US20040031652A1 - Brake disk and method for the production thereof - Google Patents

Brake disk and method for the production thereof Download PDF

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Publication number
US20040031652A1
US20040031652A1 US10/436,464 US43646403A US2004031652A1 US 20040031652 A1 US20040031652 A1 US 20040031652A1 US 43646403 A US43646403 A US 43646403A US 2004031652 A1 US2004031652 A1 US 2004031652A1
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US
United States
Prior art keywords
coating
brake disk
disk according
brake
axial
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/436,464
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English (en)
Inventor
Suryakant Khambekar
Hans Baumgartner
Wolfgang Pahle
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Knorr Bremse Systeme fuer Nutzfahrzeuge GmbH
Original Assignee
Knorr Bremse Systeme fuer Nutzfahrzeuge GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
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Application filed by Knorr Bremse Systeme fuer Nutzfahrzeuge GmbH filed Critical Knorr Bremse Systeme fuer Nutzfahrzeuge GmbH
Assigned to KNORR-BREMSE SYSTEME FUER NUTZFAHRZEUGE GMBH reassignment KNORR-BREMSE SYSTEME FUER NUTZFAHRZEUGE GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KHAMBEKAR, SURYAKANT, PAHLE, WOLFGANG, BAUMGARTNER, HANS
Publication of US20040031652A1 publication Critical patent/US20040031652A1/en
Priority to US11/005,080 priority Critical patent/US7261192B2/en
Abandoned legal-status Critical Current

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00Parts or details
    • F16D65/02Braking members; Mounting thereof
    • F16D65/12Discs; Drums for disc brakes
    • F16D65/127Discs; Drums for disc brakes characterised by properties of the disc surface; Discs lined with friction material
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00Parts or details
    • F16D65/02Braking members; Mounting thereof
    • F16D2065/13Parts or details of discs or drums
    • F16D2065/1304Structure
    • F16D2065/132Structure layered
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00Materials; Production methods therefor
    • F16D2200/0004Materials; Production methods therefor metallic
    • F16D2200/0008Ferro
    • F16D2200/0013Cast iron
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00Materials; Production methods therefor
    • F16D2200/0004Materials; Production methods therefor metallic
    • F16D2200/0008Ferro
    • F16D2200/0021Steel
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00Manufacturing; Assembly
    • F16D2250/0007Casting
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00Manufacturing; Assembly
    • F16D2250/0038Surface treatment
    • F16D2250/0046Coating

