Brake band and brake disc with improved friction performance

Abstract

The present invention relates to a braking band (2) having opposing braking surfaces (4) and being formed from a first material (37). The braking band (2) comprises at least one braking surface (4) suitable for cooperating with a brake pad and exerting a braking action. The braking band (2) incorporates at least one support structure (3) connected to at least one insert (1) in a second material (38) different from the first material (37). The support structure (3) maintains the precise position of the insert (1) during fabrication. In an unworn brake, at least one surface of the insert (1) or of the composite casting metal portion of the body and of the insert (1) is flush with the outer surface of at least one braking surface (4). The method comprises preparing the support structure (3) with the insert (1), positioning it within the casting mould (31), casting the first material (37), cooling, and mechanical machining to expose the insert (1).

Description

Brake band and brake disc with improved friction performanceDESCRIPTION

[0001] . Field of the invention

[0002] . The present invention relates to braking systems , and in particular to the production of brake discs characterised by interfused braking bands composed of di f ferent materials . In particular, this invention relates to brake bands for brake discs , brake discs themselves , and methods for the production of both brake bands and brake discs .

[0003] . Prior Art

[0004] . In a disc brake , the brake caliper is generally positioned astride the outer peripheral edge of a brake disc, suitable for rotating about an axis of rotation (X-X ) defining an axial direction (A-A) . In a disc brake , a radial direction (R-R) is also defined, substantially orthogonal to said axis of rotation (X-X ) , and a tangential ( C-C ) or circumferential ( C-C) direction, at a point orthogonal to both said axial direction (A-A) and said radial direction (R-R) .

[0005] . The brake calipers are secured to a support that remains stationary relative to the vehicle wheel , such as a vehicle suspension spindle , a vehicle wheel hub, or a fork . The brake caliper typically comprises a caliper body having two elongated portions arranged to face opposite braking surfaces of a brake disc, and at least one bridge connecting said two elongated portions . The appropriately actuated calipers press the pads against the braking band, and the braking action is produced by the friction between the pads and the braking band of the brake disc .

[0006] . Braking systems compri se the mechanisms and components utilised to decelerate or halt a vehicle by converting kinetic energy into thermal energy via friction . Brake discs , also known as rotors , are crucial components that interact with brake pads to generate the friction necessary for deceleration . The materials utilised in brake discs and their manufacturing processes substantial ly influence the performance , durability, and environmental impact of the braking system .

[0007] . In the field of braking systems , a primary obj ective is to enhance the frictional performance of brake discs while minimising wear and particulate emissions . This entails the development of brake discs capable of withstanding elevated temperatures and mechanical stresses without degradation . Furthermore, there is a focus on reducing the weight of the brake discs to improve the vehicle ' s ef ficiency and handling . Another obj ective is to ensurecompatibility with various brake pad materials to achieve optimal braking performance and longevity .

[0008] . Achieving these obj ectives necessitates addressing several challenges . Brake discs must maintain structural integrity under extreme conditions , including high-speed braking and repeated thermal cycles . The materials used must provide consistent friction characteristics and be resistant to wear . Furthermore , production processes must ensure the precise alignment and adhesion of di f ferent materials to prevent defects and guarantee reliable performance . Environmental regulations , such as the EURO 7 standards , also mandate the reduction of particulate emissions from braking systems , thereby introducing an additional layer of complexity to the design and selection of materials .

[0009] . Document US20090078515 describes a method comprising the use of magnets to position and retain inserts within a casting mould . However, this technology is complex and may result in inaccurate positioning of the inserts .

[0010] . Document EP3971440 describes a technology for coating the braking bands of brake discs . However, this technology is costly and may not achieve the requisite coating thickness for high-wear applications , such as those found in tractor brakes , heavy-duty vehicles , or trucks featuring bell-shaped or U-shaped designs .

[0011] . Document US20040084260 describes a method for manufacturing a brake rotor comprising internal and external inserts fabricated from a primary material , with proj ections extending therefrom . However, this method may result in signi ficant errors in parallelism and dimensional tolerances due to the inaccurate positioning of the rings within the mould .

[0012] . Document US 10253833 describes a disc brake rotor comprising internal and external inserts and a core formed by inj ecting an aluminium alloy . However, this method presents considerable complexity in the realisation of the ring anchoring zone and in the materials utilised for the disc body and the braking rings .

[0013] . Document EP2719915 describes a disc brake rotor comprising a core formed from a first metal and coatings formed from a second metal , bonded via a third metal . However, this method is even more complex to implement and involves the use of a third metal as an adhesive .

[0014] . Document DE102012024497 describes an internally ventilated brake disc comprising a one-piece light metal body and separate inserts . This method involves welding the inserts to the disc body, which can easily lead to dimensional and geometric manufacturing errors .

[0015] . Document US20130101780 describes a method for forming a component comprising an insert suitable for damping vibrations generated in a brake disc by braking action . The method involves positioning an insert within a mould and casting a material around the insert to form a composite component . The insert is held in position by a sacri ficial suspension device that dissolves during the casting process , leaving the insert fully incorporated within the component .

[0016] . Technical I ssue

[0017] . One of the technical problems that the present invention aims to solve is to improve existing solutions .

[0018] . One of the technical challenges to be addressed is ensuring the precise positioning and secure integration of inserts within a brake disc during the manufacturing process . A primary challenge lies in precisely positioning the insert , which is fabricated from a secondary material , while a primary material is being cast . This is essential to prevent misalignments that could compromise the brake disc ' s friction performance .

[0019] . Furthermore , the technical problem of improving the wear resistance of the brake disc is addressed . During production, it is crucial that the insert remains in the correct position to ensure that the first material flows uni formly around it , forming the body of the brake disc without defects . This process must ensure that the insert is firmly anchored within the brake disc, thereby enhancing the structural integrity and durability of the final product . Furthermore , it is necessary to expose the insert , or a composite zone formed by the reaction between the materials , to achieve optimal friction characteristics on the braking surface .

[0020] . Furthermore , the present invention aims to address the need for a braking band, a brake disc, and a method for manufacturing a braking band or a brake disc, wherein the inserts defining at least portions of the friction surfaces are maintained in a spaced relationship, thereby allowing a first material , for example cast iron, forming the body of the brake disc to flow into the space between the rings made of a second material , for example steel . This method should ensure the precise positioning and adhesion of the rings to achieve consistent friction performance and comply with environmental regulations .

