KR20200012148A - Method for refurbishment of carbon ceramic brake disc - Google Patents

Abstract

According to the present invention, a carbon ceramic brake disk reproducing method includes: a first step of preparing an old carbon ceramic brake disk; a second step of removing dust on the surface of the old carbon ceramic brake disk; a third step of polishing the surface of the old carbon ceramic brake disk and removing a friction film caused by friction with a pad; a fourth step of infiltrating polymer resin into a gap formed in the surface of the old carbon ceramic brake disk; a fifth step of applying polymer resin to the surface of the old carbon ceramic brake disk; a sixth step of carbonizing the old carbon ceramic brake disk, leaving a carbon component in the gap by thermally decomposing the polymer resin penetrated into the gap, and leaving a carbon component on the surface by thermally decomposing polymer resin applied to the surface; a seventh step of burying the old carbon ceramic brake disk in silicon powder and melting the silicon powder; an eighth step of allowing a carbon component existing in the gap to fill the gap by reacting with molten silicon and becoming a silicon carbide component and a carbon component existing on the surface of the old carbon ceramic brake disk to become an oxidation-resistant coating layer by reacting with the molten silicon and becoming a silicon carbide component; and a ninth step of polishing the carbon ceramic brake disk regenerated through the first to eighth steps. The carbon ceramic brake disk reproduced by the method of the present invention has performance comparable to a new carbon ceramic brake disk.

Description

Carbon Ceramic Brake Discs Recycling Method {METHOD FOR REFURBISHMENT OF CARBON CERAMIC BRAKE DISC}

The present invention relates to a carbon ceramic brake disc regeneration method.

An automobile brake disc is classified into a drum brake disc and a disc brake disc.

The disc brake slows or stops the rotation of the disc by friction between the surface of the disc and the pad, thereby slowing down or stopping the vehicle.

Disc brakes should be light, high thermal shock resistance, high oxidation resistance, high wear resistance, high strength, high coefficient of friction. To this end, in recent years, a carbon fiber reinforced ceramic composite material, a disk type automobile brake disc (hereinafter, abbreviated as "carbon ceramic brake disc") is made a lot.

Carbon fiber reinforced ceramic composites are materials in which the matrix is ceramic and reinforced with carbon fibers. When car brake discs are made of carbon fiber reinforced ceramic composites, automobile brake discs can be made lightweight, high thermal shock resistance, oxidation resistance, abrasion resistance, high strength and high coefficient of friction.

As shown in FIG. 1, the carbon ceramic brake disc 1 is composed of a load portion 10 and a friction layer 20 coupled to upper and lower surfaces of the load portion 10. During brake operation, the friction layer 20 is in frictional contact with the pad, and the load portion 10 supports the friction layer 20 and absorbs shock.

A shaft hole 2 through which the axle passes is provided at the center of the carbon ceramic brake disc 1. Around the shaft hole (2), through holes (3) through which bolts coupled with the hat parts pass are provided on the same circle at equal intervals. The cooling channel 4 is provided on the side of the carbon ceramic brake disc 1. Upper and lower surfaces of the carbon ceramic brake disc 1 are provided with cooling holes 5 in communication with the cooling channels 4.

The load portion 10 and the friction layer 20 are composed of a matrix M of SiC, C, Si components, and carbon fibers Cf distributed in the matrix M. FIG.

The oxidation resistant coating layer L1 is formed on the surface of the carbon ceramic brake disc 1 to prevent oxidation. Here, the surface of the carbon ceramic brake disc 1 refers to all parts exposed to the outside, such as the upper surface and the side surface of the friction layer 20, the side surface of the load portion 10, the inner wall of the cooling channel 4, and the like. .

On the other hand, while the carbon ceramic brake disc 1 undergoes a manufacturing process requiring heat treatment and cooling, minute cracks 21 as shown in FIGS. 1 and 2 inevitably occur on the surface of the disc. For this reason, although the oxidation-resistant coating layer L1 is formed in the surface, oxygen penetrates into the crack 21, and it produces an oxidation effect with carbon fiber (Cf) and a carbon component.

When this oxidation occurs, as shown in FIG. 3, the fine crack 21 becomes larger and becomes the gap T, and the carbon fiber Cf is oxidized and broken or disappeared. This phenomenon is accelerated as the gap T increases. Here, the shape of the gap (T) may appear in various ways, such as grooves, holes, slits.