Definitions

  • the invention relates to a brake disk, preferably for land vehicles, having axial friction surfaces, particularly an internally ventilated brake disk having two friction rings connected by way of webs, and to a method for its production.
  • a brake disk of the above-mentioned type is known from German Patent document DE G 298 13 236.
  • the brake disk illustrated in that document is particularly suitable for the high stress occurring in the case of commercial vehicles and was also found to be resistant to wear. For everyday use, a service life of 300,000 km or more in trucks is not unusual. Nevertheless, a basic demand exists for a further increase of the brake disk's resistance to wear while the manufacturing costs of the brake disk should remain economically justifiable.
  • Brake disk materials therefore have to meet very different demands, which partly require opposing characteristics for the materials.
  • these brake disk materials should also permit high or good heat dissipation.
  • they should have a high thermal conductivity and a high degree of emission.
  • the brake disks should have a high thermal conductivity, a low modulus of elasticity and a low thermal expansion.
  • a low wear of the disk brake is also desirable.
  • a high hardness, a high strength and a high oxidation stability are advantageous.
  • Frictional characteristics which are as uniform as possible also require a high homogeneity of the material even in the case of high thermal stress, as well as the avoidance of fluctuations in wall thickness as a result of a non-uniform wear.
  • the invention is based on the object of providing a brake disk, preferably a gray cast iron brake disk which, while its manufacturing is easy, is as wear-resistant as possible.
  • a brake disk preferably a gray cast iron brake disk which, while its manufacturing is easy, is as wear-resistant as possible.
  • the other characteristics of the brake disk should thereby be impaired as little as possible in comparison to the pertaining state of the art.
  • An advantageous manufacturing method for brake disks according to the invention should also be provided.
  • the invention achieves this object by providing a brake disk with axial friction surfaces, preferably for land vehicles, particularly an internally ventilated brake disk having two friction rings connected by way of webs.
  • the brake disk is provided on at least one of its axial friction surfaces, in sections or entirely, with a metallic, non-ceramic coating, and a method of making the same.
  • the invention accordingly provides a brake disk with axial friction surfaces, preferably for land vehicles, which brake disk may also be internally ventilated and is provided at least on one of its axial friction surfaces, in sections or entirely, with a metallic non-ceramic coating.
  • the brake disk has a disk-type core made of a cast iron material which, at least on one of its axial outer surfaces, is provided with a metallic injection-molded coating or an explosion coating.
  • the invention provides, in a simple manner, a cost-effective coating of brake disks which protects against wear and is compatible with brake disk materials made of cast iron—particularly gray cast iron materials.
  • brake disk materials made of cast iron—particularly gray cast iron materials are particularly desirable.
  • the coating permits a reduction of the heat crack formation of the brake disk, the effect of the brake judder because of thickness fluctuations of the brake disk arising during the operation also being avoidable.
  • the coatings are preferably applied to the brake body made of gray cast iron by a thermal spray coating method, which brake body thereby forms a type of core.
  • thermal sprayed layers are used on gray cast iron brake disks, however, it was now surprisingly recognized that, because of the occurring metallurgical reaction with the material of the brake disk as well as the solidification course of the sprayed layer influenced by the high heat storing capacity of the brake disk, these thermal sprayed layers affect not only the wear behavior of the brake disk in a surprisingly positive manner even at high temperatures, but also reduce the heat crack formation and the braking torque fluctuations.
  • the invention therefore creates a protective layer for brake disks made of cast iron materials, which is applied to the friction surfaces of the brake disk by thermal spraying, in which case the sprayed-on material is a metal.
  • the sprayed-on material is selected such that, in addition to the protection against wear, a protection against oxidation and against undesired metallurgical changes of the friction surface is achieved.
  • the injection molded coating preferably consists of a metal which is harder than the core, particularly unalloyed or alloyed steel.
  • the injection molded coating preferably consists of a steel alloy containing Cr.
  • the Cr content of the coating is between 10 and 20%, between 13 and 19%, between 15 and 17% or particularly preferably at 16%.
  • a brake disk has been particularly successful in the case of which the alloyed steel forming the coating contains the following additions: 16% Cr, 0.44% Ni, 0.43% Mn, 0.01% Mo, and 0.36% C.
  • the core consists of a cost-effective gray cast iron.
  • the gray cast iron forming the core is preferably a highly carburized gray cast iron which has a carbon content of from 3.7 to 4.0% and contains Mo and/or Cr.
  • the Mo content of the core is at 6 to 8% and the Cr content is at less than 5%.
  • the invention is preferably used in the case of commercial vehicle brake disks with a disk thickness of from 38 to 45 mm and an air channel width of 12 mm.
  • Reciprocally engaging contours preferably a groove structure and/or a knob structure, are preferably constructed in the transition area between the core and the injection molded coating.
  • the friction rings expediently have at least one axial collar on the inner and/or outer circumferential edge, the height of this collar corresponding preferably to the axial dimension of the coating.
  • FIG. 1 is a sectional view of a first embodiment of a brake disk according to the invention.
  • FIG. 2 is a sectional view of the area of the friction rings of another embodiment of a brake disk according to the invention.
  • FIGS. 3 and 4 are views of an enlargement of approximately 1,000:1 of the construction and distribution of hard materials increasing the wear resistance, which hard materials are indicated as light spots by means of etching;
  • FIG. 5 is a micrograph of a coating enlarged approximately 500:1.
  • FIG. 1 shows a brake disk 1 having two friction rings 2 , 3 , which are connected with one another in one piece by way of webs 4 , a ventilating duct 5 being constructed between the friction rings 2 , 3 as well as the webs 4 .
  • a pot-shaped projection 6 for fastening the brake disk on a wheel hub (not shown here) is illustrated on one friction ring 2 .
  • this core 7 is provided, in each case, with a wear-resistant metallic non-ceramic injection-molded coating 8 .
  • the complete axial outer surfaces are covered with the injection-molded coating 8 .
  • FIG. 2 it is also provided to construct between the coating 8 and the core 7 not a planar boundary surface, but rather a spatial surface structure, at which the injection-molded coating 8 and the core axially engage in one another.
  • This structure is created in that trapezoid grooves 10 are formed in the axial outer surfaces of the core 7 , which grooves 10 are filled by the coating 8 .