[0021] . Solution

[0022] . This and other obj ects and advantages are achieved with a brake band of a brake disc according to claim 1 , a brake disc according to claim 24 , and a method of manufacture according to claim

[0023] . Certain advantageous embodiments are the subj ect of the dependent claims .

[0024] . The invention relates to a brake band for brake discs , characterised by opposing braking surfaces formed from a first material , such as cast iron or aluminium . The braking band comprises at least one braking surface designed to cooperate with a brake pad and exert a braking action . An innovative aspect of the invention is the incorporation of at least one support structure , which is a separate component and, in an unworn braking band, is completely embedded in said first material . To this support structure is connected at least one insert made of a second material , di f ferent from the first material , such as steel or stainless steel , or even steel loaded with carbides , for example tungsten carbides . The support structure is designed to maintain a precise position of the insert during the manufacturing process of the brake band . In an unworn brake , at least one surface of the insert , or the composite portion of the casting metal of the body and insert , is flush with the outer surface of at least one braking surface , thereby ensuring optimal friction performance and greater wear resistance .

[0025] . Furthermore , the invention describes a method for manufacturing a brake disc with improved wear resistance . The method involves preparing a support structure to which at least one insert is connected, the insert being made of a second material di f ferent from the first material used for the brake disc body . The support structure , incorporating the insert , is positioned within a casting mould, where it maintains the precise position of the insert during the casting process . Subsequently, the first material is poured in a liquid state into the mould, allowing the material to flow around the insert and form the body of the brake disc . Once cooled and solidi fied, the brake disc is removed from the mould and mechanically machined to remove excess material and expose at least one surface of the insert or a composite zone formed by the reaction between the first and second materials on the friction surface of the brake disc . This method ensures that the insert is firmly anchored within the brake disc, thereby enhancing the structural integrity and durability of the final product .

[0026] . The present invention addresses the need for a brake band, a brake disc, and a method for maintaining the rings defining the friction surfaces in a spaced relationship, thereby allowing the first material forming the brake disc body to flow into the space between the rings without losing the precise predetermined position of the rings . This method ensures the precise positioning and adhesion of the rings , thereby achieving consistent friction performance and comply with environmental regulations .

[0027] . The method integrates braking bands fabricated from a second material with brake disc bodies fabricated from a first material ,utilising at least one support structure to maintain inserts in position during the casting process .

[0028] . This approach enhances the structural integrity and performance of brake discs , while simultaneously reducing particulate emiss ions and ensuring compatibility with diverse brake pad materials .

[0029] . An aspect of the invention resides in the integration of a support structure to maintain the precise positioning of the inserts within the brake disc during the manufacturing process . This support structure ensures that the inserts , fabricated from a material distinct from the primary body of the brake disc, are precisely positioned and securely af fixed to the brake disc . The support structure enables the creation of a composite brake disc with greater wear resistance and improved performance characteristics .

[0030] . Furthermore , the invention introduces a method for incorporating inserts into the brake disc, which involves the use of a support structure to maintain the inserts in position during the casting process . This method ensures that the inserts are precisely positioned and securely bonded to the brake disc, resulting in a brake disc with greater wear resistance and improved performance . The support structure can be fabricated from a variety of materials and configured in diverse arrangements to be adapted for di f ferent types of inserts and brake disc designs .

[0031] . The flexibility to utilise diverse materials and configurations for the support structure and inserts , thereby enabling customi sation to meet the speci fic requirements of the application .

[0032] . This approach addresses the limitations of prior methods , such as the use of fasteners or adhesives , which may not guarantee the same level of precision and safety in the positioning of the inserts . By ensuring the accurate positioning and secure retention of the inserts , the invention improves the overall performance and durability of the brake disc .

[0033] . Advantages of the present invention

[0034] . The integration of inserts , fabricated from a secondary material , into the primary body of the brake band during the casting process ensures a robust mechanical bond between the inserts and the primary body . This is partially achieved by incorporating the inserts into the main body, which improves the structural integrity and durability of the brake disc .

[0035] . The use of a support structure to maintain the inserts in a spaced relationship during the casting process allows the first material to flow uni formly into the space between the inserts . This precise positioning of the inserts ensures consistent frictionperformance and reduces the likelihood of defects such as misalignment or irregular wear .

[0036] . The formation of undercuts in the inserts , designed to incorporate the first material and resist extraction, provides a robust mechanical interlock . This interlock prevents the inserts from detaching from the main body under high-stress conditions , thereby enhancing the reliability and safety of the brake disc .

[0037] . The ability to utilise diverse materials for the inserts and the main body facilitates the optimisation of the brake disc ' s performance characteristics . For example , the use of steel for the inserts and cast iron for the main body can combine the high wear resistance of steel with the excellent thermal conductivity of cast iron, resulting in a brake disc that functions well at elevated temperatures and under high mechanical stresses .

[0038] . The methods of producing a brake band of a brake disc, as described hereinafter, provide several technical ef fects :

[0039] . 1 . Increased Adhesion Resistance : The formation of undercuts in the inserts ensures a robust mechanical bond between the inserts and the main body of the braking band . This prevents the inserts from detaching under high-stress conditions , thereby improving the reliability and safety of the brake disc . However, the provision of undercuts could lead to displacements of the braking rings during their filling in the casting phase , therefore it becomes essential to provide spacers , as described below .

[0040] . 2 . Precise Positioning : The use of a support structure to maintain the inserts in a spaced relationship during the casting process allows the first material to flow uni formly into the space between the inserts . This precise positioning ensures cons istent friction performance and reduces the likelihood of defects such as misalignment or irregular wear .

[0041] . 3 . Material Optimisation : The ability to utilise distinct materials for the inserts and the main body enables the optimisation of the brake disc ' s performance characteristics . For example , the use of steel for the inserts and cast iron for the main body can combine the high wear resistance of steel with the excellent thermal conductivity of cast iron, resulting in a brake disc that functions well at elevated temperatures and under high mechanical stresses .