When the gap T is generated and the carbon fiber Cf is broken or lost, the performance of the carbon ceramic brake disc 1 is drastically degraded.

Korea Patent Registration (10-1304188)

The present invention provides a method of regenerating a Worn-out carbon ceramic brake disc to make a refurbishment carbon ceramic brake disc having a performance comparable to a new carbon ceramic brake disc.

Carbon ceramic brake disc regeneration method for achieving the above object,

Preparing a second carbon ceramic brake disc;

A second step of removing dust from the surface of the old carbon ceramic brake disc;

A third step of grinding the surface of the old carbon ceramic brake disc to remove the friction film caused by the friction with the pad;

A fourth step of penetrating the polymer resin into the gap formed on the surface of the old carbon ceramic brake disc;

Applying a polymer resin to a surface of the old carbon ceramic brake disc;

Carbonizing the old carbon ceramic brake disc to pyrolyze the polymer resin penetrated into the gap to leave a carbon component in the gap, and to thermally decompose the polymer resin applied to the surface to leave a carbon component on the surface;

A seventh step of burying the old carbon ceramic brake disc in silicon powder and melting the silicon powder;

The carbon component present in the gap reacts with the molten silicon to become a silicon carbide component to fill the gap, and the carbon component present on the surface of the old carbon ceramic brake disc reacts with the molten silicon to become a silicon carbide component. An eighth step of forming an oxide coating layer; And

And a ninth step of grinding the carbon ceramic brake disc regenerated through the first to eighth steps.

In addition, the above object,

Preparing a second carbon ceramic brake disc;

A second step of removing dust from the surface of the old carbon ceramic brake disc;

A third step of grinding the surface of the old carbon ceramic brake disc to remove the friction film caused by the friction with the pad;

A fourth step of penetrating pyrolyzed carbon by a chemical vapor penetration method into a gap formed on a surface of the old carbon ceramic brake disc;

Applying a polymer resin to a surface of the old carbon ceramic brake disc;

A sixth step of burying the old carbon ceramic brake disc in silicon powder and melting the silicon powder;

The pyrolytic carbon component present in the gap reacts with the molten silicon to become a silicon carbide component to fill the gap, and the carbon component present on the surface of the old carbon ceramic brake disc reacts with the molten silicon to become a silicon carbide component. A seventh step of becoming an oxidation resistant coating layer; And

And an eighth step of grinding the carbon ceramic brake disc regenerated through the first to seventh steps.

Using the present invention, it is possible to regenerate old carbon ceramic brake discs to produce regenerated carbon ceramic brake discs having performance comparable to that of new carbon ceramic brakes.

In the present invention, the gap formed on the surface of the old carbon ceramic brake disc is repeated several times to penetrate and carbonize the polymer resin to fill the gap with the carbon component. This prevents molten silicon from reacting with the carbon component in the inner wall of the gap and the carbon fibers present inside the inner wall, and only fills the gap with silicon carbide, thus providing a durable carbon ceramic brake disc that is as durable as a new carbon ceramic brake. I can make it.

The present invention penetrates pyrolytic carbon into a gap formed on the surface of an old carbon ceramic brake disc by chemical vapor permeation, and deposits it with pyrolytic carbon on the inner wall of the gap. This prevents molten silicon from reacting with the carbon component in the inner wall of the gap and the carbon fibers present inside the inner wall, and only fills the gap with silicon carbide, thus providing a durable carbon ceramic brake disc that is as durable as a new carbon ceramic brake. I can make it.

In the present invention, the cracks formed on the surface of the old carbon ceramic brake disc are infiltrated with pyrolytic carbon by chemical vapor permeation, depositing pyrolyzed carbon only on the inner wall of the crack, and the remaining part is repeatedly infiltrated and carbonized with the polymer resin. The gap is filled with carbon. This prevents molten silicon from reacting with the carbon component in the inner wall of the gap and the carbon fibers present inside the inner wall, and only fills the gap with silicon carbide, thus providing a durable carbon ceramic brake disc that is as durable as a new carbon ceramic brake. I can make it.