  • the coating 8 axially has such a thick construction that it extends axially beyond the grooves.
  • a flat coating area is formed axially outside the grooves 10 , which coating area covers the axial outer surfaces of the brake disk with the exception of the area of the collars 9 .
  • the construction of a spatial structure, illustrated only as an example in FIG. 2, in the boundary area between the coating 8 and the core 7 has several advantages.
  • the spatial structure avoids an abrupt transition to the gray cast iron material after the abrasion of the complete injection-molded coating 8 , and thus a relative abrupt transition to another braking behavior.
  • the adhesion of the injection-molded coating 8 on the friction rings is improved; among other things, because the contact surface between the coating 8 and the core or the friction rings 2 , 3 is enlarged.
  • transition area between the core 7 and the injection-molded coating 8 a wide variety of different geometries can be implemented; thus, for example, reciprocally engaging trapezoidal or rectangular shapes or, for example, a knob structure on the surface of the friction rings 2 , 3 , which is covered by the injection-molded coating 8 .
  • the arc spraying method was found to be particularly useful for producing the injection-molded coating on the brake disk.
  • the coating is applied from an arc, which has a temperature of up to 4,000° C., by means of an atomizer gas,—in the simplest case, compressed air—to the surface of the brake disk 1 in thin layers while the latter is moved along.
  • an atomizer gas in the simplest case, compressed air
  • approximately 250 to 450 g coating material for each side is sprayed onto the friction surfaces of a brake disk 1 of a diameter of 430 mm and a weight of approximately 25 kg.
  • the base material preferably a ferrous material, and more preferably a gray cast iron material, is used, among others. Also, other cast materials are possible in principle.
  • Gray cast iron brake disks have a carbon content of several (for example, 3 to 4) percent in weight.
  • the gray cast iron materials in German Patent document DE G 298 13 236 are carburized to the saturation limit for achieving the highest possible thermal conductivity.
  • carbon contents of from 3.7 to 4.0 percent in weight are realized.
  • Another preferred coating material according to material No. 1.4122 has, for example, the following composition in an analysis (percent in weight):
  • the high chromium fraction will form chrome carbon by which the resistance to wear of the sprayed layer is increased.
  • the thermal sprayed layer will influence this heat crack formation such that, because of the higher stability of the coating material in comparison to gray cast iron, the flowing of the material in the heating-up phase during the braking does not occur as rapidly, and the high tensile stress in the cooling phase is therefore suppressed, whereby, in connection with the higher stability of the coating material, the crack formation is avoided.
  • Judder problems in the case of brake disks are caused by thickness fluctuations of the brake disk friction ring, which occur as a result of manufacturing faults or as a result of operational influences.
  • Such a sequence of operational influences may consist of localized flattenings of the friction surfaces which are caused during driving, thus in the unbraked condition, as a result of a periodical beating of the brake linings against the brake disk (cold judder).
  • a second form of judder is caused by structural changes of the brake disk material under the effect of heat.
  • a structure of hard material fractions is formed locally, partly as a result of reactions with the brake lining material, which structure also has a volume enlargement in comparison to the basic structure, so that these converted portions grow out of the brake disk friction surface. Since, because of the hard material fraction, these portions also wear off less than the unconverted areas of the friction surface, this growing-out is intensified with an increasing wear of the brake disk, and thereby also the resulting brake judder. Since relatively inert materials can be used for the thermal sprayed layers, such as the described chrome steel, the described friction surface changes and thus the hot judder can also be avoided.
  • a metal-cutting pretreatment of the unfinished cast body is recommended; for example, by means of precision-turning to a friction ring thickness measurement which is below the desired final measurement by the amount of the desired coating thickness.
  • the brake disk then be cleaned from machining residues.
  • a mechanical cleaning and a roughening by means of blasting with fine corundum or a similar blasting material with comparable characteristics is recommended.
  • a roughening of the surface also takes place; for example, preferably an elimination of oxidation layers by means of particle blasting.
  • Spray wire Material No. 4122; diameter 1.6 mm
  • Spray runs 5 individual runs with 160 mm/min parallel advance
  • Spraying parameters Current intensity 300 A, voltage 30 V
  • Atomizer gas 80 qm/h compressed air at 5 bar
  • the brake disk Since, after coating, the brake disk has a relatively rough surface, a finish-machining for smoothing the surface is required. This preferably takes place mechanically by means of grinding. However, for avoiding any loss of coating material, a non-cutting finishing, for example, by means of finish-rolling can also be used. In addition, precision-turning is advantageous for finishing.
  • FIG. 5 is a micrograph, which is enlarged approximately 500:1.
  • the micrograph of the coating shows the existing demands on the quality of the construction of the protective layer. It is important to limit the porosity.
  • the dark points correspond to pores, thus, hollows in the layer.
  • the porosity should amount to no more than 5%; that is, the fraction of dark spots in the micrograph should not be greater than 5%.
  • FIGS. 3 and 4 show the formation and distribution of the hard materials increasing the wear resistance, which are indicated as light spots by means of etching.
  • the light spots represent carbides which essentially consist of chrome carbides. However, carbides may also be formed which are the result of other alloy constituents, as well as metallic oxides which also have positive effects on the hardness and the resistance to wear of the coating.
  • the hardness of the coating should amount to from 350 to 500 HV1.
  • Carbides and oxides should be present in the structure in a finely distributed manner, which, with respect to size, distribution and frequency, should preferably correspond to the type of the attached micrographs. At least 5% of the surface of the micrograph, but preferably 10 to 20% of the surface, should appear in an etched micrograph on a cross-section through the coating or the layer structure as a result of the presence of finely distributed carbides and oxides as light strips in order to form a particularly wear-resistant and effective coating.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Turning (AREA)
  • Forging (AREA)
US10/436,464 2000-11-13 2003-05-13 Brake disk and method for the production thereof Abandoned US20040031652A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US11/005,080 US7261192B2 (en) 2000-11-13 2004-12-07 Brake disk and method for the production thereof

