JP2009503396A - ブレーキディスクおよびクラッチディスクの改良またはブレーキディスクおよびクラッチディスクに関連する改良 - Google Patents
ブレーキディスクおよびクラッチディスクの改良またはブレーキディスクおよびクラッチディスクに関連する改良 Download PDFInfo
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- 238000000034 method Methods 0.000 claims abstract description 53
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 37
- 239000004917 carbon fiber Substances 0.000 claims abstract description 33
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 30
- 238000005470 impregnation Methods 0.000 claims abstract description 22
- 239000011226 reinforced ceramic Substances 0.000 claims abstract description 11
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 19
- 229910052710 silicon Inorganic materials 0.000 claims description 19
- 239000010703 silicon Substances 0.000 claims description 19
- 239000000126 substance Substances 0.000 claims description 18
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 16
- 229910052799 carbon Inorganic materials 0.000 claims description 16
- 239000000835 fiber Substances 0.000 claims description 12
- 239000011159 matrix material Substances 0.000 claims description 10
- 238000006243 chemical reaction Methods 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 239000000463 material Substances 0.000 claims description 6
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 4
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 4
- 239000012808 vapor phase Substances 0.000 claims description 4
- 239000004744 fabric Substances 0.000 claims description 3
- 230000008569 process Effects 0.000 abstract description 17
- CREMABGTGYGIQB-UHFFFAOYSA-N carbon carbon Chemical compound C.C CREMABGTGYGIQB-UHFFFAOYSA-N 0.000 abstract description 4
- 239000011203 carbon fibre reinforced carbon Substances 0.000 abstract description 4
- 239000000047 product Substances 0.000 description 18
- 229920005989 resin Polymers 0.000 description 12
- 239000011347 resin Substances 0.000 description 12
- 239000002131 composite material Substances 0.000 description 4
- 238000000280 densification Methods 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 239000011148 porous material Substances 0.000 description 4
- 239000012783 reinforcing fiber Substances 0.000 description 4
- 239000002296 pyrolytic carbon Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 238000001513 hot isostatic pressing Methods 0.000 description 2
- 230000010076 replication Effects 0.000 description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- 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
- 239000001273 butane Substances 0.000 description 1
- 238000003763 carbonization Methods 0.000 description 1
- 239000012159 carrier gas Substances 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 230000001010 compromised effect Effects 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000002783 friction material Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 229910021397 glassy carbon Inorganic materials 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 239000013067 intermediate product Substances 0.000 description 1
- 238000000462 isostatic pressing Methods 0.000 description 1
- 230000003137 locomotive effect Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- OFBQJSOFQDEBGM-UHFFFAOYSA-N n-pentane Natural products CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 238000009419 refurbishment Methods 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 230000007847 structural defect Effects 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
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Abstract
Description
して用いるにはまだ充分な強度または完全性を有してはいない。したがって、通常は部分的に緻密化されたプリフォームを炉から取り出し、閉塞された気孔を再開口するためにその表面を機械加工するのが慣例であり、その後化学気相含浸処理を再開する場合がある。許容可能な密度約1.8g/cm3〜1.9g/cm3を有するディスクを得るためには、通常少
なくとも1つのさらなる機械加工工程および第三の化学気相含浸処理段階が必要となり、合計処理時間は一般的に約150日程度である。米国特許第6,878,331号では、所望の密度を達成するまでに化学気相含浸処理を一般的に3回〜5回繰り返さねばならないと記載している。
化学気相含浸処理は、それ公知の方法で適切な炉内で行われてもよく、加熱コストをできる限り低く抑えることができるように断熱性が高くしてあることが好ましい。メタン、プロパン、ブタンまたはこれらのガスの混合物の如き低分子量炭化水素を、たとえば熱分解炭素源として用いてもよく、また、窒素の如きキャリアガスと共に使用してもよい。費用上の理由から、メタンを用いることが好ましい。この処理は、一例として、約1100℃、たとえば1100℃±50℃で、最長21日間、好ましくは7日〜14日間で行われてもよく、一般的にこの期間中にプリフォームの密度は初期密度0.3g/cm3〜0.6
g/cm3から1.0g/cm3〜1.5g/cm3の範囲の数値に増加する。
Claims (17)
- 原動機付き陸上車両用の炭素繊維強化セラミックブレーキディスクまたはクラッチディスクを製造する方法であって、
所望のディスクの寸法と略一致する寸法を有している炭素繊維プリフォームを調製することと、
単一段階化学気相含浸工程において、炭素を用いて前記プリフォームを緻密化処理することと、
