DE102017210021B4 - Lightweight composite brake rotor for a vehicle disc brake - Google Patents

Abstract

A lightweight composite composite brake rotor (1) for a motor vehicle brake, having a multi-layered sandwich construction, comprising at least three components, of which a centrally arranged carrier (6) rotationally fixed Radschnittstellen (7), and receiving interfaces (8) for two non-rotatably on the carrier (6), and each of the friction rings (9,10) of a plurality of concentrically offset circular sector segments (11, 11 ', 11 ") with identical curvature, composed, is constructed, characterized in that each circular sector segment (11, 11 ', 11 ") includes a scaffold body (13, 13', 13 '') of open-pored ceramic foam, and in that the pores of each ceramic scaffold body (13, 13 ', 13' ') are covered with metallic cast alloy material (14 ) are interspersed.

Description

The invention relates to a Leichtbaukompositbremsrotor for cooperation with a motor vehicle disc brake with the features of the preamble of claim 1.

From the WO 2015/179420 A1 is a modular segmented, multi-component wear resistant built brake rotor without special lightweight properties, for interaction with friction linings of a caliper, and with interchangeably arranged on a receiving surface of a carrier Reibbelagwerkstoffkörpern, to form a Reibkontaktoberfläche, which also with a wear protection layer system (eg TiN, TiXN) can be provided.

A particularly vibration damped, heavy metal, composite brake disc with an enclosed core of other material is from the DE 25 37 038 A1 known. A Leichtbauverbundgussbremsscheibe with associated manufacturing process goes out of the DE 10 2009 059 806 A1 out. So that the necessary frictional properties can be achieved while avoiding segregation, segregation, dendrite formation or oxide contamination, the construction of this brake disk comprises a multi-body and multi-material construction with an inner disk made of an aluminum casting alloy interspersed with ventilation ducts, and two friction rings fixedly connected to the inner disk by casting Hard material particle reinforcement or aluminum MMC. In this case, the hard material particle reinforcement is applied to the friction surface of the aluminum friction rings in a particularly homogeneous structure and metered by spray compacting.

Ceramic brake discs having ventilated carbon-ceramic friction rings are known from racing and from the Brake Manual, Springer Verlag 2006, Ed. Breuer / Bill, pp. 420-426. A friction ring is made of CMC material (Ceramic Matrix Composite). To this end, randomly oriented and short-fiber carbon fibers are embedded in a silicon carbide matrix. The custom machined ceramic friction ring is interchangeably screwed or clamped to a brake disk pot of stainless steel or aluminum material. Production throughput and production, in short the cost situation, can be improved.

The EP 0 788 468 B1 describes a method for producing a friction unit namely brake rotor with ventilation channels by infiltrating as far as possible the final contour of the rotor corresponding porous carbon body (precursor) with liquid silicon, and this is then subjected to a heat treatment for pyrolysis. It is recommended to perform a mechanical treatment of the precursor after its curing - but before silicization and pyrolysis. In principle, concentricity errors or imbalance can be eliminated by machining the ceramic body. For exchangeable attachment of the ceramic rotor to a wheel hub, a separate core body is recommended.

A motor vehicle brake disc with friction ring in composite construction is from the DE 42 37 655 A1 known. In this case, two mutually connected friction rings are provided, wherein a (axially to the wheel axis) visible, so vehicle outside, placed friction ring made of a fiber composite material and a (axially) inside vehicle friction ring with the brake disk chamber consists of a metallic gray cast iron. As a result, in the region of the friction surfaces, two different tribosystems with a thermally permanent composite structure are obtained, which enables an improved weight balance and wherein at deviations of the friction ring a ceramic friction surface and a metallic friction surface is to be processed, which reduces the workload.

From the DE 10 2014 200 705 A1 discloses an automotive ventilated brake disc comprising composite pot and friction ring, including manufacturing methods. At least one fixed, and at least partially hollow, annular-closed insert made of a ceramic material is positively enclosed by a metallic casting material in order to form substantially the friction surfaces.

From the DE 197 21 473 C2 goes out a friction unit, the disc-shaped friction body composed of circular segment parts puzzle-like toothed, and is placed on a core body. Here, the circular segment parts each extend from the common center, which is the axis of rotation of a brake disc, to radially outward, so that the result is a uniform and point-symmetrical structure, with evenly distributed heat dissipation over the entire surface.