1 shows a new carbon ceramic brake disc.
FIG. 2 is a cross-sectional view of the micro crack shown in FIG. 1.
3 is a cross-sectional view of a gap formed in an old carbon ceramic brake disc.
4 is a flowchart illustrating a method of regenerating a carbon ceramic brake disc according to a first embodiment of the present invention.
FIG. 5 is a diagram for describing a fourth step shown in FIG. 4.
FIG. 6 is a diagram for describing a fifth step illustrated in FIG. 4.
FIG. 7 is a diagram for describing a sixth step illustrated in FIG. 4.
FIG. 8 is a diagram for describing an eighth step illustrated in FIG. 4.
9 is a flowchart illustrating a method of regenerating a carbon ceramic brake disc according to a second embodiment of the present invention.
FIG. 10 is a diagram for describing a fourth step shown in FIG. 9.
FIG. 11 is a diagram for describing a fifth step illustrated in FIG. 9.
FIG. 12 is a diagram for describing a seventh step illustrated in FIG. 9.

Hereinafter, the carbon ceramic brake disc regeneration method according to the first embodiment of the present invention will be described in detail.

As shown in Figure 4, the carbon ceramic brake disc regeneration method according to the first embodiment of the present invention,

Preparing a used carbon ceramic brake disc (S11);

A second step (S12) of removing dust from the surface of the old carbon ceramic brake disc;

A third step (S13) of grinding the surface of the old carbon ceramic brake disc to remove the friction film caused by the friction with the pad;

A fourth step (S14) of penetrating the polymer resin into the gap formed on the surface of the old carbon ceramic brake disc;

A fifth step (S15) of applying a polymer resin to a surface of the old carbon ceramic brake disc;

Carbonizing the old carbon ceramic brake disc to thermally decompose the polymer resin penetrated into the gap to leave a carbon component in the gap, and to thermally decompose the polymer resin applied to the surface to leave a carbon component on the surface (S16) ;

A seventh step (S17) of embedding the old carbon ceramic brake disc in the silicon powder and melting the silicon powder;

The carbon component present in the gap reacts with the molten silicon to become a silicon carbide component to fill the gap, and the carbon component present on the surface of the old carbon ceramic brake disc reacts with the molten silicon to become a silicon carbide component. Eighth step (S18) to be an oxide coating layer; And

The ninth step (S19) of grinding the carbon ceramic brake disc regenerated through the first to eighth step.

Hereinafter, each step will be described in detail with reference to FIGS. 1 to 3.

For reference, since the gap T due to oxidation may occur anywhere on the surface of the carbon ceramic brake disc 1, the matrix M shown in FIGS. 2, 3, and 5 to 8 is a matrix of the friction layer or It can be any one of the matrix of the load portion.

The first step S11 will be described.

Prepare a Worn-out carbon ceramic brake disc.

The old carbon ceramic brake disc refers to a carbon ceramic brake disc whose performance is drastically reduced due to an oxidation action, a gap T, and a carbon fiber Cf being oxidized to break or disappear, as shown in FIG. 3. do.

The second step S12 will be described.

 Ultrasonic vibration is applied to the carbon ceramic brake discs, or high pressure air is blown to remove dust from the old carbon ceramic brake discs.

The third step S13 will be described.

A grinder is used to polish the surface of the old carbon ceramic brake disc. Then, the friction film L2 caused by the friction between the brake pad and the disk is removed. At the same time, the oxidation resistant coating film L1 is removed, and the friction layer 20 is also shaved off.

The fourth step S14 will be described.

Place the old carbon ceramic brake disc in a container containing the polymer resin (Pn1). Seal the vessel and apply pneumatics to it.

Alternatively, the old carbon ceramic brake disc is placed in a container, and the inside of the container is vacuumed. Then, the polymer resin (Pn1) is put into a closed container.

As shown in FIG. 5, the polymer resin Pn1 penetrates and fills the gap T in the gap T formed on the surface of the old carbon ceramic brake disc. Here, the polymer resin (Pn1) is a thermosetting resin such as phenol resin and epoxy resin.

The fifth step S15 will be described.

As shown in FIG. 6, a polymer resin (Pn 2) for an oxidation resistant coating is applied to the surface of the old carbon ceramic brake disc by a brush or a spray method. The polymer resin for oxidation-resistant coating (Pn2) is a thermosetting resin such as phenol resin and epoxy resin.

