TWI656285B - Floating disc of composite material - Google Patents

Abstract

A floating disc of composite material is mainly composed of an outer ring disc, an inner disc, and a plurality of combined groups; the outer ring disc has a plurality of first group portions extending inward from the inner ring side; The disc is composed of an aluminum substrate and a metal reinforcement layer or a metal reinforcement layer that has been sealed on the surface of the aluminum substrate. A plurality of second groups are provided on the outer periphery corresponding to the first group. The plurality of combined groups, each combined group including a rivet, a limiting piece and an insert piece, the insert piece is provided with a set of holes, the rivet penetrates the first set of parts of the outer ring disc, the inner disc The second group of parts, the limiting piece, and the group of holes of the abutting member make the end of the rivet force against the outside of the abutting member to achieve the effect of combined positioning. The floating disc can efficiently release thermal energy to the outside, so as to achieve stable and reliable movement.

Description

Floating disc of composite material

The present invention relates to a floating disk of a composite material, in particular to a floating disk having the advantages of light weight, thinness, and sufficient heat dissipation characteristics.

The conventional brake disc is, for example, China's published patent No. M483919, and its main structural features are: it includes a brake ring, a wear layer, an inner disc, and a plurality of connecting members. The brake ring is made of a high-strength, high-heat-resistant aluminum alloy, and has a plurality of first protrusions extending inwardly. An edge of each first protrusion has a respective first depression. The wear-resistant layer is formed of a ceramic material and covers the surface of the brake ring. The inner plate is made of an aluminum alloy or a magnesium alloy, and has a plurality of second protrusions extending outward. An edge of each second protrusion has a respective second depression. Each second protrusion corresponds to a first protrusion. Each first recess forms a connection hole with its corresponding second recess. Each connecting member is fixed in a connecting hole, so that each second protruding portion is joined with its corresponding first protruding portion; and the main disadvantages of its structure are: the manufacturing process is complicated and the cost is too high.

Conventional brake disc structure with composite material I312392 is composed of a disc-shaped inner disc body made of light metal material, and at least two outer disc bodies are laminated and bonded to the upper and lower surfaces of the inner disc body with a metallurgical reaction process, and The outer discs are disc-shaped and made of ferrous metal. A shaft hole is fixed at the center of these outer discs for fixing to the hub, and penetrates the inner discs. Lightweight characteristics; its main disadvantages are: expensive manufacturing process.

In view of the various shortcomings derived from the conventional discs, the inventor of this case was eager to improve and innovate, and finally successfully developed a floating disc of this composite material.

The object of the present invention is to provide a floating disk with a weight reduction of 20% to 30% and high heat dissipation.

A secondary object of the present invention is to provide a floating disk made of composite material, which provides the characteristic that the thicker the metal reinforcing layer is, the higher the heat dissipation is.

Another object of the present invention is to provide a floating disk of a composite material. The heat energy of the outer ring disk is efficiently released to the atmosphere or the outside, and the floating disk can be operated stably and reliably.

A floating disc of composite material that can achieve the above-mentioned object of the invention includes: an outer ring disc, the inner ring side of which is provided with a plurality of first sets of sections; An inner disc is composed of an aluminum substrate and a metal reinforced layer or a metal reinforced layer that has been sealed on the surface of the aluminum substrate. The outer plate extends outwardly corresponding to the first group of parts. The segment is provided with a plurality of second group sections; a plurality of combined groups, each combined group including a rivet, a limiting piece and an inlay; the rivet is provided with a large diameter section having a relatively large diameter, and the large diameter section The unit of length is greater than the thickness unit of the inner disc and the outer ring disc. A diameter is smaller than the large diameter section and a small diameter section provided above the large diameter section, and a transversely formed between the large diameter section and the A stop section of the small-diameter section; a set of holes is provided on each of the stopper piece and the indenter, and a main plane and a work plane are formed on the surface of the stopper piece, and the main plane is parallel to the work plane. Connected by a pressing surface; when the large diameter section of the rivet passes through the first group portion of the outer ring disk and the second group portion of the inner disk plate, the large diameter section protrudes from the The outer ring disc and the length unit of the inner disc form a moving range. At the same time, the small-diameter section is provided with the limiting piece and the The group of holes of the abutting member causes the end of the small diameter section of the rivet to press against the outer surface of the abutting member to form a surrounding section, and the surrounding section correspondingly presses the main plane of the limiting piece and the abutting member. Pieces to achieve the effect of combined positioning.

