CN107850155A - 成型材料和制造方法 - Google Patents

成型材料和制造方法 Download PDF

Info

Publication number
CN107850155A
CN107850155A CN201680042784.1A CN201680042784A CN107850155A CN 107850155 A CN107850155 A CN 107850155A CN 201680042784 A CN201680042784 A CN 201680042784A CN 107850155 A CN107850155 A CN 107850155A
Authority
CN
China
Prior art keywords
moulding material
carbon fiber
product
impregnating agent
fabric
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.)
Granted
Application number
CN201680042784.1A
Other languages
English (en)
Other versions
CN107850155B (zh
Inventor
奥马尔·奇维迪尼
洛伦佐·米廖利
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Lembao Public Ltd
Original Assignee
Freni Brembo SpA
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=54289025&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=CN107850155(A) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Freni Brembo SpA filed Critical Freni Brembo SpA
Publication of CN107850155A publication Critical patent/CN107850155A/zh
Application granted granted Critical
Publication of CN107850155B publication Critical patent/CN107850155B/zh
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • 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
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D65/12—Discs; Drums for disc brakes
    • F16D65/125—Discs; Drums for disc brakes characterised by the material used for the disc body
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/653—Processes involving a melting step
    • C04B35/657—Processes involving a melting step for manufacturing refractories
    • 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
    • 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
    • C04B35/83—Carbon fibres in a carbon matrix
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2475/00—Frictional elements
    • 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
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/38—Non-oxide ceramic constituents or additives
    • C04B2235/3817—Carbides
    • C04B2235/3826—Silicon carbides
    • 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
    • C04B2235/5216—Inorganic
    • C04B2235/524—Non-oxidic, e.g. borides, carbides, silicides or nitrides
    • C04B2235/5248—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
    • 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
    • C04B2235/5268—Orientation 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
    • C04B2235/616—Liquid infiltration of green bodies or pre-forms
    • 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
    • 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
    • C04B2235/95—Products characterised by their size, e.g. microceramics
    • 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
    • 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
    • F16D2200/0052—Carbon
    • 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
    • F16D2200/006—Materials; Production methods therefor containing fibres or particles
    • 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
    • F16D2200/0082—Production methods therefor
    • 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
    • F16D2200/0082—Production methods therefor
    • F16D2200/0086—Moulding materials together by application of heat and pressure
    • 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
    • F16D2200/0082—Production methods therefor
    • F16D2200/0091—Impregnating a mat of fibres with a binder
    • 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
    • F16D2250/00—Manufacturing; Assembly
    • F16D2250/0038—Surface treatment
    • F16D2250/0053—Hardening

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Composite Materials (AREA)
  • Braking Arrangements (AREA)
  • Ceramic Products (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

一种成型材料(1、1')，例如用于盘式制动器的盘，优选地为通风盘，该成型材料包括沿着发展轴线(X)重叠的处于螺旋形状的多个材料层(6)，其中每个材料层(6)通过主要地或唯一地由碳纤维(8)制成的织物(2)形成，所述层的至少一部分由浸渍剂浸渍。本发明还涉及用于制造该成型材料的方法。