[0042] . 4 . Improved Durability : The partial incorporation of the inserts into the main body during the casting process enhances the structural integrity and durability of the brake disc . This method ensures that the inserts are securely anchored within the main body, thereby mitigating the risk of detachment or failure during operation .

[0043] . 5. Design Versatility: The method enables the integration of various types of support structures and spacers, integrated with the ventilation core to support the support structure in position. This design versatility enables the production of brake bands with diverse configurations and performance characteristics, thereby satisfying a broad spectrum of applications.

[0044] . 6. Compliance with Environmental Standards: The method supports the use of materials and designs that reduce particulate emissions during braking, thereby contributing to compliance with stringent environmental regulations such as the EURO 7 standards.

[0045] . 7. Thermal Management: The incorporation of a ventilation duct and the utilisation of materials possessing elevated thermal conductivity, such as aluminium and its alloys, facilitate efficient heat dissipation. This reduces the risk of thermal cracking or fissuring and improves the overall performance of the brake disc under high-temperature conditions.

[0046] . 8. Customisation for Heavy-Duty Applications: The method enables the production of inserts designed for heavy-duty applications, ensuring that the brake discs can withstand the demanding conditions of such environments. This encompasses the application of thermal treatments to enhance surface hardness and the strategic design of inserts to mitigate particulate emissions, alongside the fabrication of a primary braking band body, where requisite, devoid of a ventilation duct.

[0047] . Figures

[0048] . Further characteristics and advantages of the braking band, the disc brake, and the production method will become apparent from the following description of its preferred embodiments, provided by way of non-limiting example, with reference to the accompanying figures, wherein:

[0049] . FIG. 1 illustrates a Support Structure 3, comprising a Frame 8, a Support Ring 9, a Connecting Arm 10, Connecting Means 12, and Arm Ends 23. Support Structure 3 is designed to maintain the precise positioning of the inserts during the manufacturing process of a brake disc.

[0050] . FIG. 2 illustrates a top view of a Support Structure 3, comprising a Support Ring 9, a Connecting Arm 10, and Arm Ends 23.

[0051] . FIG. 3 illustrates, in axonometric projection, an Insert 1 connected to a Support Structure 3, comprising a Support Ring 9, a Connecting Arm 10, Connecting Means 11, and Arm Ends 23.

[0052] . FIG. 4 illustrates, in axonometric projection, material for a raw insert and six distinct embodiments of Inserts 1, each comprising Insert Seats 7 and Counter-Connection Means 13.

[0053] . FIG. 5 illustrates an assembly diagram of a support structure and insert assembly, wherein each Insert 1 is connected to the Support Structure 3 by means of Screws 14.

[0054] . FIG. 6 illustrates a compositional diagram of a mould for casting or injecting a brake disc, wherein a group of a plurality of Inserts 1 is mounted on a first Support Structure 3, which is connected to a Core 34 inserted into a First Half-Mould 31, to which a second group of a plurality of inserts connected to a second support structure has previously been connected; a Second Half-Mould 32 is closed onto the first half-mould and, following casting or injection into the casting cavity, a Solidified Casting 25 is formed.

[0055] . FIG. 7 illustrates two sets of Inserts 1 affixed to opposing Support Structures 3, embedded within a Braking Band 2 comprising two opposing Braking Surfaces 4. The frames of each support structure are connected to the core and secure the inserts in position. On the left, the figure depicts the raw brake disc following casting or injection, still exhibiting machining allowance on the braking surfaces. On the right, the same finished brake disc is shown, with the core removed and the surfaces machined to present the braking surfaces to which the inserts are affixed.

[0056] . FIG. 8 illustrates, on the left, a plurality of Inserts 1 affixed to a Support Structure 3 to define Radial Separation Areas 16 and a Circumferential Separation Area 17, wherein the Circumferential Separation Areas 17 form a Discontinuous Circumferential Path 18. On the right, this left-hand assembly is shown embedded and flush with the inserts on the braking surface of a braking band of a Finished Brake Disc 39.

[0057] . FIG. 9 illustrates a sectional view of a finished brake disc, wherein each insert embedded within the first material exhibits Recesses 21 forming Undercuts 19, which enable said first material 37 to firmly engage, at least along the insert's edge, the Second Material 38 of the insert, thereby securely locking the insert to the first material.

[0058] . FIG. 10 illustrates a sectional view of a finished brake disc, wherein each insert embedded within the first material exhibits inclined chamfers 20 forming an undercut 19, thereby enabling said first material 37 to firmly engage the second material 38 of the insert, at least along the insert's edge, and securely affix the insert to the first material.

[0059] . FIG. 11 illustrates, in separate parts in an axonometric view, a frame and insert assembly during the phase of mounting the inserts to the frame by means of rivets 15.

[0060] . FIG. 12 illustrates, in sectional axonometry, a detail of a Support Structure 3, a Connecting Arm 10, and a Support Ring 9,wherein a pair of Inserts is connected to the frame by means of a Geometric Coupling 22 .

[0061] . FIG . 13 illustrates , in axonometric view, a detail of four stages of preparation of a mould, wherein a core is coupled with a first assembly of frame and inserts , and a first hal f-mould is coupled with a second assembly of frame and a plurality of inserts .

[0062] . FIG . 14 depicts , on the left , an axonometric view of a core featuring seats for the ends of arms 24 , along with two frame assemblies and a plurality of inserts connected to opposite faces of the core prior to its insertion into a mould . The ends of the arms are inserted into seats provided in the edges of the core and in its central part . On the right , a section of a detail of a blank still coupled to a core is shown, illustrating how the frame assemblies and inserts are connected to the core .

[0063] . FIG . 15 illustrates , in accordance with a di f ferent embodiment , on the left in axonometry, a core having seats for the ends of arms 24 and two groups of frames and a plurality of inserts connected to opposite faces of the core before it is inserted into a mould, wherein forks 27 , embracing the outer edge of the core , block the radially outer ends of the frame arms , while on the right a section of a detail of a blank still coupled to a core in which it can be seen how the frame and insert assemblies are connected to the core in which the ends of the radially inner arms are inserted into seats provided in the core .