1‧‧‧ inner disc

11‧‧‧ aluminum substrate

12‧‧‧ micropore

13‧‧‧ metal reinforced layer

14‧‧‧ riveting perforation

15‧‧‧ extension

16‧‧‧Second Group

17‧‧‧ bolt hole

2‧‧‧ outer ring disc

21‧‧‧The first group

D‧‧‧thickness unit

3‧‧‧Combination group

31‧‧‧Rivets

311‧‧‧Large Trail Section

312‧‧‧footpath

313‧‧‧stop

314‧‧‧surround

32‧‧‧ limit film

321‧‧‧main plane

322‧‧‧Working plane

323‧‧‧Pressing surface

324‧‧‧set of holes

33‧‧‧ Inlay

331‧‧‧group holes

L‧‧‧ length unit

4‧‧‧ read disk

41‧‧‧perforation

42‧‧‧Rivets

43‧‧‧through hole

44‧‧‧Extended Wing

FIG. 1 is a front view of a floating disc made of composite material according to the present invention; FIG. 2 is a partially enlarged side cross-sectional view of part A of FIG. 1; Fig. 4 is a sectional view and a partially enlarged schematic view of the limiting piece; Fig. 5 is a sectional view of the rivet; and Fig. 6 is a partially enlarged sectional view of the inner disc, which shows that the surface portion of the aluminum substrate forms a plurality of the same or the same size Figure 7 is a partial enlarged cross-sectional view of the inner disc, showing the surface of the aluminum substrate and the micropores on the surface to form a metal reinforcing layer; Figure 8 is a flowchart of a manufacturing method of the composite material floating disc; Figure 9 FIG. 10 is a front view of a floating disc made of composite material according to the present invention; and FIG. 10 is a partially enlarged side cross-sectional view of part B of FIG. 9.

Please refer to FIG. 1 to FIG. 7, which are schematic front views of a floating disc of composite material according to this embodiment, which mainly include: the floating disc includes an inner disc 1 with an aluminum substrate 11, and is installed in the inner disc. The outer ring disc 2 of the disc 1; and a metal reinforcing layer 13 provided on the surface of the aluminum substrate 11 described above or a metal reinforcing layer that has been subjected to a sealing process (a sealing process for a micropore 12) 13; and the metal reinforcing layer 13 described above or the metal reinforcing layer 13 that has been subjected to sealing (a sealing hole of a micropore 12) is partially provided, and / or the metal reinforcing layer 13 described above has been performed The thickness of the metal reinforcing layer 13 treated by the sealing (which is the sealing of a micropore 12) is partially different.

The outer ring disc 2 has a plurality of thickness units (D) and a plurality of first group portions 21 provided with semi-circular recessed holes inwardly extending from the inner ring side. The outer ring disc 2 has a temperature rise during braking. (disc) has a direct impact on the brake pad (pad), When the actual disc brake is used, the temperature will increase, which will cause the dynamic friction coefficient between the disc and the shoe to decrease, and also cause great thermal stress and thermal strain.

The inner disc 1 has a thickness unit (D) that is the same as that of the outer ring disc 2 and is formed by the aluminum base material 11 and the metal reinforcing layer 13 provided on the surface of the aluminum base material 11 described above. The metal reinforcing layer 13 is formed by plugging. The metal reinforcing layer 13 is formed by a predetermined proportion of a low temperature alumina powder material component and a bonding material component to form a composite material which is connected to the aluminum substrate 11 at elevated temperature. An outer section 15 corresponding to an extension section 15 extending outward of the first group section 21 is provided with a plurality of second group sections 16 corresponding to semicircular recessed holes. The metal reinforcing layer 13 is also a porous alumina layer.