However, because the efficiency requirements for both concentricity and dimensional accuracy under simple diameter variation with the friction rings of modern motor vehicles, at high cost pressures and necessary weight savings, are significantly increased, there is a need to demonstrate a correspondingly improved, simplified, ie advanced, solution, including provision of one cost-effective manufacturing process. An object of the present invention is therefore to avoid the disadvantages of the prior art and at the same time a to provide an innovatively improved solution whose construction also allows a simple diameter variation for the purpose of large-scale variation.

To solve the problem is proposed in a generic rotor according to the features of the preamble of claim 1, that each of the friction rings of a plurality of concentric staggered circular sector segments with identical curvature, segmented composed, is constructed, and for the formation of the friction rings of light metallic MMC Hard material, it is recommended that each circular segment segment includes a scaffold body of open-pore ceramic sponge. At least the pores of each ceramic skeleton body are impregnated with metallic cast alloy material (matrix material). Each cast alloy material includes at least partially, or predominantly, aluminum as the alloying ingredient. According to the invention, a high-volume, rational, automatable and modularly scalable rotor structure, including a processing of ceramic MMC lightweight material, is made possible for the first time.

The insertion of the said circular ring sector segments into a mold or into a prefabricated carrier is reproducible and yet simple if the carrier is essentially disc-shaped without a pot, and wherein each of the front sides of the carrier has cavities open on one side as a positive receiving interface for the circular sector segments, and wherein the cavities are aligned in the axial direction to one another, and plane-parallel to one another, are arranged on the carrier. Advantageously, the cavities are designed as simple circular rings. The structure of the carrier is further simplified when the carrier is solid, without radial ventilation channel formed.

A highly efficient heat dissipation into a wheel disc is achieved by having the carrier for the friction rings on wheel interfaces, which are arranged in relation to a central Raddrehachse, on a radially outer circle on the carrier. This in turn implies that the circular ring sector segments, in relation to a Raddrehachse, are arranged on a radially inner pitch circle on the carrier. In addition, the thermal management is improved by the carrier is formed of cast aluminum alloy material. The heat dissipation to the ambient air is improved if the carrier integrates coolant, in particular cooling fins. Unwanted thermal expansion is easily compensated by means of compensating means. It is possible that the compensating means as a recess, in particular as a groove in the carrier is formed. In order to include a transmitter for Raddrehsensorik each carrier from the friction ring can integrate at least one encoder means for Raddrehsensorik. Combinations of coolant and encoder means are possible, comfortable and therefore useful in principle. If the carrier allows punctual cavities and / or a fixation of additional mass, a simple balancing is possible.

For the full-surface surrounding friction surface design is provided that adjacent annulus sector segments are adjacent to each other substantially directly. The contact of adjacent circular ring sector segments is preferably carried out under elastic bias (press fit) on the adjacent contact surfaces.

To avoid acoustic excitation, it is recommended that the contact surfaces of inboard arranged annulus sector segments be rotated relative to the contact surfaces of outboard arranged annulus sector segments.

Favorable rationalization is made possible by having all annulus sector segments of the friction ring have identical arc lengths. The friction behavior is adaptable, that is changeable by the friction rings are provided with a surface structuring such as in particular with one or more grooves, and / or with through holes.

The friction behavior is adaptable, that is changeable by the friction rings are provided with a surface structuring such as in particular with one or more grooves, and / or with through holes.

This also proposes a method of manufacturing a lightweight composite brake rotor for a motor vehicle brake as follows. The composite material of the rotor comprises a plurality of components, wherein a centrally arranged carrier of a first material via non-rotatable wheel interfaces and receiving interfaces for a friction ring of a second material, which is partially or completely prefabricated in another place, separately, hard material. In partial Vorfabrikation the annulus segment body is proposed that a) first a Reibringrohling is created from several skeletal bodies by kreisringsektorsegmentförmige scaffold body of porous ceramic sponge concentric in the cavity of an open, divided mold are inserted until a circular composite friction ring blank is present in the mold, b) that the divided casting mold is closed, and that c) then a liquid cast metal alloy material is pressed with such pressure in the mold mold, so that d) by composite casting at the same time the carrier is formed, e) the friction ring blank is infiltrated with the cast alloy material, and f) the friction ring is enclosed positively and / or non-positively in the carrier. Preferably, prior to infiltration of the framework bodies, their preheating is effected by bringing them at least approximately to the melting temperature of the molten metal.