The sixth step S16 will be described.

Put the old carbon ceramic brake disc in a vacuum resistance furnace and carbonize it.

Then, as illustrated in FIG. 7, the polymer resin Pn1 penetrated into the gap T is thermally decomposed to leave the carbon component C in the gap T, and the polymer resin Pn2 applied to the surface is thermally decomposed to the surface. The carbon component (C) remains.

The fourth step S14 and the sixth step S16 are repeated several times (3 to 5 times). The reason is that when the polymer resin (Pn1) penetrated into the gap (T) is thermally decomposed, the volume is reduced, so that the carbon component (C) is present in the gap (T) without sticking to the inner wall of the gap (T), and thus, This is because it can react with the carbon component present in the inner wall of the gap (T) and the inner wall. In order to prevent this problem, the fourth step S14 to the sixth step S16 are repeated several times to completely fill the gap T with the carbon component C.

The seventh step S17 will be described.

Put the old carbon ceramic brake disc on the crucible containing silicon powder and put the crucible into the vacuum resistance furnace. The vacuum furnace heats the crucible. Silicon powder is melted.

An eighth step S18 will be described.

As shown in FIG. 8, the carbon component C present in the gap T reacts with the molten silicon Si to become a silicon carbide (SiC) component to fill the gap T. At the same time, the carbon component (C) present on the surface of the old carbon ceramic brake disc reacts with the molten silicon to form a silicon carbide (SiC) component, thereby forming an oxidation resistant coating layer (L1).

The ninth step S19 will be described.

The regenerated carbon ceramic brake disc is polished through the first step S11 to the eighth step S18.

Hereinafter, the carbon ceramic brake disc regeneration method according to the second embodiment of the present invention will be described in detail.

As shown in Figure 9, the carbon ceramic brake disc regeneration method according to the second embodiment of the present invention,

Preparing a second carbon ceramic brake disc (S21);

A second step (S22) of removing dust from the surface of the old carbon ceramic brake disc;

A third step (S23) of grinding the surface of the old carbon ceramic brake disc to remove the friction film caused by the friction with the pad;

A fourth step (S24) of penetrating the cracked carbon formed on the surface of the old carbon ceramic brake disc by the chemical vapor penetration method;

A fifth step (S25) of applying a polymer resin to a surface of the old carbon ceramic brake disc;

A sixth step (S26) of embedding the old carbon ceramic brake disc in silicon powder and melting the silicon powder;

The pyrolytic carbon component present in the gap reacts with the molten silicon to become a silicon carbide component to fill the gap, and the carbon component present on the surface of the old carbon ceramic brake disc reacts with the molten silicon to become a silicon carbide component. A seventh step (S27) to be an oxidation resistant coating layer; And

The eighth step (S28) of grinding the carbon ceramic brake disc regenerated through the first to seventh step.

Hereinafter, each step will be described in detail with reference to FIGS. 1 to 3.

For reference, since the gap T due to oxidation may occur anywhere on the surface of the carbon ceramic brake disc 1, the matrix M shown in FIGS. 10 to 12 may be either a matrix of the friction layer or a matrix of the load portion. Can be

The first step S21 will be described.

Prepare a Worn-out carbon ceramic brake disc.

As shown in FIG. 3, the old carbon ceramic brake disc includes a carbon ceramic brake disc whose oxidation has occurred, a gap T is formed, and the carbon fiber Cf is oxidized and broken or disappeared, resulting in a drastic reduction in performance. Refers to.

The second step S22 will be described.

 Ultrasonic vibration is applied to the carbon ceramic brake discs, or high pressure air is blown to remove dust from the old carbon ceramic brake discs.

The third step S23 will be described.

A grinder is used to polish the surface of the old carbon ceramic brake disc. Then, the friction film L2 caused by the friction between the brake pad and the disk is removed. At the same time, the oxidation resistant coating film L1 is removed, and the friction layer 20 is also shaved off.

The fourth step S24 will be described.

Place the old carbon ceramic brake disc in a chemical vapor permeation device.

As shown in FIG. 10, the gap T formed on the surface of the old carbon ceramic brake disc penetrates the pyrolytic carbon PyC to fill all the gaps T with the pyrolytic carbon PyC.