Description

成型材料和制造方法
技术领域
本发明涉及成型材料和用于生产该成型材料例如盘式制动器盘的制造方法。
背景技术
使用以碳基材料(所谓的碳碳或“C/C”)制成的用于盘式制动器的盘早就为人所知。
这些盘是通过下述过程获得的：提供重叠的织物层、合适的树脂添加物并且随后提供适当的热处理，该热处理导致热导率和碳的致密化处理增加。
该过程可以例如通过CVD(化学气相沉积)、CVI(化学气相渗透)或LPI(液态聚合物渗透)来执行。
在一些应用中，这些材料可以用于在高温下充当摩擦元件，这种情况不适用于标准道路应用，而是适用于高档应用。
传统上，对于C/C盘式制动器盘的生产，由于在相关的层状结构内部形成的特殊架构，因此盘中存在因具有低的抗弯曲性而对结构水平至关重要的区域。
因此可见，在这些区域的对应处可能产生裂缝或断裂，从性能的角度来看，对于用于极为过度的制动应用如运动跑车的情况下或甚至在其他以高速行进的运输工具的情况下的某些高使用水平(use bands)而言，该裂缝或断裂是不可接受的。
发明内容
本发明关于前述内容提出提供一种能够不仅是由于在材料内部发展(develops)的连续的层状结构而显著减少盘式制动器中断裂的可能性的成型材料和方法。
该目的通过根据权利要求13所述的成型材料并且通过根据权利要求1所述的方法来实现。引用这些权利要求的权利要求示出了优选的实施方案。
附图说明
现在将借助于附图详细地描述本发明的目的，在附图中：
-图1是根据可能的实施方案的本发明的成型材料的制作步骤的立体图；
-图2a和图2b表示根据本发明可实现的用于盘式制动器的盘，根据可能的变体，图2a的盘是通风型的。
具体实施方式
上述目的通过用于生产成型材料1、1'的制造方法来实现，该方法包括以下步骤：
i)提供主要地或唯一地由碳纤维8制成的织物2，该织物围绕发展轴线X特别是围绕螺旋发展轴线X(如图1中所示)以螺旋形状制造；
ii)轴向地重叠所述织物2的圈状物4，以便形成多个材料层6；
iii)可选地撑起(needling)——例如使用成型的撑木(needles)——步骤ii)的圈状物4，以便将碳纤维或这种纤维的前体变换成材料层6的厚度；
iv)通过浸渍剂优选地通过酚醛树脂浸渍步骤ii)或步骤iii)的材料层6的至少一部分；
v)使步骤iii)或iv)的产物致密化至期望的密度范围以获得成型材料1、1'。例如，期望的密度范围可以是约1.3-1.45g/cm3。
在本说明书中，除非另有说明，否则术语“径向”、“轴向”、“角”和“圆周”将始终相对于发展轴线X来理解。
根据示出的实施方案，发展轴线X基本上是直线。
关于表述“螺旋”，在本说明书中，该术语基本上意指以三维弯曲的形式制造的织物2在其平行于轴线X移动时以优选恒定的距离或连续可变的距离围绕该发展轴线X发展。
换句话说，术语“螺旋”是指基本上以螺旋结构的形式制造的织物，该织物围绕发展轴线X进行缠绕。
由此可见，根据一实施方案，以丝带或条带的形式制造织物2，该丝带或条带围绕发展轴线X以曲线方式(可选地以环状方式)延伸。
根据另一变体，在步骤ii)中，材料层6将具有布置在与发展轴线X基本上正交的平面中的相应的层表面，有利的是平面表面。特别地，这种表面面向彼此以实现至少部分的相互抵接。
根据特别有利的实施方案，该过程特别适用于生产用于优选具有通风型的盘式制动器的盘。
仅举例来说，碳纤维的至少一部分(优选地为所有这种纤维)从氧化聚丙烯腈纤维中获得。例如，但非必须，这种纤维可以由SGL Carbon SE公司以商标名进行生产。
根据优选的变体，成型材料1包括含碳基质(即，由至少50％的碳构成)，碳纤维8的至少一部分至少部分地嵌入在该成型材料中。
根据优选实施方案，步骤i)包括至少下述步骤：将碳纤维8织造成通过多个圈状物4以基本上连续的方式发展的经纱和纬纱织物2。
更确切地，织物2的经纱将围绕穿过圈状物的轴线X以螺旋或螺旋结构的形式发展，而纬纱将相对于所述轴线X以基本上或大体上径向的方式进行定向。
根据第一变体，步骤i)包括提供至少部分(例如完全)碳化的碳纤维8的步骤。
根据第二变体，步骤i)包括提供处于聚合状态的碳纤维8的步骤。根据该变体，在步骤ii)之后，该方法优选地包括在例如约1500-1900℃，优选约1700℃的温度下使材料层6的碳纤维8碳化的步骤。
可选地，步骤iv)可以至少部分地与步骤ii)同时进行，并且可以包括下述子步骤：将浸渍剂分布在圈状物4之间分以便将浸渍剂放置在材料层6之间。
根据各种实施方案，浸渍剂可以处于固体颗粒的形式(例如粉末)、膜或条带的形式(可选地具有螺旋/螺旋结构的几何形状)或液态形式。
根据有利的变体，该过程至少包括下述步骤：对应于步骤v)或在步骤v)之后使浸渍剂硬化。