A plurality of combination groups 3, each combination group 3 including a rivet 31, a limiting piece 32, and an indenter 33; as shown in FIG. 5, the rivet 31 is provided with a large diameter section 311 having a relatively large diameter, and The length unit (L) of the large-diameter section 311 is greater than the thickness unit (D) of the inner disk 1 and the outer ring disk 2; a diameter smaller than that of the large-diameter section 311 and disposed above the large-diameter section 311 A small-diameter section 312 is formed laterally between the large-diameter section 311 and a stop section 313 of the small-diameter section 312; as shown in FIG. 3 and FIG. 4, the limiting piece 32 and the interference piece 33 are provided separately. A set of holes 324 and 331 are formed on the surface of the limiting piece 32 with a main surface 321 (primary surface) and a work surface 322. The main surface 321 and the work plane 322 are formed by a pressing surface 323. When the large-diameter section 311 of the rivet 31 passes through the first group portion 21 of the outer ring disc 2 and the second group portion 16 of the inner plate 1, the large-diameter section 311 is convex Out of the outer ring The length unit (L) of the disc 2 and the inner disc 1 forms a range of movement, and at the same time, the small-diameter section 312 penetrates the limiting piece 32 and the group holes 324, 331 of the indentation piece 33, The end of the small-diameter section 312 of the rivet 31 is forced to abut against the outer surface of the inserting member 33 to form a surrounding section 314. The surrounding section 314 is corresponding to the main plane 321 and the insert of the limiting piece 32. The resisting member 33 achieves the combined positioning effect. When the outer disk 2 and the inner disk 1 are offset, the pressing surface 323 of the limiting piece 32 has a pressing effect to retract the pressing surface 323. The plane 322 is blocked by the inner disc 1 and the outer ring disc 2, so that the stop section 313 and the surrounding section 314 of the rivet 31 press the stopper piece 32 and the indentation piece 33 to each other, reaching the limit. The bit slice 32 can maintain the double lacing of the moving range and eliminate the effect of kick-off drift.

FIG. 7 shows a partially enlarged sectional view of the inner disc 1. In the floating disc of the present embodiment, the inner disc 1 includes the aluminum substrate 11 and the metal reinforcing layer 13 that has been subjected to sealing treatment. The metal reinforcing layer 13 is disposed on a surface of the aluminum substrate 11. From the viewpoint of strength, the thickness of the aluminum base material 11 is preferably 5.0 mm or more, for example, 5.5 mm. The thickness of the metal reinforcing layer 13 is, for example, about 10 μm. In addition, the thicker the metal reinforcing layer 13 is, the higher the heat dissipation property is, but the processing time and the costs associated with it increase. An aluminum substrate 11 having a relatively high thermal conductivity exists inside the inner disc 1, and a metal reinforcing layer 13 formed of an aluminum oxide film having a relatively high thermal emissivity is provided on the surface of the aluminum substrate 11. .

When the brake system is activated, it is nothing more than the use of friction To convert the kinetic energy of the outer ring disc 2 into thermal energy and dissipate it into the atmosphere, but if the outer ring disc 2 does not dissipate the heat energy to the atmosphere in time, most of the heat energy is also dissipated through the combination group 3 . If such thermal energy is transmitted to the inner disc 1, the thermal energy will be efficiently transmitted to the entirety of the aluminum substrate 11 having a high thermal conductivity, and high by the metal reinforcing layer 13 having a high thermal emissivity. Efficiently radiate to the outside. Therefore, the inner disc 1 can efficiently release the heat generated in the floating disc to the outside, and can make the operation stable and reliable.

The purpose of the present invention is to provide a method for manufacturing the inner disk 1 of a floating disk of a composite material which can have irregular and interconnected porous holes and can form a large heat dissipation surface area.

Referring to FIG. 8, a method for manufacturing a composite inner disc structure according to the present invention includes the following steps: Step 1: providing a low temperature alumina powder material component and a bonding material component in a predetermined ratio to form a composite material, wherein, The low-temperature alumina powder material component, the bonding material component, and the aluminum substrate 11 each include a plurality of powder particles having a predetermined particle size, and the heat-resistant temperature of the aluminum substrate 11 is higher than the bonding material component. Step two: forming the aluminum substrate 11 into a predetermined shape and placing it into a heating device; step three: heating up to a predetermined temperature to make the aluminum substrate 11 react and electrolyze (electrolytic effect), the predetermined temperature is controlled to be lower than the melting point of the aluminum substrate 11 and higher than the melting point of the bonding material component In the temperature range, as the temperature increases, the low-temperature alumina powder material component will be ashed and gasified when heated, and the bonding material component will melt and flow to be distributed and connected between the aluminum substrate 11 And step four: rapid cooling and solidification to form a metal reinforcing layer 13 can produce a finished product of the inner disc 1 structure.