[0064] . FIG . 16 illustrates , in accordance with a di f ferent embodiment , on the left in axonometry, a core having seats for the ends of arms 24 and two assemblies of frames and a plurality of inserts connected to opposite faces of the core before it is inserted into a mould, wherein clips 28 , embracing the outer edge of the core , block the radially outer ends of the frame arms , while on the right a section of a detail of a blank still coupled to a core in which it is seen how the assemblies of frames and ins erts are connected to the core in which the ends of the radially inner arms are inserted into seats provided in the core or blocked by a further third mould 29 .

[0065] . FIG . 17 illustrates , in accordance with a di f ferent embodiment , on the left in axonometry, a core having seats for the ends of arms 24 and two assemblies of frames and a plurality of inserts connected to opposite faces of the core before it is inserted into a mould, wherein forks 27 , embracing the outer edge of the core , block the radially outer ends of the frame arms , while on the right a section of a detail of a blank still coupled to a core in which it is seen how the frame assemblies and inserts are connected to the core in which the ends of the radially inner arms are inserted into seats provided in the core or blocked by a further third mould 29 and a further fourth mould 30 .

[0066] . FIG. 18 illustrates, in axonometric projection, an assembly comprising a plurality of inserts affixed to a Support Structure 3, which is formed by a Frame 8 having Support Rings 9 and equidistantly spaced Connecting Arms 10 with projecting cantilevered Arm Ends 23, according to a first embodiment, wherein the inserts are connected to the frame by means of Rivets 15.

[0067] . FIG. 18 illustrates, in axonometric view, an assembly comprising a plurality of inserts secured to a Support Structure 3, which is formed by a Frame 8 having Support Rings 9 and equidistantly spaced Connecting Arms 10 with projecting cantilevered Arm Ends 23, according to a second embodiment, wherein the inserts are connected to the frame by means of Screws 14.

[0068] . FIG. 20 illustrates, in axonometric projection, a core 34 featuring radially external Arm End Seats 24 and internal spacers 40 forming seats for the ends of arms 24.

[0069] . FIG. 21 illustrates, in axonometry, the core of Figure 20, wherein a frame assembly 8 and a plurality of inserts 1 are coupled, and wherein the ends of the radially internal arms are inserted into the seats 24 of the spacers 40 and bonded therein with adhesive 26.

[0070] . FIG. 22 illustrates, in axonometric view, a core 34 having radially external seats for the ends of arms 24 on the outer edge, intermediate spacers 40 with seats for arms, and internal spacers 40 forming seats for the ends of arms 24.

[0071] . FIG. 23 illustrates, in section and axonometry, the core with the assemblies depicted in Figure 22.

[0072] . FIG. 24 illustrates, in accordance with a further embodiment, an axonometric view of a core 34 having radially external seats for the ends of arms 24 on the outer edge, intermediate spacers 40 with seats for arms, and internal spacers 40 forming seats for the ends of arms 24.

[0073] . FIG. 25 illustrates, in both sectional and axonometric views, the core with the assemblies depicted in Figure 24.

[0074] . FIG. 26 illustrates a sectional view of a Solidified Casting 25, wherein two frame assemblies 8 and a plurality of inserts 1 are embedded, and a Core 34, wherein the inserts are connected to the frame by rivets 15.

[0075] . FIG. 27 illustrates a Solidified Casting 25 featuring a Braking Band 2, from which Arm Ends 23 protrude, and on whose braking surface Inserts 1 are coated with a machining allowance 36.

[0076] . FIG. 28 illustrates, in axonometric projection from the wheel side, a Finished Brake Disc 39 comprising a Ventilated Braking Band 35, on whose Braking Surface 4 a plurality of inserts 1 are flush.

[0077] . FIG . 29 illustrates , in axonometric proj ection, the disc of Figure 28 from the vehicle side .

[0078] . Description of certain preferred embodiments

[0079] . In accordance with a general embodiment , a disc brake 39 comprises a braking band 2 .

[0080] . Said braking band 2 , having a band body suitable for rotating about a rotation axis X-X, defines axial directions A-A coincident with or parallel to said rotation axis X-X, radial directions R-R orthogonal to said rotation axis X-X, and circumferential directions C-C, each orthogonal to one of said axial directions A-A and one of said radial directions R-R at a point of their intersection .

[0081] . Within the context of the patent , a "brake band" denotes a speci fic portion of a brake disc, encompassing the friction surfaces and, where present , the ventilation duct . The braking band is a critical component of the brake disc, as it interacts directly with the brake pads to generate the friction necessary for braking . The braking band is engineered to withstand elevated temperatures and mechanical stresses , thereby preserving its structural integrity and performance characteristics .

[0082] . The braking band typically comprises two principal components : the main body and the inserts . The main body of the braking band is constructed from a primary material , such as cast iron, ductile iron, or aluminium and its alloys , but also steel . This material is selected for its excellent thermal conductivity and its capacity to dissipate the heat generated during braking . The main body constitutes the structural foundation of the braking band and provides support for the inserts . The inserts are fabricated from a secondary material , such as steel , stainless steel , or cast iron - for example , non-lamellar cast iron - and also from composite materials , including steel with carbide inclusions . These rings are partially incorporated into the main body during the casting process . The inserts provide the primary friction surfaces that interact with the brake pads . The choice of material for the inserts must of fer high wear resistance and maintain constant friction characteristics at elevated temperatures and under mechanical stress .

[0083] . In summary, the braking band is a critical component of the brake disc, engineered to deliver consistent friction performance , extended service li fe , and reduced particulate emissions . The innovative integration of diverse materials and manufacturing techniques ensures that the brake band meets the stringent requirements of modern braking systems while adhering to environmental regulations .

[0084] . The " interfusion process" is a technical concept within the context of the patent for the production of brake discs . This processinvolves the partial incorporation of inserts , fabricated from a secondary material , into the primary body of the brake disc, which is manufactured from a primary material , during the casting process . The interfusion process ensures a robust mechanical bond between the inserts and the main body, thereby enhancing the structural integrity and durability of the brake disc .