根据另一有利的变体，步骤iv)可以至少部分地与步骤v)同时进行，并且可以包括下述子步骤：
a)在真空下加热步骤ii)或iii)的产物；
b)将浸渍剂以流体形式特别是以液体形式注入到子步骤a)的产物中；
c)使子步骤b)的产物中的浸渍剂硬化，优选地用热的方法。
从技术角度来看，该实施方案被认为是最好的之一——在面对较高的总体生产成本时——该实施方案允许获得具有复杂几何形状和严格的尺寸公差的高强度材料。
根据可单独或共同实施的其他实施方案，该过程可以包括选自下述项中的一个或多个步骤：
vi)在例如约800-1000℃的温度下使步骤v)或子步骤c)的产物热解；
vii)例如为了获得步骤v)、步骤vi)或子步骤c)的产物内部用于其相关安装所需的结构，机械地加工该产物；
viii)用硅渗透步骤v)、步骤vi)、步骤vii)或子步骤c)的产物，使得碳纤维8的一部分碳C和/或所述材料1的含碳基质通过与所渗透的硅Si的一部分反应来形成碳化硅SiC；
ix)可选地用抗氧化剂研磨和/或处理步骤vi)至viii)的产物中的至少一种。
优选地，在步骤v)之前，该过程包括下述步骤：在弱加热的情况下，例如在70-100℃的范围内的一温度下，通过真空袋压缩步骤ii)、步骤iii)或步骤iv)的材料层6。
根据另外的实施方案，步骤v)可以包括至少下述步骤：通过CVD(化学气相沉积)热压和/或致密化步骤iv)的产物。
上述目的也通过成型材料1、1'例如用于盘式制动器的盘来实现，如下所述。
根据可能的实施方案，这种盘式制动器盘可以具有通风型或非通风型。
由于该材料优选地通过前述过程获得，即使没有明确说明，以制造步骤的观点来看，这种材料的优选或辅助变体可以包括能够从上述描述中推导甚至仅是隐含的任何特性。
成型材料1、1'包括沿着发展轴线X重叠的处于螺旋形状的多个材料层6(根据之前提供的定义)，其中每个材料层6通过主要地或唯一地由碳纤维8制成的织物2形成。这些层中的至少一部分由浸渍剂优选地由酚醛树脂浸渍。
例如如图2中所示，发展轴线X(或螺旋发展轴线X)在其使用期间可以被定向成平行于成型材料1、1'或盘式制动器盘的旋转轴线R。
根据优选的变体，织物2具有通过多个材料层6以基本上连续的方式发展的经纱和纬纱构造。
优选地，使碳纤维8的至少一部分(例如全部)碳化。
根据另一有利的变体，该材料1、1'可以包括通过碳纤维8的一部分碳C与渗透在所述材料1、1'中的硅Si的至少一部分反应而获得的碳化硅SiC的区域。优选地，这种碳化硅区域以桥接的方式布置在相邻的材料层6之间，特别是将材料层固定并将材料层粘合在一起。
根据也可分开实施的各种实施方案，圈状物4的内径可以等于或大于约100毫米(例如≥150毫米)，和/或材料层6在径向方向上的宽度可以在10-280毫米的范围内。
有利地，该成型材料1、1'的特征在于其具有小于5％、例如等于或小于3％的残余孔隙度。具体而言，可以在用硅进行渗透的步骤viii)结束时评估该孔隙度。
根据可能的实施方案，成型材料1、1'中的材料层6的数量可以在18-26的范围内，可选地在20-24的范围内。
根据第一变体，沿着发展轴线X，成型材料可以具有约25-35毫米的厚度。例如，具有这种厚度的成型材料可以是或包括通风型的盘式制动器。
根据第二变体，沿着发展轴线X，成型材料可以具有例如包含在5-10毫米的范围内的约10毫米的最大厚度。例如，具有该厚度的成型材料可以是或包括非通风型的盘式制动器。
创新地，本发明的成型材料和方法允许很好地解决现有技术的缺点。
更确切地，前面讨论的连续结构允许减少——或者甚至消除——已知成型材料的低阻力弱点，同时保持碳纤维的基本上圆形的布置。
有利地，本发明的方法和成型材料可以在任何现存的生产线中以非常简单的方式实施，尤其是凭借其构造的简单性。
有利地，本发明的方法和成型材料凭借下述事实允许实现大幅节省制造费用：相对于通常设置的那些，具体的处理不需要补充的或附加的设备。
有利地，本发明的方法和成型材料允许控制待成型材料的实现成本和时间，尤其是在制造的早期阶段。
有利地，本发明的方法和成型材料允许消除额外的切割步骤以及为了实现成型材料而将不同尺寸的圆形部段进行重叠的需求。
有利地，本发明的方法和成型材料允许避免在制造期间过度压缩的步骤，因为圈状物之间的重叠因织物自身的性质和布置的原因自发地提供基本上平坦的表面，该平坦的表面在成型材料的使用中是有利的且期望得到的。
对于上述方法和成型材料的实施方案，为了满足特定需要，本领域技术人员可以用其他功能上的等同物对元件进行变型或替换。
甚至这些变体都包括在由所附权利要求限定的保护范围内。
此外，所描述的属于可能的实施方案的每个变体均可以独立于所描述的其他变体来实现。