The beneficial effect of the present invention is that the low-temperature alumina powder material component is combined with the low-temperature alumina powder material component, the connecting material component, and the aluminum substrate 11 to enable the low-temperature alumina powder material component to be made under the predetermined temperature. Gasification or ashing, melting of the bonding material components, and cooperation with the aluminum base material 11 in a dispersed state after electrolysis, and after cooling treatment, connected holes are formed in the final product to connect the bonding material groups. Parts of the bonded phase, and a dispersed phase structure that can be distributed arbitrarily and can conduct temperature, so that the finished inner disc 1 can be smoothly manufactured by the manufacturing method.

The bonding material component accounts for 1% to 10% of the total weight, and is a substance selected from the group consisting of aluminum, bismuth, antimony, tin, zinc, tellurium, and combinations thereof.

For example, the inner disc 1 is formed as follows. First, the aluminum base material 11 having a thickness of 5.5 mm was prepared. The aluminum substrate 11 is relatively rigid. For example, the purity of aluminum in the aluminum substrate 11 is 90.00% by mass or more and less than 99.99% by mass. The aluminum substrate 11 contains impurities, and the surface portion of the aluminum substrate 11 forms a plurality of micropores 12 having the same number or size. This aluminum substrate 11 is also referred to as an aluminum alloy.

Next, the aluminum substrate 11 is anodized or electrolyzed in a heating device. Anodization or electrolysis is performed by using, for example, a sulfuric acid aqueous solution (or a bonding material component) having a concentration of 10% by mass or more and 20% by mass or less and a temperature of 20 ° C or more and 30 ° C or less as an electrolytic solution. The aluminum substrate 11 is immersed for 20 minutes to 30 minutes under conditions of 2A / dm ² or more and 3A / dm ² or less, or under an applied voltage of 10V to 30V. A metal strengthening layer 13 is formed on the surface and the plurality of micro holes 12. In addition, such an anodic oxidation or electrolytic action is also referred to as an alumina film treatment, and a film formed by the alumina film treatment is also referred to as the metal reinforcing layer 13.

Furthermore, if necessary, an etching process may be performed after the anodization. By the etching process, the thickness of the metal reinforcing layer 13 formed by anodization can be increased. The etching treatment is performed using, for example, an aqueous solution of 10% by mass of phosphoric acid or an organic acid such as formic acid, acetic acid, or citric acid, or a mixed aqueous solution of chromium phosphoric acid as an etching solution. In addition, the above-mentioned anodizing and etching processes may be repeatedly performed as necessary.

Thereafter, a sealing process is performed. For example, the plugging treatment is performed using pressurized water vapor or boiling water. Specifically, sealing can be performed by applying water vapor at several atmospheric pressures. Alternatively, the sealing treatment may be performed by heating with boiling water adjusted to a pH of about 5.5 to 6.5 for several tens of minutes. In either case, a sealing agent such as nickel acetate may be added. The inner disc 1 is formed as described above.

In addition, since the metal reinforcing layer 13 having a high thermal emissivity is provided on the surface of the inner disk 1, the heat dissipation performance is improved. Due to the existence of the aluminum substrate 11 having a higher thermal conductivity than the stainless steel material inside the inner disc 1, the heat transmitted to the inner disc 1 is diffused to the entire inner disc 1, and the inner disc 1 1 The heat is efficiently dissipated in the whole. Here, if we focus on the thermal emissivity, it is an extremely low value of about 0.35 relative to the thermal emissivity of stainless steel. Although the average emissivity of the inner disk 1 also depends on the thickness of the metal reinforcing layer 13 , But up to about 0.78. The thermal emissivity of the metal reinforcing layer 13 formed by the aluminum oxide film was 0.85.