For complete prefabrication of the circular ring segment body whose infiltration process is upstream, so that the rotor production is analogous, but without the process step of infiltration, takes place.

Between cast mold and scaffold body / annulus segment takes place after inserting at least temporarily releasable position assurance by integration of suitable holding or securing means, such as kokillenseitig movably mounted slide, holding projections and / or other measures. The Kreisringsegementkörpern / scaffold bodies may also be assigned to spacing means to ensure their mutual parallelism, ie meadow mutual displacement or displacement in the mold exclude. In the simplest case axially spaced spacer cams are provided for this purpose on the back of scaffold bodies.

• 1 perspektivische Zusammenbauzeichnung eines neuartigen Fahrzeugradsystems mit Felgenring, Radschüssel, Bremsrotor und Bremsaktuatorik, ohne periphere Achsbauteile,
• 2 perspektivische Ansicht einer ersten Ausführungsform eines erfindungsgemäßen Bremsrotors,
• 3 mikroskopisch hochvergrößertes Schliffbild zum Werkstoffgefüge des Bremsrotors in 2,
• 4 perspektivische Ansicht einer zweiten Ausführungsform eines erfindungsgemäßen Bremsrotors,
• 5 eine Schnittansicht längs der Schnittlinie V-V in 4,
• 6 Skizze zur Bremsscheibenvariation mittels mehrerer, zueinander durchmesserverschieden, sowie aus unterschiedlich gekrümmt gefertigten Kreisringsektorsegmenten, zusammengesetzt aufgebauter Bremsrotoren, und
• 7 ein poröser keramischer Gerüstkörper.

The invention is explained below with reference to the drawing in detail. In the drawing shows:

• 1 perspective assembly drawing of a novel vehicle wheel system with rim ring, wheel disc, brake rotor and brake actuator, without peripheral axle components,
• 2 Perspective view of a first embodiment of a brake rotor according to the invention,
• 3 microscopically highly magnified microsection of the material structure of the brake rotor in 2 .
• 4 Perspective view of a second embodiment of a brake rotor according to the invention,
• 5 a sectional view taken along the section line VV in 4 .
• 6 Sketch for brake disc variation by means of several, mutually different diameter, as well as made of different curved circular sector segments, assembled constructed brake rotors, and
• 7 a porous ceramic framework.

A novel vehicle wheel system includes 1 Rim ring, Radschüssel, radially innenumgriffen brake rotor and Bremsaktuatorik in the form of a fixed caliper, which is intended for fixing to periperen Achsbauteilen, and wherein these peripheral in 1 is omitted.

The invention is based on the production of a sandwich composite easily slightly composite composite brake rotor on a composite casting technology, including insert on, as this basically from the DE 10 2014 200 705 A1 the Applicant, so that the relevant disclosure content for material and composite casting technology with basically obsolete central pot and its replacement by an external fixation (radially innenumgriffener rotor) is included herein. This gained space is mainly used to concentrate on the structurally differently designed features and interfaces of the rotor.

The Leichtbaukompositbremsrotor comprises at least three components, of which a centrally arranged carrier rotatable wheel interfaces, and receiving interfaces for two non-rotatably-rotatably on the carrier, as well as plane-parallel fixed friction rings forms. Each of the friction rings is composed of a plurality of sector segments of identical curvature, composed.

The carrier is basically disc-shaped without a pot, and wherein each of the end faces of the carrier via unilaterally open cavities as a positive receiving interface for the circular sector segments, and wherein the cavities in the axial direction coaxial with each other, and aligned plane-parallel to each other, are arranged on the carrier. The cavities are preferably formed as circular rings.

Radschnittstellen are arranged in relation to the central Raddrehachse on a radially externally allocated pitch circle on the support. The circular ring sector segments are provided in relation to the wheel axis of rotation on a radially inwardly allocated pitch circle. The mutually adjacent circular sector segments of a common friction ring are adjacent to each other substantially directly.