Claims (18)

1.一种用于生产成型材料(1、1')例如用于盘式制动器的盘且优选为通风盘的方法，包括下述步骤：
i)提供主要地或唯一地由碳纤维(8)制成的织物(2)，所述织物围绕发展轴线(X)以螺旋形状制造；
ii)轴向地重叠所述织物(2)的圈状物(4)，以便形成多个材料层(6)；
iii)可选地撑起步骤ii)的所述圈状物(4)，以便将所述碳纤维或这种纤维的前体变换成所述材料层(6)的厚度；
iv)通过浸渍剂例如酚醛树脂浸渍步骤ii)或步骤iii)的材料层(6)的至少一部分；
v)使步骤iii)或iv)的产物致密化至期望的密度范围以获得所述成型材料(1、1')。
2.根据权利要求1所述的方法，其中，步骤i)包括至少下述步骤：将所述碳纤维(8)织造成通过多个所述圈状物(4)以基本上连续的方式发展的经纱和纬纱织物(2)，其中，所述织物(2)的经纱通过所述圈状物围绕所述轴线(X)发展，而所述纬纱相对于所述轴线(X)以基本上径向的方式进行定向。
3.根据前述权利要求中任一项所述的方法，其中，以丝带的形式制造所述织物(2)，所述丝带围绕所述发展轴线(X)以曲线形式延伸。
4.根据权利要求1或2所述的方法，其中，步骤i)包括提供处于聚合状态的碳纤维(8)的步骤，并且其中，在步骤ii)之后，所述方法包括在例如约1500-1900℃的温度下使所述材料层(6)的所述碳纤维(8)碳化的步骤。
5.根据前述权利要求中任一项所述的方法，其中，步骤iv)至少部分地与步骤ii)同时进行，并且包括下述子步骤：将所述浸渍剂分布在所述圈状物(4)之间，以便将所述浸渍剂放置在所述材料层(6)之间。
6.根据前述权利要求中任一项所述的方法，包括至少下述步骤：对应于步骤v)或在步骤v)之后使所述浸渍剂硬化。
7.根据权利要求1至4中任一项所述的方法，其中，步骤iv)至少部分地与步骤v)同时进行，并且包括下述子步骤：
a)在真空下加热步骤ii)或iii)的所述产物；
b)将所述浸渍剂以液态形式注入到子步骤a)的所述产物中；
c)使子步骤b)的所述产物中的所述浸渍剂硬化。
8.根据权利要求6或7所述的方法，包括选自下述项中的一个或多个步骤：
vi)在例如约800-1000℃的温度下使步骤v)或子步骤c)的所述产物热解；
vii)机械地加工步骤v)、步骤vi)或子步骤c)的所述产物；
viii)用硅渗透步骤v)、步骤vi)、步骤vii)或子步骤c)的所述产物，使得所述碳纤维(8)的一部分碳(C)和/或所述材料(1)的含碳基质通过与所渗透的硅(Si)的一部分反应来形成碳化硅(SiC)；
ix)可选地用抗氧化剂研磨和/或处理步骤vi)至viii)的的所述产物中的至少一种。
9.根据前述权利要求中任一项所述的方法，其中，所述浸渍剂处于固体粒状的形式、可选地为螺旋状的膜或条带的形式或液态形式。
10.根据前述权利要求中任一项所述的方法，包括在步骤v)之前的下述步骤：在弱加热的情况下，例如在70-100℃的范围内的一温度下，通过真空袋压缩步骤ii)、步骤iii)或步骤iv)的所述材料层(6)。
11.根据前述权利要求中任一项所述的方法，其中，步骤v)包括至少下述步骤：通过CVD(化学气相沉积)热压和/或致密化步骤iv)的所述产物。
12.根据前述权利要求中任一项所述的方法，其中，期望的密度范围是约1.3g/cm3至1.45g/cm3。
13.一种成型材料(1、1')，例如用于盘式制动器的盘，优选地为通风盘，所述成型材料包括沿着发展轴线(X)重叠的处于螺旋形状的多个材料层(6)，其中，每个材料层(6)通过主要地或唯一地由碳纤维(8)制成的织物(2)形成，所述层的至少一部分由浸渍剂浸渍。
14.根据前述权利要求所述的成型材料，其中，所述织物(2)具有通过所述多个材料层(6)以基本上连续的方式发展的经纱和纬纱构造。
15.根据权利要求13至14中任一项所述的成型材料，其中，所述碳纤维(8)的至少一部分被碳化。
16.根据权利要求13至15中任一项所述的成型材料，其中，所述发展轴线(X)在其使用期间被定向成平行于所述成型材料(1、1')或用于盘式制动器的盘的旋转轴线(R)。
17.根据权利要求13至16中任一项所述的成型材料，包括通过所述碳纤维(8)的一部分碳(C)与渗透在所述材料(1、1')中的硅(Si)的至少一部分反应而获得的碳化硅(SiC)的区域，所述碳化硅的区域被布置成桥接在相邻的材料层(6)之间。
18.根据权利要求13至17中任一项所述的成型材料，其中，所述圈状物(4)的内径等于或大于约100毫米，并且其中所述材料层(6)在径向方向上的宽度在10-280毫米的范围内。
CN201680042784.1A 2015-07-22 2016-07-22 成型材料和制造方法 Active CN107850155B (zh)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
IT102015000036808 2015-07-22
ITUB2015A002386A ITUB20152386A1 (it) 2015-07-22 2015-07-22 Materiale sagomato e procedimento di fabbricazione
PCT/IB2016/054376 WO2017013626A1 (en) 2015-07-22 2016-07-22 Shaped material and manufacturing method