Meanwhile, only the inner wall of the gap T may be wrapped with pyrolytic carbon PyC, and the remaining part of the gap T may be filled with a polymer resin. In this case, a carbonization process is added between the fifth step S25 and the sixth step S26.

The fifth step (S25) will be described.

As shown in FIG. 11, a polymer resin (Pn) for an oxidation resistant coating is applied to a surface of an old carbon ceramic brake disc by a brush or a spray method. The polymer resin (Pn) for oxidation-resistant coating is a thermosetting resin such as a phenol resin and an epoxy resin.

The sixth step S26 will be described.

Put the old carbon ceramic brake disc on the crucible containing silicon powder and put the crucible into the vacuum furnace. The vacuum resistance heating furnace heats the crucible. Silicon powder is melted.

The seventh step S27 will be described.

As shown in FIG. 12, the pyrolytic carbon (PyC) component present in the gap T reacts with the molten silicon (Si) to become a silicon carbide (SiC) component to fill the gap T. At the same time, the carbon component (C) present on the surface of the old carbon ceramic brake disc reacts with the molten silicon to form a silicon carbide (SiC) component, thereby forming an oxidation resistant coating layer (L1).

For reference, in FIG. 12, the silicon carbide (SiC) component filling the gap T is formed by the reaction between pyrolytic carbon (PyC) and molten silicon (Si), and the silicon carbide (SiC) constituting the oxidation resistant coating layer (L1). ) Component is generated by the reaction with the carbon component of the polymer resin (Pn) and molten silicon (Si), it was divided by hatched.

An eighth step S28 will be described.

The regenerated carbon ceramic brake discs are polished through the first step S21 to the seventh step S27.

1: carbon ceramic brake disc 10: load part
20: friction layer 21: crack
T: break M: matrix
Cf: carbon fiber

Claims (5)

Preparing a second carbon ceramic brake disc;
A second step of removing dust from the surface of the old carbon ceramic brake disc;
A third step of grinding the surface of the old carbon ceramic brake disc to remove the friction film caused by the friction with the pad;
A fourth step of penetrating the polymer resin into the gap formed on the surface of the old carbon ceramic brake disc;
Applying a polymer resin to a surface of the old carbon ceramic brake disc;
Carbonizing the old carbon ceramic brake disc to pyrolyze the polymer resin penetrated into the gap to leave a carbon component in the gap, and to thermally decompose the polymer resin applied to the surface to leave a carbon component on the surface;
A seventh step of burying the old carbon ceramic brake disc in silicon powder and melting the silicon powder;
The carbon component present in the gap reacts with the molten silicon to become a silicon carbide component to fill the gap, and the carbon component present on the surface of the old carbon ceramic brake disc reacts with the molten silicon to become a silicon carbide component. An eighth step of forming an oxide coating layer; And
And a ninth step of grinding the carbon ceramic brake disc regenerated through the first to eighth steps. The method of claim 1, wherein the fourth and sixth steps are repeated several times, so that the inside of the gap is filled with all the carbon components. Preparing a second carbon ceramic brake disc;
A second step of removing dust from the surface of the old carbon ceramic brake disc;
A third step of grinding the surface of the old carbon ceramic brake disc to remove the friction film caused by the friction with the pad;
A fourth step of penetrating pyrolyzed carbon by a chemical vapor penetration method into a gap formed on a surface of the old carbon ceramic brake disc;
Applying a polymer resin to a surface of the old carbon ceramic brake disc;
A sixth step of burying the old carbon ceramic brake disc in silicon powder and melting the silicon powder;
The pyrolytic carbon component present in the gap reacts with the molten silicon to become a silicon carbide component to fill the gap, and the carbon component present on the surface of the old carbon ceramic brake disc reacts with the molten silicon to become a silicon carbide component. A seventh step of becoming an oxidation resistant coating layer; And
And an eighth step of grinding the carbon ceramic brake disc regenerated through the first to seventh steps. The method of claim 3, wherein in the fourth step,
And the inside of the gap is filled only with pyrolytic carbon. The method of claim 3, wherein in the fourth step,
Only the inner wall of the gap is wrapped with pyrolytic carbon, the remainder of the gap is filled with polymer resin,
And carbonizing the polymer resin between the fifth step and the sixth step.

Images