Especially 6 illustrates that the respective adjacent circular ring sector segments of a friction ring with slight elastic bias (press fit) over radially directed to the wheel axis, smooth-shaped, contact surfaces adjacent to each other. This applies equally to the respective inboard or outboard placed friction surfaces. The contact surfaces of the inboard arranged annulus sector segments may be rotated relative to the contact surfaces of the outboard arranged annulus sector segments to each other, offset provided.

The friction rings are formed with frameworks for construction of hard material, and each circular sector segment has for this purpose a scaffold body of open-pore ceramic sponge. All scaffold bodies, or all circular sector segments, from the rotor or friction ring have identically matching arc lengths. At least the pores of each ceramic skeleton body are interspersed with metallic cast alloy material (matrix material). The light metal casting alloy material includes, at least in part, or predominantly, aluminum as an alloying ingredient. In principle, the carrier can be formed separately cast from a cast aluminum alloy material before the fixation of the friction ring sector segments takes place. Alternatively, these steps take place together in a single mold / mold by the Kreiringsektorsegmente be previously inserted into the mold / mold. In particular, the carrier may be as in 5 can be solid, without radial ventilation channel, be formed.

Like from the 1 and 2 As can be seen, each of the friction rings can be provided with a surface structuring, in particular with one or more grooves, and / or with through-holes.

Of the 4 is an embodiment of a rotor with a carrier removed, which integrates radially outward on the circumference at a distance from each other and offset between the Radschnittstellen sections with coolant. The cooling means can be designed as raised pronounced regions with an efficiently enlarged surface, which are formed, in particular, transversely to the rotational movement, namely as a fin-shaped cooling rib piece oriented radially inwards in the direction of the wheel rotational axis.

All embodiments of the 1-6 let each in the range of a wheel interface, such as between the wheel and the carrier, detect elastic compensating means. The balancing means are provided in the radial direction between the friction surface of the friction ring and the respective wheel interface. In this case, each compensating means is formed as a recess, in particular as an open groove or slot in the carrier. In plan view, the contour of the recess is curved clasp-shaped.

For easy compensation of any imbalance, it is particularly useful when the friction ring is assigned at least one balancing, and wherein the balancing means is formed as a separate recess and / or as an additional mass in the carrier.

For structural simplification in cooperation with electronically controlled motor vehicle brake systems, each carrier may have an encoder means as a donor for Raddrehsensorik. It is possible to provide the encoder means interchangeable, in particular ring-shaped, or to integrally integrate the encoder means into the primary shaping of the carrier. Furthermore, it is understood that coolant and encoder means can be integrally combined provided by cooling fins are effective at the same time as an encoder for the rotary sensor system.

A much wider application of Leichtbaucompositbremsrotor is made possible by the friction ring as a brake disc with a pot, or as a cup-shaped brake drum is pronounced.

The invention also extends to a suitable method for producing a Leichtbaukompositbremsrotor for a motor vehicle brake sandwich material composite of several components, a centrally arranged carrier of a first material on non-rotatable Radschnittstellen and receiving interfaces for a friction ring of a second material has, on another Place, separately, prefabricated from hard material. For better preparation, including rationalization, it is proposed that a) firstly a friction ring blank be prepared from several framework bodies by circular sector segment-shaped scaffold bodies of open-pored ceramic sponge being concentrically inserted into the cavity of an open, divided casting mold until a ring-shaped composite friction ring blank is present in the casting mold b) that the split mold is closed, and that c) then a liquid cast metal alloy material is pressed into the mold mold such that d) by composite casting at the same time the carrier is formed, e) the friction ring blank is infiltrated with the cast alloy material, and f) the friction ring is enclosed positively and / or non-positively in the carrier.