Publications (2)

Publication Number Publication Date
CN107850155A true CN107850155A (zh) 2018-03-27
CN107850155B CN107850155B (zh) 2021-06-25

Family

ID=54289025

Family Applications (1)

Application Number Title Priority Date Filing Date
CN201680042784.1A Active CN107850155B (zh) 2015-07-22 2016-07-22 成型材料和制造方法

Country Status (6)

Country Link
US (1) US11649865B2 (zh)
EP (1) EP3325839B1 (zh)
CN (1) CN107850155B (zh)
IT (1) ITUB20152386A1 (zh)
SI (1) SI3325839T1 (zh)
WO (1) WO2017013626A1 (zh)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102018216268A1 (de) * 2017-09-29 2019-04-04 Robert Bosch Gmbh Additiv hergestellte bremsklotzanordnung mit gesteuertem kompressibilitätsfaktor
CN113321208B (zh) * 2021-07-06 2023-08-04 山东热坤新材料有限公司 一种高致密性石墨烯膜的制备方法

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4955123A (en) * 1986-01-28 1990-09-11 Lawton Peter G Production of a shaped filamentary structure
WO2003033930A1 (fr) * 2001-10-15 2003-04-24 Daihatsu Motor Co., Ltd. Corps rotatif de frein pour vehicule
US6767602B1 (en) * 1996-09-30 2004-07-27 Messier-Bugatti Preparation of textile preforms for brake discs in composite material
US20060151912A1 (en) * 2005-01-11 2006-07-13 Dieter Bauer Carbon/ceramic matrix composites and method of making same
DE102012021772A1 (de) * 2012-11-08 2014-05-08 Alfred Buck Kohlefaser-Bremseinheit, Verfahren zu dessen Herstellung und Verwendung
EP2781784A1 (en) * 2013-03-21 2014-09-24 Brembo SGL Carbon Ceramic Brakes GmbH Carbon fibre reinforced brake discs
CN104507676A (zh) * 2012-05-16 2015-04-08 派特欧赛拉米克斯股份公司 成形复合材料