緻密化された前記プリフォームを溶融珪素との反応によって珪化処理することと
を含む、方法。 - 前記プリフォーム内の前記炭素繊維の平均長が少なくとも50mmである、請求項1記載の方法。
- 前記プリフォーム内の前記炭素繊維の平均長が、前記ディスクの内周と外周との間の半径方向の距離と等しいまたは超える長さである、請求項1記載の方法。
- 前記プリフォームが、炭素繊維布の連続シート材または円筒材から裁断される、請求項1乃至3のうちのいずれか一つに記載の方法。
- 前記連続シート材が不織フェルトである、請求項4記載の方法。
- 初期の前記プリフォームが0.3g/cm3〜0.6g/cm3の密度を有する、請求項1
乃至5のうちのいずれか一つに記載の方法。 - 前記緻密化されたプリフォームが1.0g/cm3〜1.5g/cm3の密度を有する、請
求項1乃至6のうちのいずれか一つに記載の方法。 - 前記単一段階化学気相含浸工程が合計で最長21日の間実施される、請求項1乃至7のうちのいずれか一つに記載の方法。
- 前記含浸工程が合計で7日〜14日の間実施される、請求項8記載の方法。
- 前記緻密化されたプリフォームが、前記溶融珪素との反応前に前記所望のディスクの寸法に機械加工される、請求項1乃至9のうちのいずれか一つに記載の方法。
- 前記溶融珪素との反応が、前記緻密化されたプリフォームを溶融珪素槽に少なくとも部分的に浸漬することにより、または、真空排気された容器内に過剰珪素と共に封入し高温および等方圧力に晒すことによって行われる、請求項1乃至10のうちのいずれか一つに記載の方法。
- 珪化処理され、緻密化された前記プリフォームが、前記所望のディスクの寸法に機械加工される、請求項1乃至11のうちのいずれか一つに記載の方法。
- 請求項1乃至12のうちのいずれか一つに記載の方法により得られる炭素繊維強化セラミックブレーキディスクまたはクラッチディスク。
- 原動機付き陸上車両用の炭素繊維強化セラミックブレーキディスクまたはクラッチディスクであって、
少なくとも50mmの平均繊維長を有しているとともに、等方性のある粗い層形状または滑らかな層形状の珪化炭素マトリクス内に実質的に完全に封入されている強化炭素繊維網から実質的に構成されてなる、原動機付き陸上車両用の炭素繊維強化セラミックブレーキディスクまたはクラッチディスク。 - 前記炭素繊維の前記平均長が、前記ディスクの内周と外周との間の半径方向の距離を超える長さである、請求項13または14記載のブレーキディスクまたはクラッチディスク。
- 炭素:炭化珪素:遊離珪素の相対的な含有量比が、それぞれ対応して、50重量%〜65重量%:30重量%〜45重量%:1重量%〜10重量%の範囲である、請求項13乃至15のうちのいずれか一つに記載のブレーキディスクまたはクラッチディスク。
- 前記炭素:炭化珪素:遊離珪素の相対的な含有量比が、それぞれ対応して、55重量%〜60重量%:35重量%〜40重量%:2重量%〜6重量%の範囲である、請求項16記載のブレーキディスクまたはクラッチディスク。
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Application Number | Priority Date | Filing Date | Title |
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GB0515647A GB2428671B (en) | 2005-07-29 | 2005-07-29 | Method for the manufacture of carbon fibre-reinforced ceramic brake or clutch disks |
PCT/GB2006/002815 WO2007012865A1 (en) | 2005-07-29 | 2006-07-28 | Improvements in or relating to brake and clutch discs |
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JP2009503396A true JP2009503396A (ja) | 2009-01-29 |
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JP2008523455A Pending JP2009503396A (ja) | 2005-07-29 | 2006-07-28 | ブレーキディスクおよびクラッチディスクの改良またはブレーキディスクおよびクラッチディスクに関連する改良 |
Country Status (5)
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US (1) | US20100000831A1 (ja) |
EP (1) | EP1910247B1 (ja) |
JP (1) | JP2009503396A (ja) |
GB (1) | GB2428671B (ja) |
WO (1) | WO2007012865A1 (ja) |
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GB0701847D0 (en) * | 2007-01-31 | 2007-03-14 | Surface Transforms Plc | Improvements in or relating to brake and clutch discs |
GB0701849D0 (en) * | 2007-01-31 | 2007-03-14 | Surface Transforms Plc | Improvements in or relating to brake and clutch discs |
JP4976255B2 (ja) * | 2007-10-19 | 2012-07-18 | 株式会社アクロス | 摩擦クラッチ |
EP2844449B1 (en) | 2012-05-02 | 2020-09-02 | Intellectual Property Holdings, LLC | Ceramic preform and method |
US10556831B2 (en) | 2013-11-01 | 2020-02-11 | Mbda Uk Limited | Method of manufacturing ceramic matrix composite objects |
EP2868639A1 (en) * | 2013-11-01 | 2015-05-06 | MBDA UK Limited | Method of manufacturing ceramic matrix composite objects |
EP3209471A4 (en) | 2014-10-20 | 2018-06-27 | Intellectual Property Holdings, LLC | Ceramic preform and method |
CN104482086A (zh) * | 2014-11-04 | 2015-04-01 | 安徽省中力车辆制动系统制造有限公司 | 一种碳纤维复合陶瓷刹车片 |
EP3397873B1 (en) | 2015-12-31 | 2022-09-07 | Intellectual Property Holdings, LLC | Method of making a metal matrix composite vented brake rotor |
CN108698122B (zh) | 2016-02-04 | 2021-11-26 | 知识产权控股有限责任公司 | 用于形成金属基质复合物构件的装置及方法 |
US10830296B2 (en) | 2017-04-21 | 2020-11-10 | Intellectual Property Holdings, Llc | Ceramic preform and method |
DE102017217358A1 (de) * | 2017-09-28 | 2019-03-28 | Sgl Carbon Se | Verfahren zur Herstellung von komplexen geometrischen Bauteilen enthaltend Kohlenstoff oder Siliziumkarbid |
US11702370B2 (en) | 2018-01-10 | 2023-07-18 | SiC Technologies, Inc. | Systems, devices, and methods for manufacturing carbon ceramic brake discs |
CN108178633B (zh) * | 2018-01-24 | 2021-08-17 | 湖南屹林材料技术有限公司 | 一种中低速磁悬浮列车用滑撬体材料及其制备方法 |
US20210299981A1 (en) * | 2020-03-27 | 2021-09-30 | Hamilton Sundstrand Corporation | Carbon component with controlled vibration |
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EP1910247A1 (en) | 2008-04-16 |
GB2428671A (en) | 2007-02-07 |
GB2428671B (en) | 2011-08-31 |
US20100000831A1 (en) | 2010-01-07 |
EP1910247B1 (en) | 2015-09-23 |
WO2007012865A1 (en) | 2007-02-01 |
GB0515647D0 (en) | 2005-09-07 |
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