In summary, the manufacturing method and the subject matter in brief summarize the following advantages. Simply diameter-scalable MMC composite brake rotor (Metal Matrix Composite) with weight optics from the rotor for the best possible corrosion resistance. Therefore, the invention appears particularly suitable for recuperative, at least partially electrically powered, vehicles. The rotor, in particular the carrier is mainly from an aluminum base material such as in particular z. B AlSi7Mg0,3 or similar. In order to achieve the required mechanical, thermal and tribological properties of the friction ring, silicon carbide particles with a certain grain size are added to the aluminum alloy. However, the usual casting methods (eg pouring) can lead to segregation processes. To prevent adverse segregation during casting, the invention proposes to form the friction rings porous ceramic framework body in Kreisringsektorsegmentform before, which are penetrated by the casting material. The framework bodies are preferably formed of silicon carbide. The handy circular sector segments are heated to approximately the melting temperature of the aluminum base, placed in a die-castable position, and infiltrated with the base material under pressure and temperature (e.g., squeeze-mold process). Here, the porous framework body are penetrated by the liquid base material and form during solidification of the base material with this a solid bond in the form of a Durchdringungsgefüges.

LIST OF REFERENCE NUMBERS

1

Leichtbaucompositbremsrotor

2

rim

3

wheel disc

4

brake rotor

5

Brake actuator (fixed caliper)

6

carrier

7

wheel interface

8th

Recording Interface

9

friction ring

10

friction ring

11, 11 ', 11 "

Circular ring sector segment

12, 12 ', 12 "

contact area

13, 13 ', 13 "

scaffold body

14

Matrix material / casting alloy material

15

surface structuring

16, 16 ', 16 "

coolant

17, 17 ', 17 "

compensation means

18

encoder means

19

counterbalance

A

wheel rotation

Ax

axially

I

Inboard (relative to a vehicle wheel house)

O

Outboard (relative to a vehicle wheel house)

R

radial direction

T

tangential

Claims (23)