Family Cites Families (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3712428A (en) 1970-06-22 1973-01-23 Carborundum Co Reinforced carbon bodies
FR2490687A1 (fr) 1980-09-24 1982-03-26 Coisne Lambert Ets Tissu de forme speciale, procede et machine a tisser un tel tissu
FR2553485B1 (fr) 1983-10-17 1989-05-05 Goodrich Co B F Disque de frein ou d'embrayage poreux reutilisable en composite carbone et procede de fabrication
US4813126A (en) 1986-10-01 1989-03-21 Williamson Windings Inc. Apparatus and method for fabricating magnetic devices
FR2643656B1 (fr) 1989-02-27 1992-02-14 Brochier Sa Structure textile en forme de spirale, procede d'obtention et machine a tisser correspondante
US5080851A (en) * 1990-09-06 1992-01-14 United Technologies Corporation Method for stabilizing complex composite preforms
FR2669940B1 (fr) 1990-12-03 1994-10-21 Europ Propulsion Fil forme a partir de fibres refractaires ou de leurs precurseurs et son application a la fabrication de pieces en materiau composite.
US5217770A (en) 1991-08-15 1993-06-08 The B. F. Goodrich Company Braided shaped filamentary structures and methods of making
US5662855A (en) 1994-05-17 1997-09-02 The B.F. Goodrich Company Method of making near net shaped fibrous structures
US5546880A (en) 1994-12-29 1996-08-20 The Bf Goodrich Company Annular filamentary structures and methods of making
FR2741634B1 (fr) * 1995-11-27 1998-04-17 Europ Propulsion Procede pour la realisation de preformes fibreuses destinees a la fabrication de pieces annulaires en materiau composite
FR2754813B1 (fr) 1996-10-18 1999-01-15 Europ Propulsion Densification de substrats poreux disposes en piles annulaires par infiltration chimique en phase vapeur a gradient de temperature
DE19711829C1 (de) 1997-03-21 1998-09-03 Daimler Benz Ag Verfahren zur Herstellung einer faserverstärkten Verbundkeramik
US6248417B1 (en) 1997-09-08 2001-06-19 Cytec Technology Corp. Needled near netshape carbon preforms having polar woven substrates and methods of producing same
US6325608B1 (en) * 1999-05-17 2001-12-04 North Carolina A&T State University Apparatus and method for forming densified, carbon-carbon composites
WO2002055773A1 (en) 2001-01-12 2002-07-18 Sumitomo Electric Industries, Ltd. Spiral woven fabric and high-speed rotating body using it
EP1342553B1 (de) 2002-03-08 2016-05-18 Airbus Operations GmbH Verfahren zum Herstellen eines Fensterrahmens für Flugzeuge aus faserverstärktem Kunststoff und Vorrichtung zur Durchführung des Verfahrens
DE10233729B4 (de) 2002-07-24 2006-01-26 Sgl Carbon Ag Faserverstärkte keramische Bremsbeläge
US6878331B2 (en) * 2002-12-03 2005-04-12 Ucar Carbon Company Inc. Manufacture of carbon composites by hot pressing
WO2006127002A1 (en) 2005-05-25 2006-11-30 Honeywell International Inc. Manufacture of thick preform composites via multiple pre-shaped fabric mat layers
GB2426756A (en) 2005-06-03 2006-12-06 Huntercombe Consultancy Ltd Porous body containing within its pores a chemically bonded phosphate ceramic
GB2444927A (en) 2006-12-22 2008-06-25 Huntercombe Consultancy Ltd A ventilated brake disc
EP2472136B1 (en) 2010-12-30 2015-05-27 Brembo SGL Carbon Ceramic Brakes GmbH Carbon ceramic friction disks and process for their preparation
WO2015084556A1 (en) 2013-11-12 2015-06-11 Advanced Carbon Technologies, Llc Continuous fiber brake rotor preform and apparatuses and methods for manufacturing same