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE10056161.6 2000-11-13
DE10056161A DE10056161A1 (de) 2000-11-13 2000-11-13 Bremsscheibe und Verfahren zu deren Herstellung
PCT/EP2001/012719 WO2002038978A1 (de) 2000-11-13 2001-11-02 Bremsscheibe und verfahren zu deren herstellung

Related Parent Applications (1)

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PCT/EP2001/012719 Continuation WO2002038978A1 (de) 2000-11-13 2001-11-02 Bremsscheibe und verfahren zu deren herstellung

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US11/005,080 Continuation US7261192B2 (en) 2000-11-13 2004-12-07 Brake disk and method for the production thereof

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US20040031652A1 true US20040031652A1 (en) 2004-02-19

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US10/436,464 Abandoned US20040031652A1 (en) 2000-11-13 2003-05-13 Brake disk and method for the production thereof
US11/005,080 Expired - Lifetime US7261192B2 (en) 2000-11-13 2004-12-07 Brake disk and method for the production thereof

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US (2) US20040031652A1 (de)
EP (1) EP1336054B1 (de)
JP (1) JP2004513311A (de)
AT (1) ATE407302T1 (de)
AU (1) AU2002224827A1 (de)
BR (1) BR0115309A (de)
CZ (1) CZ20031247A3 (de)
DE (2) DE10056161A1 (de)
WO (1) WO2002038978A1 (de)