When focusing on the thermal conductivity, the thermal conductivity of the stainless steel material is 17 W / mK, and the thermal conductivity of the aluminum substrate 11 is 120 W / mK. Furthermore, although the thermal conductivity of pure aluminum is as high as 236 W / mK, pure aluminum does not have sufficient strength.

In addition, although aluminum does not have sufficient strength, it is preferable to use one having a relatively high mechanical strength as compared with stainless steel as the aluminum base material 11. The tensile strength and elongation of the aluminum substrate 11 including the metal reinforcing layer 13 are 310 N / mm ² and 12% aluminum alloy, respectively. Alternatively, a 5000-series aluminum alloy may be used as the aluminum substrate 11. For example, as the aluminum base material 11, an aluminum alloy having a tensile strength and an elongation of 190 N / mm ² and 12%, respectively, may be used. In addition, when the thickness of the metal reinforcing layer 13 is 10 μm, the surface Vickers hardness Hv of the metal reinforcing layer 13 is about 120, which is higher than the surface Vickers hardness Hv of the aluminum substrate 11 which is generally 50, and The surface Vickers hardness Hv of stainless steel is equivalent to 140 ~ 180.

Since the specific gravity of aluminum (Al: 2.7) is about one third of that of stainless steel compared to stainless steel (Fe: 7.39) and the inner disc 1 is relatively light, the costs related to transportation and installation can be suppressed, especially It is preferably used for moving bodies with considerable momentum. The provision of the metal reinforcing layer 13 also improves the corrosion resistance.

Furthermore, in the floating disc of this embodiment, since the inner disc 1 includes the metal reinforcing layer 13, the heat dissipation of the combination group 3 between the inner disc 1 and the outer ring disc 2 can be improved. Sex.

Please refer to FIG. 9 and FIG. 10 further for a floating disk of a composite material, wherein the floating disk of the composite material is a floating disk type formed by riveting an inner disk 1 and an outer ring disk 2 State, in the inner plate 1 and the outer ring plate 2 are respectively provided with hollow holes for lightening and heat dissipation; the inner ring side of the outer ring plate 2 is provided with a plurality of semi-circular recessed holes extending inwardly. The assembly 21; and the inner disc 1 are composed of the aluminum substrate 11 and the metal reinforcing layer 13 provided on the surface of the aluminum substrate 11 or the metal reinforcing layer 13 that has been sealed. A plurality of second group portions 16 corresponding to semi-circular recessed holes are provided on the extension section 15 corresponding to the outward extension of the first group section 21 on the outer periphery, and a plurality of riveting perforations 14 are provided on the extension section 15 in a ring shape. The inner disk 1 is provided with a plurality of bolt holes 17 in a circular array; 铆 After the inner disk 1 and the outer ring 2 are fitted, they are riveted and combined by the combination group 3; The reading disc 4 is a ring-shaped body. A through hole 43 is provided at the center of the reading disc 4. A plurality of extension wings 44 are formed on the outer periphery of the reading disc 4. A perforation 41 of the riveted perforation 14 of the disc 1 can be riveted by a riveting bolt 42 through the perforation 41 of the reading disc 4 and the riveted perforation 14 of the inner disc 1. It is integrally formed; and at the portion of the perforation 41 of the reading disc 4 corresponding to the riveted perforation 14 of the inner disc 1 described above, the extension wing 44 is extended from the outer periphery of the reading disc 4 to make the reading When the take-up plate 4 is riveted to the inner disc plate 1 by covering, the bolt hole 17 can be fully exposed without obstruction, and after detecting and correcting the roundness and deflection through the instrument, the bolt is passed through the The bolt hole 17 of the inner disc 1 is locked to a rim to complete the assembly of the floating disc of the composite material and the rim.

The structure design of the floating disc of the composite material of the present invention can effectively solve the tolerance values such as the true roundness and the left and right yaw degrees after the inner disc 1 and the reading disc 4 are assembled, so that The magneto-electric wheel speed sensor can obtain a more accurate value when reading the electromotive force change of the read disc 4, thereby ensuring the accuracy of the electronically controlled braking performance of its ABS braking system, thereby greatly improving its braking Safety performance.