[0085] . In accordance with one embodiment , the inserts , typically fabricated from a high-temperature-resistant material such as , for example , steel or stainless steel , are prepared with speci fic features such as undercuts or "undercuts" . These undercuts are designed to incorporate the first material and resist extraction, thereby providing a robust mechanical interlock . The prepared inserts are then positioned within a casting mould . The support structure is utilised to maintain the inserts in a spaced relationship within the mould . The support structure may be integrated with the inserts and secured in a correct position with the main body or a core , for example , a core for the realisation of the ventilation ducts of the braking band . This precise positioning ensures that the inserts are correctly aligned and spaced during the casting process , thereby enhancing the accuracy of the dimensional and geometric tolerances of the final product .

[0086] . Subsequently, the primary material , such as cast iron, spheroidal cast iron, or aluminum and its alloys , is melted and poured into the casting mold . The molten material flows into the space between the inserts , filling the space , chamber, or casting cavity for the main body of the braking band, avoiding filling any ventilation ducts , i f present , due to the presence of a speci fic core . As the initial molten material flows around the inserts , it partially incorporates them into the main body . Any undercuts in the inserts ensure that the primary material secures the inserts in position, establishing a robust mechanical bond . This interfusion of materials results in a brake disc with inserts firmly anchored within the main body .

[0087] . Once the first material has been allowed to cool and solidi fy, it forms the final brake disc with interfused inserts . The solidi fied material maintains the inserts in their preci se positions , thereby ensuring consistent frictional performance and structural integrity .

[0088] . The interfusion process of fers several advantages . Firstly, it establishes a robust mechanical bond between the inserts and the main body . The support structure ensures that the first material firmly incorporates the rings , preventing detachment under conditions of high stress . Secondly, the use of the support structure to maintain the inserts in a spaced relationship during the casting process allows the first material to flow uni formly into the space between the inserts and any undercuts . This precise positioningensures consistent friction performance and reduces the likelihood of defects such as misalignment or irregular wear .

[0089] . Furthermore , the possibility of utilising disparate materials for the inserts and the primary body facilitates the optimisation of the brake disc ' s performance characteristics . For example , the use of steel for the inserts and cast iron for the main body combines the high wear resistance of steel with the excellent thermal conductivity of cast iron . The partial incorporation of the inserts into the main body during the casting process enhances the structural integrity and durability of the brake disc . This method ensures that the inserts are securely anchored within the main body, thereby mitigating the risk of detachment or failure during operation .

[0090] . The interfusion process also enables the integration of various types of support structures and, potentially, spacers integrated with the core provided in the mould, such as the core that allows for the creation of the ventilation duct ( s ) . This des ign versatility enables the production of brake bands with diverse configurations and performance characteristics , thereby satis fying a broad spectrum of applications . Furthermore , the interfusion process supports the use of materials and designs that reduce particulate emissions during braking, thereby contributing to compliance with stringent environmental regulations such as the EURO 7 standards .

[0091] . Thermal management is another signi ficant advantage of the interfusion process . The inclusion of a ventilation duct and the use of materials with high thermal conductivity, such as aluminium and its alloys , aid in the ef fective dissipation of heat . This mitigates the risk of thermal cracking and enhances the overall performance of the brake disc under elevated temperature conditions . The interfusion process also enables the production of inserts designed for heavy-duty applications , ensuring that the brake discs can withstand the demanding conditions of such environments . This includes the use of heat treatments to improve surface hardness and the design of inserts to reduce particulate emissions . Furthermore , this process enables the application of this technology to solid discs lacking a ventilation duct .

[0092] . In summary, the interfusion process is a manufacturing technique that ensures the secure integration of inserts into the main body of a brake disc . By partially incorporating the inserts during the casting process , this method improves the structural integrity, durabi lity, and performance of the brake disc, rendering it suitable for a wide range of applications and compliant with environmental standards . The process involves preparing the inserts , potentially with undercuts , positioning them within a casting mould with a support structure , casting the main body material ,intermingling the materials , and solidi fying the final product . The advantages of the interfusion process include : a ) increased adhesion resistance ; b ) precise positioning; c ) material optimisation; d) improved durability; e ) design versatility; f ) compliance with environmental standards ; g) ef fective thermal management ; and h) customisation for heavy-duty applications .

[0093] . Within the context of the patent , the term " Support Structure" denotes a structure utilised in the production process of brake discs . This support structure plays a fundamental role in maintaining the precise position of the inserts within the brake disc during the casting process . The support structure ensures that the inserts , fabricated from a secondary material distinct from the primary body of the brake disc, are precisely aligned and securely af fixed to the brake disc . During the manufacturing process , the support structure maintains the inserts in a spaced relationship within the mould . This spacing allows the molten material , which forms the main body of the brake disc, to flow around the inserts and fill the mould cavity . The support structure may be integrated with the inserts and may be designed to lock in position with the main body or with a component , such as a core used to create ventilation ducts in the brake disc . The support structure may assume various forms and be constructed from diverse materials . The support structure may comprise elements such as frames , rings , or arms that connect to the inserts . The support structure ensures that the inserts remain in their precise positions during the casting process , which is crucial for achieving accurate dimensional and geometric tolerances in the final product . Once the molten material has cooled and solidi fied, the support structure assists in ensuring that the inserts are securely anchored within the main body of the brake disc . This robust mechanical bond between the inserts and the main body enhances the structural integrity and durability of the brake disc, ensuring consistent frictional performance and mitigating the likelihood of defects such as mi salignment or irregular wear . In summary, the " Support Structure" is an essential component in the production of high-performance brake discs , providing stability and precision during the casting process and contributing to the overall quality and reliability of the final product . In accordance with one embodiment , the " support structure" is composed of various components that work together to maintain the precise position of the inserts within the brake disc during the casting process . The primary components of the support structure include :

[0094] . Frame ( 8 ) : The frame constitutes a potential embodiment of the support structure . It can be fabricated from various materials , such as steel or aluminium, and provides the structural foundation for connecting the other components . The frame is engineered to be robust and resilient , thereby maintaining the stability of the inserts throughout the casting process . The frame is designed toincorporate appendages suitable for anchoring to the mould or core, thereby maintaining the desired position of the inserts connected thereto during the casting or injection of the initial molten material .

[0095] . 2. Support rings (9) : The support rings are circular elements that form part of the frame. In accordance with a preferred embodiment, they may be arranged concentrically and serve to maintain the inserts in the desired radial and circumferential position. The support rings are interconnected and affixed to the frame via the connecting arms.