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US20070023242A1 (en) * 2005-07-05 2007-02-01 Daimlerchrysler Ag Composite brake disk
US20080131621A1 (en) * 2006-12-05 2008-06-05 Warran Boyd Lineton Method for fusing hard ceramic-metallic layer on a brake rotor
US20130161132A1 (en) * 2011-12-23 2013-06-27 Robert Bosch Gmbh Brake disk
US20160025167A1 (en) * 2014-07-24 2016-01-28 Ford Global Technologies, Llc Method for producing a brake disk and a brake disk
CN105814333A (zh) * 2013-10-25 2016-07-27 福特全球技术公司 用于生产制动盘的方法及制动盘
CN106103804A (zh) * 2014-03-11 2016-11-09 戴姆勒股份公司 由铁合金组合物构成的制动盘涂层及其制造方法
US20160369857A1 (en) * 2015-06-16 2016-12-22 Hyundai Motor Company Drum in hat brake disk for vehicle and manufacturing method thereof
US10221806B2 (en) 2012-05-01 2019-03-05 Ford Global Technologies, Llc Cylindrical engine bore
US10274032B2 (en) * 2014-03-26 2019-04-30 Ford Global Technologies, Llc Process for producing a brake disk and brake disk
WO2020173756A1 (de) * 2019-02-25 2020-09-03 Robert Bosch Gmbh Reibbremskörper für eine reibbremse eines kraftfahrzeugs, reibbremse und verfahren zur herstellung eines reibbremskörpers
CN113474573A (zh) * 2019-02-24 2021-10-01 欧瑞康表面处理解决方案股份公司普费菲孔 结构化的制动盘
US11137041B2 (en) * 2018-12-11 2021-10-05 Hyundai Motor Company Brake disk including decarburized layer and nitride compound layer, and method of manufacturing the same
CN114929530A (zh) * 2019-12-20 2022-08-19 乐姆宝公开有限公司 用于盘式制动器的盘的制动带
EP4382762A1 (de) * 2022-12-06 2024-06-12 KNORR-BREMSE Systeme für Nutzfahrzeuge GmbH Beschichtetes verschleisselement

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CN100400921C (zh) * 2003-05-15 2008-07-09 费雷尼布莱柏股份公司 盘式制动器的通风型盘式制动带
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US9566957B2 (en) 2011-03-31 2017-02-14 Gunite Corporation Disk brake hub assembly
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DE102011016029B4 (de) * 2011-04-04 2012-12-27 Wabco Radbremsen Gmbh Bremsscheibe für ein Landfahrzeug sowie Landfahrzeug, insbesondere mit einer solchen Bremsscheibe
DE102011075821A1 (de) 2011-05-13 2012-11-15 Robert Bosch Gmbh Bremsscheibe und Verfahren zum Herstellen einer Bremsscheibe
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DE102011056307A1 (de) * 2011-12-13 2013-06-13 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Bremsscheibe und Verfahren zum Herstellen derselben
KR101522718B1 (ko) * 2012-06-11 2015-05-28 이종만 브레이크 디스크와 그 제작 방법
US10012279B2 (en) 2013-03-15 2018-07-03 Tech M3, Inc. Braking systems incorporating wear and corrosion resistant rotors
US10197121B2 (en) 2013-03-15 2019-02-05 Tech M3, Inc. Wear resistant braking systems
KR101532731B1 (ko) * 2013-04-22 2015-07-06 이종만 브레이크 디스크와 그 제작 방법, 및 제작 장치
DE102013215997B4 (de) * 2013-08-13 2022-06-30 Bayerische Motoren Werke Aktiengesellschaft Bremsscheibe für ein Fahrzeug
US10082187B2 (en) * 2014-12-22 2018-09-25 Ford Global Technologies, Llc Mechanically roughened brake rotors
US11073186B2 (en) 2018-05-16 2021-07-27 Tenneco Inc. Brake pad backing plate
EP3620546B1 (de) * 2018-09-04 2022-11-23 Ford Global Technologies, LLC Bremsscheibe und verfahren zum herstellen einer bremsscheibe
DE102019207290A1 (de) * 2019-05-18 2020-11-19 Robert Bosch Gmbh Reibbremskörper für eine Reibbremse eines Kraftfahrzeugs, Verfahren zur Herstellung, Reibbremse
DE102019207291A1 (de) * 2019-05-18 2020-11-19 Robert Bosch Gmbh Reibbremskörper für eine Reibbremse, Reibbremse und Verfahren zur Herstellung
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US7261192B2 (en) 2007-08-28
CZ20031247A3 (cs) 2003-12-17
DE10056161A1 (de) 2002-05-29
DE50114290D1 (de) 2008-10-16
EP1336054B1 (de) 2008-09-03
JP2004513311A (ja) 2004-04-30
EP1336054A1 (de) 2003-08-20
US20050082123A1 (en) 2005-04-21
BR0115309A (pt) 2004-01-06
ATE407302T1 (de) 2008-09-15

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