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4955123A (en) * 1986-01-28 1990-09-11 Lawton Peter G Production of a shaped filamentary structure
US6767602B1 (en) * 1996-09-30 2004-07-27 Messier-Bugatti Preparation of textile preforms for brake discs in composite material
WO2003033930A1 (fr) * 2001-10-15 2003-04-24 Daihatsu Motor Co., Ltd. Corps rotatif de frein pour vehicule
US20060151912A1 (en) * 2005-01-11 2006-07-13 Dieter Bauer Carbon/ceramic matrix composites and method of making same
CN104507676A (zh) * 2012-05-16 2015-04-08 派特欧赛拉米克斯股份公司 成形复合材料
DE102012021772A1 (de) * 2012-11-08 2014-05-08 Alfred Buck Kohlefaser-Bremseinheit, Verfahren zu dessen Herstellung und Verwendung
EP2781784A1 (en) * 2013-03-21 2014-09-24 Brembo SGL Carbon Ceramic Brakes GmbH Carbon fibre reinforced brake discs

Also Published As

Publication number Publication date
US11649865B2 (en) 2023-05-16
CN107850155B (zh) 2021-06-25
SI3325839T1 (sl) 2021-12-31
EP3325839A1 (en) 2018-05-30
WO2017013626A1 (en) 2017-01-26
US20180209497A1 (en) 2018-07-26
EP3325839B1 (en) 2021-06-09
ITUB20152386A1 (it) 2017-01-22

Similar Documents

Publication Publication Date Title
CN103547549B (zh) 用第二材料渗透多孔材料的方法及相关装置
US9046138B2 (en) Friction discs having a structured ceramic friction layer and method of manufacturing the friction discs
US9353816B2 (en) Low cost, high density aircraft friction materials utilizing low fiber volume nonwoven preforms with pitch densification
US8454867B2 (en) CVI followed by coal tar pitch densification by VPI
CN104507676B (zh) 成形复合材料
CN101070395B (zh) 炭/炭-碳化硅复合材料刹车闸瓦闸片的制造方法
JP2016519645A (ja) 炭化物マトリックスを用いた複合材料を製造する方法
US6818288B2 (en) Fiber-reinforced ceramic composites
JP2001505863A (ja) 複合炭素／炭素―炭化ケイ素材料の摩擦部材およびその製造方法
JP2003201184A (ja) 繊維強化セラミック複合材料
JP2007535461A (ja) 炭素繊維強化のセラミックの複合体の製造方法
CN101050347B (zh) 一种炭/炭密封材料的制造方法
EP1377759A1 (en) Annular carbon fiber brake preform and manufacturing method
US20110111123A1 (en) Increased area weight segments with pitch densification to produce lower cost and higher density aircraft friction materials
CN103539476B (zh) 用低粘度树脂来渗透致密化的碳‑碳复合材料
EP3204661B1 (en) Method for making brake discs in material reinforced with fibres and brake disc made with such method
CN107709271B (zh) 成形材料和制造方法
CN107850155A (zh) 成型材料和制造方法
EP0912459A1 (en) Densification of a porous structure (i)
CN211420008U (zh) 碳陶复合材料制备用针刺机构
KR100694245B1 (ko) 탄소/세라믹 브레이크 디스크 제조방법
US20090092822A1 (en) Method of Introduction of Filling Materials in Liquid Form Into Porous Bodies
KR101679581B1 (ko) 탄소복합재 제조방법
KR101467665B1 (ko) 탄소-탄화규소 복합재료 제조방법
EP3401294B1 (en) Carbon-carbon composites including encapsulated isotropic carbon and production method thereof

Legal Events

Date Code Title Description
PB01 Publication
PB01 Publication
SE01 Entry into force of request for substantive examination
SE01 Entry into force of request for substantive examination
GR01 Patent grant
GR01 Patent grant
CP01 Change in the name or title of a patent holder

Address after: Italy Bergamo

Patentee after: Lembao public Ltd.

Address before: Italy Bergamo

Patentee before: Fullerney Lembold Public Ltd.

CP01 Change in the name or title of a patent holder