[0096] . 3. Connecting arms (10) : The connecting arms are elements that connect the support rings to the frame. They may be circumferentially equidistant to ensure a uniform distribution of forces. The connecting arms may be welded to the support rings or formed integrally therewith. These arms ensure that the support rings remain in position during the casting process.

[0097] . 4. Connection means (11) : The connection means are elements that enable the inserts to be secured to the support structure. They may include screw seats (12) or rivet seats (12) , which enable the inserts to be securely connected to the support structure by means of screws or rivets. These connecting means ensure that the inserts remain in position during the casting process and subsequently during the use of the brake disc.

[0098] . 5. Counter-connection means (13) : The counter-connection means are present on the inserts and are designed to align with the connection means of the support structure. They may include insert screw seats (7) or insert rivet seats (7) , which enable the inserts to be securely and precisely affixed to the support structure.

[0099] . 6. Undercut (19) : The undercut is a feature of the inserts that enables the first material to encircle the insert during the casting process, thereby establishing a robust mechanical bond. In accordance with possible embodiments, the undercut may be an inclined chamfer (20) , a recess (21) , or a perimeter recess (21) . These components work together to ensure that the inserts are precisely positioned and securely bonded to the brake disc during the casting process. The support structure maintains the inserts in a spaced relationship within the mould, thereby permitting the molten material to flow around the inserts and fill the mould cavity. Once the molten material has cooled and solidified, the support structure helps to ensure that the inserts are firmly anchored within the main body of the brake disc, thereby improving the structural integrity and durability of the final product.

[0100] . Within the context of the patent, the term "inserts" refers to components utilised during the manufacturing process of brake discs. The insert is a component fabricated from a secondarymaterial, distinct from the primary material employed for the main body of the brake disc. This second material may be, for example, steel, stainless steel, or a composite material, for example, with carbide inclusions, for example, titanium carbide. The insert is designed to increase wear resistance and improve the friction performance of the brake disc. The structure of the insert and its method of connection to the support structure are described in detail below :

[0101] . 1. Insert Structure:

[0102] . - The insert may have various shapes, such as a circular crown (5) or a sector of a circular crown (6) . It may also comprise a plurality of inserts arranged to form concentric circular crowns.

[0103] . - The insert may exhibit specific features, such as an undercut (19) , which may be inclined chamfers (20) , recesses (21) , or perimeter recesses (21) . These undercuts enable the primary material to encircle the insert during the casting process, thereby establishing a robust mechanical bond.

[0104] . - The insert may include counter-connection means (13) , such as insert screw seats (7) or insert rivet seats (7) , which enable the insert to be securely and precisely affixed to the support structure .

[0105] . The inserts may be arranged within the braking band to create specific separation areas and pathways between them. This arrangement is designed to optimise the friction performance and wear resistance of the brake disc. The arrangement of the inserts and the spaces or paths they leave between them are described in detail below:

[0106] . 1. Radial arrangement:

[0107] . - The inserts may be arranged to create at least a first radial separation area (16) between the inserts, directed radially. This radial arrangement enables the creation of edges between the first material (37) and the second material (38) , which are suitable for revitalising the braking material of a pad that cooperates with the braking surface (4) of the braking band (2) .

[0108] . 2. Circumferential arrangement:

[0109] . - The inserts may be arranged so as to create at least a second circumferential separation area (17) between the inserts, directed circumferentially. This circumferential arrangement permits the creation of paths between the inserts, which may be discontinuous (18) or arranged at least intermittently along radii differing from the theoretical axis of rotation of the braking band (2) .

[0110] . 3. Concentric circular crowns:

[0111] . - The inserts may be arranged to form concentric circular crowns. In this case, the inserts may comprise a plurality of inserts (1) forming concentric circular crowns, each consisting of a plurality of circular crown sectors (6) . This arrangement enables the uniform distribution of forces and mechanical stresses during braking, thereby enhancing wear uniformity and friction performance.

[0112] . 4. Spaces between the inserts:

[0113] . - The spaces between the inserts are designed to allow the first material (37) to flow uniformly around the inserts during the casting process. These spaces facilitate the establishment of a robust mechanical bond between the primary material and the inserts, thereby enhancing the structural integrity of the brake disc.

[0114] . 5. Undercut:

[0115] . - The inserts may exhibit undercut features (19) , such as inclined chamfers (20) , recesses (21) , or perimeter recesses (21) . These undercuts enable the primary material to encircle the insert during the casting process, thereby establishing a robust mechanical bond and preventing the detachment of the inserts from the main body of the brake disc.

[0116] . In summary, the inserts are strategically positioned within the braking band to optimise friction performance and wear resistance. The radial (16) and circumferential (17) separation areas, along with the discontinuous circumferential paths (18) between the inserts, are engineered to ensure a uniform flow of the primary material during casting and to form edges that enhance the effectiveness of the braking material. This arrangement contributes to improving the structural integrity and durability of the brake disc .

[0117] . 2. Connecting the insert to the support structure:

[0118] . - The support structure (3) is designed to maintain the insert in a precise position during the brake band manufacturing process. The support structure may comprise a frame (8) with support rings (9) and connecting arms (10) .

[0119] . - The support rings (9) and the connecting arms (10) may be connected to each other and to the frame (8) by means of connecting means (11) , such as screw seats (12) or rivet seats (12) .

[0120] . - The insert is connected to the support structure via counter-connection means (13) , which may be insert screw seats (7) or insert rivet seats (7) . These counter-connection means are aligned with the connection means (11) of the support structure. In accordance with one embodiment, the insert is connected by comoulding with the support structure (3) , for example as depicted in Figure 12.

[0121] . - The insert may be secured to the support structure by means of screws (14) or rivets (15) , thereby ensuring a secure and precise connection.

[0122] . - During the casting process, the first material is poured into the mould, flowing around the insert and the support structure. The undercut (19) of the insert enables the first material to encircle the insert, thereby establishing a robust mechanical bond.

[0123] . - Once the molten material has cooled and solidified, the insert remains firmly anchored within the main body of the brake disc, thereby enhancing the structural integrity and durability of the final product.

