-situ polymerization of wetting monomers |
| DE10225954A1 (en) | 2002-06-11 | 2003-12-24 | Schunk Kohlenstofftechnik Gmbh | Fiber composite component |
| JP4297138B2 (en) * | 2005-07-05 | 2009-07-15 | 三菱樹脂株式会社 | Carbon fiber reinforced SiC composite and sliding material |
| GB2428671B (en) * | 2005-07-29 | 2011-08-31 | Surface Transforms Plc | Method for the manufacture of carbon fibre-reinforced ceramic brake or clutch disks |
-
2007
- 2007-01-31 GB GBGB0701849.2A patent/GB0701849D0/en not_active Ceased
-
2008
- 2008-01-31 JP JP2009547753A patent/JP2010516617A/en active Pending
- 2008-01-31 EP EP08701978A patent/EP2109636A1/en not_active Withdrawn
- 2008-01-31 WO PCT/GB2008/000308 patent/WO2008093078A1/en active Application Filing
- 2008-01-31 CN CN200880010466A patent/CN101688007A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| WO2008093078A1 (en) | 2008-08-07 |
| JP2010516617A (en) | 2010-05-20 |
| EP2109636A1 (en) | 2009-10-21 |
| GB0701849D0 (en) | 2007-03-14 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| EP1910247B1 (en) | Improvements in or relating to brake and clutch discs | |
| US7067077B2 (en) | Process for manufacturing friction material suitable for use as brake lining | |
| KR100512307B1 (en) | Friction element in composite carbon/carbon-silicon carbide material and method for manufacturing same | |
| RU2184715C2 (en) | Fiber-reinforced composite ceramic material and its manufacturing process | |
| US6231791B1 (en) | Silicon carbide articles reinforced with short graphite fibers | |
| US7575799B2 (en) | Carbon fiber containing ceramic particles | |
| CN101687715B (en) | Improvements in brake and clutch discs | |
| EP1763644A1 (en) | Method for producing carbon-carbon brake material with improved initial friction coefficient or "bite" | |
| EP1124074B1 (en) | A shaped composite material for breaking applications and a method for the preparation thereof | |
| US8349231B2 (en) | Shaped composite material | |
| JP2004533388A (en) | Wear-resistant carbon brake material | |
| CN106699210A (en) | Carbon-ceramic brake part and preparation method thereof | |
| CN101688007A (en) | Improvements in or relating to brake and clutch discs | |
| GB2475233A (en) | Process for forming carbon fibre reinforced ceramic composite | |
| JP2792180B2 (en) | brake |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C06 | Publication | ||
| PB01 | Publication | ||
| C10 | Entry into substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| C02 | Deemed withdrawal of patent application after publication (patent law 2001) | ||
| WD01 | Invention patent application deemed withdrawn after publication |
Open date: 20100331 |