A lightweight composite composite brake rotor (1) for a motor vehicle brake, having a multi-layered sandwich construction, comprising at least three components, of which a centrally arranged carrier (6) rotationally fixed Radschnittstellen (7), and receiving interfaces (8) for two non-rotatably on the carrier (6), and each of the friction rings (9,10) of a plurality of concentrically offset circular sector segments (11, 11 ', 11 ") with identical curvature, composed, is constructed, characterized in that each circular sector segment (11, 11 ', 11 ") includes a scaffold body (13, 13', 13 '') of open-pore ceramic foam, and in that the pores of each ceramic scaffold body (13, 13 ', 13'') are coated with cast metallic alloy material (14 ) are interspersed. Lightweight composite composite brake rotor (1), for a motor vehicle brake Claim 1 , characterized in that the carrier (6) is disc-shaped without pot, and wherein each of the end faces of the carrier (6) on one side open cavities as a positive receiving interface (8) for the circular sector segments (11, 11 ', 11'') has , and wherein the cavities in the axial direction (Ax) aligned with each other, and aligned plane-parallel to each other, are arranged on the carrier (6). Lightweight composite composite brake rotor (1), for a motor vehicle brake Claim 2 , characterized in that the cavities are formed as circular rings. Lightweight composite composite brake rotor (1), for a motor vehicle brake according to one or more of Claims 1 - 3 , characterized in that the wheel interfaces (7), in relation to a central Raddrehachse (A), are arranged on a radially outer pitch circle on the carrier. Lightweight composite composite brake rotor (1), for a motor vehicle brake according to one or more of Claims 1 - 4 , characterized in that the circular ring sector segments (11, 11 ', 11 "), in relation to a Raddrehachse (A), are arranged on a radially inner pitch circle on the carrier (6). Lightweight composite composite brake rotor (1), for a motor vehicle brake according to one or more of Claims 1 - 5 , characterized in that adjacent circular sector segments (11, 11 ', 11 ") directly adjoin one another. Lightweight composite composite brake rotor (1), for a motor vehicle brake according to one or more of Claims 1 - 6 , characterized in that the adjacent circular sector segments (11, 11 ', 11 ") under elastic bias (press fit) via contact surfaces (12, 12 ', 12'') adjacent to each other. Lightweight composite composite brake rotor (1), for a motor vehicle brake according to one or more of Claims 1 - 7 characterized in that the contact surfaces (12, 12 ', 12'') of inboard arranged sector segments (11, 11', 11 '') in relation to the contact surfaces (12, 12 ', 12 ") of outboard arranged sector segments ( 11, 11 ', 11'') are mutually rotated, offset provided. Lightweight composite composite brake rotor (1), for a motor vehicle brake according to one or more of Claims 1 - 8th , characterized in that all annular sector segments (11, 11 ', 11 ") of the friction ring (9,10) have identical arc length. Lightweight composite composite brake rotor (1), for a motor vehicle brake Claim 1 , characterized in that the cast alloy material (14) includes, at least partially, or predominantly, aluminum as an alloying ingredient. Leichtbaukompositbremsrotor (1), for a motor vehicle brake according to one or more of the preceding claims, characterized in that the carrier (6) is formed of a cast aluminum alloy material poured. Leichtbaukompositbremsrotor (1), for a motor vehicle brake according to one or more of the preceding claims, characterized in that the carrier (6) solid, without radial ventilation channel is formed. Leichtbaukompositbremsrotor (1), for a motor vehicle brake according to one or more of the preceding claims, characterized in that the friction rings (9,10) with a surface structuring (15), in particular with one or more grooves, and / or provided with through holes are. Leichtbaukompositbremsrotor (1), for a motor vehicle brake according to one or more of the preceding claims, characterized in that the carrier (6) coolant (16, 16 ', 16 "), in particular integrated cooling fins. Leichtbaukompositbremsrotor (1), for a motor vehicle brake according to one or more of the preceding claims, characterized in that in the region of the wheel interfaces (7) between the wheel bowl (3) and support (6), elastic compensation means (17, 17 ', 17'' ) are provided. Lightweight composite composite brake rotor (1), for a motor vehicle brake Claim 15 , characterized in that the compensating means (17, 17 ', 17 ") as a recess in the carrier (6) is formed. Leichtbaukompositbremsrotor (1), for a motor vehicle brake according to one or more of the preceding claims, characterized in that the carrier (6) integrates encoder means (18) for Raddrehsensorik. Lightweight composite composite brake rotor (1), for a motor vehicle brake Claim 14 and 17 , characterized in that the coolant (16, 16 ', 16 ") includes the encoder means (18), and vice versa. Leichtbaukompositbremsrotor (1), for a motor vehicle brake according to one or more of the preceding claims, characterized in that the friction ring (9, 10) as a brake disc with a pot, or as a cup-shaped brake drum is formed. A lightweight composite brake rotor (1) for a motor vehicle brake according to one or more of the preceding claims, characterized in that at least one balancing means (19) is associated with the friction ring (9, 10), and wherein the balancing means (19) as a separate recess and / or as Additional mass is formed. Method for producing a lightweight composite brake rotor (1) for a Motor vehicle brake with composite material of several components, wherein a centrally arranged carrier (6) of a first material on non-rotatable Radschnittstellen (7) and receiving interfaces (8) for a friction ring (9, 10) of a second material, the other place, as a scaffold body (13, 13 ', 13'') separately, is partially prefabricated from hard material, characterized in that a) first a friction ring blank of a plurality of scaffold bodies (13, 13', 13 '') is created by kreisringsektorsegmentförmige scaffold body (13, 13 ', 13'') of open-pore ceramic sponge are concentrically inserted into the cavity of an open, divided casting mold until an annular composite friction ring blank is present in the mold, b) that the divided mold is closed, and that c) then a liquid metal casting alloy material Pressure is injected into the mold mold such that d) by Verbundgus s at the same time the carrier (6) is formed, e) the friction ring blank is infiltrated with the cast alloy material, and f) the friction ring in the carrier (6) is positively and / or non-positively enclosed. Method for producing a lightweight composite brake rotor (1) for a motor vehicle brake with material composite of a plurality of components, wherein a centrally arranged carrier (6) consists of a first material via non-rotatable wheel interfaces (7) and receiving interfaces (8) for a friction ring (9, 10) second material, which is prefabricated in another place of hard material, characterized in that a) first a friction ring blank of several circular sector segments (11, 11 ', 11 ") with identical curvature, inserted in an open mold mold, assembled and secured to b) that the divided mold mold is closed, and c) then a liquid metal cast alloy material is pressed with pressure in the mold mold, so that d) formed by composite casting at the same time the carrier (6) and e) the friction ring is enclosed positively and / or non-positively in the carrier (6). Method according to Claim 21 or 22 , characterized in that scaffold bodies (13, 13 ', 13'') or circular sector segments (11, 11', 11 ") are fixed in the casting mold and preheated before the composite casting.

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