[0124] . In summary, the insert is designed to be robust and wearresistant, and is connected to the support structure via connection and counter-connection means, ensuring precise positioning and secure connection during the brake disc manufacturing process.

[0125] . Within the context of the patent, the term "spacers" (also denoted by reference 40 in the figures) pertains to components employed during the brake disc manufacturing process to maintain, in conjunction with the support structure, the inserts in a specific position. These spacers ensure that the inserts maintain a spaced relationship within the casting mould, thereby creating both the necessary space for the casting material and the appropriate relative positioning. This spacing enables the molten material, which forms the main body of the brake disc, to flow uniformly into the space between the brake rings . By maintaining the correct spacing and precise relative position, the spacers contribute to the structural integrity and durability of the brake disc. They ensure that the inserts are securely incorporated into the main body, providing a strong mechanical bond that improves the overall performance and reliability of the brake disc.

[0126] . The spacers may assume various forms and be integrated with different parts of the brake disc or the casting mould. They may be mechanical inserts, rivets, or elements integrated with the ventilation structure. The primary function of the spacers is to maintain the inserts in position during the casting process, thereby ensuring precise positioning and consistent friction performance. This helps to prevent defects such as misalignment or irregular wear in the final brake disc.

[0127] . An example of spacers includes mechanical inserts that are used to maintain the inserts in position during the casting process. These inserts may be integrated into the cores or into the mould halves. Another example involves the use of rivets as spacers, which are inserted into the inserts to maintain their position. Furthermore, the spacers can be integrated with the ventilation core,ensuring that the inserts are correctly positioned while simultaneously permitting adequate airflow and heat dissipation .

[0128] . The spacers may also be integrated with the inserts themselves , thereby providing an integrated mechanism for maintaining correct spacing . This integration can take various forms , such as conical spacers , parallelepiped spacers , circumferentially arranged spacers , and annular or circumferential spacers , for example , with a sinusoidal profile . Each of these designs of fers unique advantages in terms of maintaining correct spacing and ensuring consistent friction performance .

[0129] . In certain embodiments , the spacers are configured to connect opposing inserts or to support and / or connect opposing inserts . This configuration aids in maintaining the correct spacing between the inserts and ensures that the molten material flows uni formly into the space between them . The use of integrated spacers within the brake disc body or within the mould halves further enhances the precision and consistency of the casting process .

[0130] . Within the context of the patent , the terms " first material" and " second material" refer to the distinct materials utilised for the various components of the brake disc . The " first material" is utilised to form the main body of the brake disc, whi le the " second material" is utilised to form the inserts . The use of two distinct materials constitutes an aspect of the invention, as it enables the optimisation of the brake disc ' s performance characteristics .

[0131] . The " first material" is utilised to form the principal body of the brake disc . This material is typically selected for its excellent thermal conductivity and its capacity to dissipate the heat generated during braking . Common examples of the first material include cast iron, spheroidal cast iron, and aluminium and its alloys . Cast iron and spheroidal cast iron are known for their high thermal conductivity and ability to withstand elevated temperatures , rendering them ideally suited for the main body of the brake disc . Aluminium and its alloys , on the other hand, of fer the advantage of being lightweight while providing good thermal conductivity .

[0132] . The " second material" is utilised to form the brake disc inserts . This material is selected for its high wear resistance and its ability to maintain consistent friction characteristics under elevated temperatures and mechanical stresses . Common examples of the second material include steel , stainless steel , and non-lamellar cast iron . Steel and stainless steel are known for their high strength and wear resistance , making them ideal for inserts that interact with brake pads . Non-lamellar cast iron also of fers good wear resistance and can be used as an alternative material for brake rings .

[0133] . The use of two distinct materials for the main body and the brake disc inserts offers several advantages. By employing distinct materials for the main body and the brake rings, the brake disc can be optimised for both thermal management and wear resistance. The primary material, such as cast iron or aluminium, provides excellent thermal conductivity, enabling the brake disc to effectively dissipate heat. The second material, such as steel or stainless steel, offers high wear resistance, ensuring that the inserts can withstand the mechanical stresses and high temperatures generated during braking.

[0134] . The combination of materials enhances the overall durability of the brake disc. The main body, constructed from the primary material, is capable of effectively managing the heat generated during braking, thereby mitigating the risk of thermal cracking. The inserts, fabricated from the secondary material, are engineered to withstand wear and consistently maintain friction characteristics, thereby ensuring reliable performance throughout the operational lifespan of the brake disc.

[0135] . The interfusion process, which involves the partial incorporation of the inserts into the main body during the casting process, creates a strong mechanical bond between the two materials. This bond enhances the structural integrity of the brake disc, thereby mitigating the risk of insert detachment or failure under conditions of elevated stress.

[0136] . The use of different materials enables the design of brake discs that reduce particulate emissions during braking. For example, the use of steel for the inserts and cast iron for the main body can help to meet stringent environmental regulations such as the EURO 7 standards .

[0137] . The ability to utilise diverse materials for the main body and inserts provides versatility in the design of the brake disc. This enables the production of brake discs with diverse configurations and performance characteristics, thereby catering to a broad spectrum of applications, ranging from standard passenger vehicles to heavy-duty vehicles.

[0138] . The use of lightweight materials, such as aluminium, for the main body can reduce the overall weight of the brake disc. This can contribute to improving the efficiency and performance of the vehicle, as well as reducing fuel consumption and emissions.

[0139] . In addition to standard ventilated brake discs, the invention also comprises solid brake discs without ventilation ducts. In this embodiment, the brake disc is designed for applications where ventilation is not required, such as in certain heavy-duty vehicles or off-road vehicles. The solid brake disc design provides a robust and durable solution for environments where thebrake disc is exposed to elevated levels of dirt and debris , which could obstruct the ventilation ducts .

[0140] . In summary, the use of two distinct materials for the main body and the brake disc inserts enables the optimisation of the brake disc ' s performance characteristics . The first material provides excellent thermal conductivity and heat dissipation, while the second material of fers high wear resistance and consistent friction characteristics . This combination enhances the durability, structural integrity, and overall performance of the brake disc, rendering it suitable for a broad spectrum of applications and compliant with prevailing environmental standards . The inclusion of solid brake disc designs without ventilation ducts further expands the versatility of the invention, providing solutions for speci fic heavy-duty applications .