6 to 7 are partial enlarged cross-sectional views of the floating disk of this embodiment. The inner disc 1 is as described above with reference to FIGS. 6 to 7, and includes the aluminum substrate 11 and the metal 化 层 13。 The layer 13. As described above, in the inner disk 1, by increasing the thickness of the metal reinforcing layer 13 in a region where heat dissipation is particularly required, thermal radiation can be increased. In addition, by partially providing the metal reinforcing layer 13, the surface area of the metal reinforcing layer 13 can be increased, and heat dissipation characteristics can be improved.

The invention uses electrolysis to make a nano-aluminum substrate composite material, and different volume percentages of porous alumina reinforced layers have been successfully produced. The scanning electron microscope (SEM) analysis results show that the alumina films are uniformly dispersed in the aluminum. In the substrate 11. Adding low-temperature alumina powder material components to the composite increases the aluminum grain size, which tends to become smaller and smaller. When the low-temperature alumina powder material component reaches 20% by mass, the aluminum grain size is about 0.84 μm. .

The addition of nano-alumina particles can effectively strengthen the aluminum substrate 11. When the alumina content is 20% by mass, the surface Vickers hardness is increased to 120 Hv, which is almost 2.5 times the hardness of the aluminum substrate 11 after electrolysis. . The tensile strength was increased from 74N / mm ² (the aluminum substrate 11 was subjected to electrolysis) to 310N / mm ² (20% by mass of alumina film); compared with other processes, because the electrolysis is a solid phase process, The alumina film and the aluminum substrate 11 have good bonding, not only can obtain fine crystal strengthening, the particle dispersibility between the aluminum substrate 11 is also better than the traditional process, so the aluminum-based composite material produced by electrolytic action has Better mechanical properties.

In summary, this case is not only innovative in terms of space type, but also can enhance the above-mentioned multiple effects compared with conventional items. It should have fully met the requirements of statutory invention patents that are novel and progressive. Apply for it in accordance with the law. To approve this invention patent application, to encourage invention, to the utmost convenience.

Claims (1)

A floating disc of composite material includes: an outer ring disc having a thickness unit and a plurality of first groups of semi-circular recessed holes extending inwardly from the inner ring side; an inner disc having an The outer ring disc has the same thickness unit, and is composed of an aluminum substrate and a metal reinforcing layer or a metal reinforcing layer that has been sealed on the surface of the aluminum substrate. The metal reinforcing layer is A low-temperature alumina powder material component and a connecting material component are formed into a composite material at a predetermined ratio to be heated and connected to the aluminum substrate, and an extension section corresponding to the outward extension of the first group portion is provided on the outer periphery correspondingly. The semi-circular recessed hole has a plurality of second groups; a plurality of combined groups, each combined group including a rivet, a stop piece, and an inlay; the rivet has a relatively large diameter section, and the large The length unit of the diameter section is greater than the thickness unit of the inner disc and the outer ring disc. A diameter is smaller than the large diameter section and a small diameter section provided above the large diameter section, and a laterally formed on the large diameter section. And a stop section of the small diameter section; the stopper and the A set of holes is provided on each of the abutment pieces. A main plane and a working plane are integrally formed on the surface of the limiting piece. The main plane and the working plane are connected by a pressing surface. When the large diameter of the rivet The first set of sections of the outer ring disc and the second set of sections of the inner ring disc are formed in sections, so that the large diameter section protrudes from the outer ring disc and the length unit of the inner disc to form a moving range. At the same time, the small-diameter section is penetrated by the limiting piece and the group of holes of the indenter, so that the end of the small-diameter section of the rivet is forced against the outer surface of the indenter to form a surrounding section, the surrounding Corresponding to the segment, the main plane of the limiting piece and the indentation piece are combined to achieve the positioning effect; a reading disc is a ring-shaped body, and a through hole is formed in the center of the reading disc, which extends on the outer periphery of the reading disc. Forming a plurality of extension wings, the extension wings are provided with a perforation corresponding to the riveting perforation of the inner disc, and a riveting bolt can pass through the perforation of the reading disc and the riveting perforation of the inner disc, The two are riveted together to form one body.