[0141] . According to a general embodiment , a braking band 2 with mutually opposing braking surfaces 4 is formed from a first material 37 . Brake band 2 comprises at least one braking surface 4 , which is suitable for cooperating with a brake pad to exert a braking action . The braking band 2 incorporates at least one support structure 3 ; the support structure is a separate component and, when the braking band is not worn, is completely embedded in said first material 37 ; the support structure is connected to at least one insert 1 made of a material suitable for increasing wear resistance , in at least one second material 38 di f ferent from the first material 37 . The support structure 3 is positioned to maintain the precise position of insert 1 during the manufacturing process of brake band 2 . In an unworn brake , at least one surface of insert 1 , or of the composite casting metal portion of the body and insert 1 , is flush with the outer surface of at least one braking surface 4 .

[0142] . According to a further embodiment , at least one insert 1 is a plurality of inserts 1 . This configuration enables the uni form distribution of forces and mechanical stresses during braking, thereby improving wear uni formity and friction performance .

[0143] . According to a further embodiment , at least one insert 1 is a circular crown 5 . This configuration enables the creation of a continuous and uni form friction surface , thereby improving braking ef fectiveness .

[0144] . According to a further embodiment , at least one insert 1 is a sector of a circular crown 6 . This configuration optimises the arrangement of the inserts within the braking band, thereby improving wear resistance and friction performance .

[0145] . According to a further embodiment , at least one insert 1 is a plurality of inserts 1 forming concentric circular crowns . This configuration enables the uni form distribution of forces andmechanical stresses during braking, thereby improving wear uniformity and friction performance.

[0146] . According to a further embodiment, at least one insert 1 is a plurality of inserts 1 forming concentric circular crowns, each comprising a plurality of circular crown sectors 6. This configuration optimises the arrangement of the inserts within the braking band, thereby enhancing wear resistance and friction performance .

[0147] . According to a further embodiment, at least one support structure 3 is a frame 8 comprising at least one support ring 9 and at least one connecting arm 10. This configuration ensures the stability of the inserts during the casting process, maintaining their precise position.

[0148] . According to a further embodiment, said support structure 3 is made of a third material different from both said first material 37 and said second material 38.

[0149] . According to a further embodiment, said support structure 3 is made of a third material, for example steel, which is different from both said first material 37, for example spheroidal cast iron, and said second material 38, for example a composite material comprising silicon carbides.

[0150] . According to a further embodiment, at least one support structure 3 is a frame 8 comprising a plurality of concentric support rings 9 and a plurality of connecting arms 10. This configuration enables the uniform distribution of forces and mechanical stresses during braking, thereby improving wear uniformity and friction performance .

[0151] . According to a further embodiment, at least one connecting arm 10 is connected to at least one support ring 9. This configuration ensures the stability of the inserts during the casting process, maintaining their precise position.

[0152] . According to a further embodiment, at least one connecting arm 10 is welded to the support ring 9. This configuration ensures a robust and stable connection between the connecting arm and the support ring, thereby enhancing the structural strength of the support structure.

[0153] . According to a further embodiment, at least one connecting arm 10 is integrally formed with at least one support ring 9. This configuration ensures a robust and stable connection between the connecting arm and the support ring, thereby enhancing the structural strength of the support structure.

[0154] . According to a further embodiment, the connecting arms 10 are circumferentially equidistantly spaced. This configurationenables the uni form distribution of forces and mechanical stresses during braking, thereby improving wear uni formity and friction performance .

[0155] . According to a further embodiment , said at least one support structure 3 is a frame 8 . This configuration ensures the stability of the inserts during the casting process , maintaining their precise position .

[0156] . According to a further embodiment , at least one of at least one support ring 9 and at least one connecting arm 10 comprises connecting means 11 for connecting to at least one insert 1 . This configuration enables the inserts to be securely af fixed to the support structure , thereby ensuring their stability throughout the casting process .

[0157] . According to a further embodiment , these connecting means 11 are seats for screws 12 . This configuration enables the inserts to be securely fastened to the support structure via screws , thereby ensuring their stability throughout the casting process .

[0158] . According to a further embodiment , these connecting means 11 are seats for rivets 12 . This configuration enables the inserts to be securely fastened to the support structure via rivets , thereby ensuring their stability throughout the casting process .

[0159] . According to a further embodiment , at least one insert 1 is provided with counter-connection means 13 . This configuration enables the inserts to be aligned and securely fastened to the support structure , thereby ensuring their stability during the casting process .

[0160] . According to a further embodiment , these counter-connection means 13 are seats for insert screws 7 that are alignable with seats for screws 12 provided in at least one support structure 3 . This configuration enables the inserts to be securely fastened to the support structure via screws , thereby ensuring their stability throughout the casting process .

[0161] . According to a further embodiment , these counter-connection means 13 are seats for insert rivets 7 that are alignable with seats for rivets 12 provided in at least one support structure 3 . This configuration enables the inserts to be securely fastened to the support structure via rivets , thereby ensuring their stability during the casting process .

[0162] . According to a further embodiment , said at least one insert 1 is connected to said at least one support structure 3 by means of at least one screw 14 . This configuration enables the inserts to be securely fastened to the support structure via screws , thereby ensuring their stability throughout the casting process .

[0163] . According to a further embodiment , said at least one insert 1 is connected to said at least one support structure 3 by means of at least one rivet 15 . This configuration enables the inserts to be securely af fixed to the support structure via rivets , thereby ensuring their stability throughout the casting process .

[0164] . According to a further embodiment , said at least one insert 1 is a plurality of inserts 1 arranged so as to create at least a first separation area 16 between said inserts 1 directed radially, so that the change of material between said first material 37 and said second material 38 creates edges suitable for reviving the braking material of a pad that cooperates with the braking surface 4 of said braking band 2 . This configuration enhances the ef fectiveness of the braking material , thereby ensuring optimal friction performance .

[0165] . According to a further embodiment , said at least one insert 1 is a plurality of inserts 1 arranged so as to create at least a second separation area 17 between said inserts 1 directed circumferentially . This configuration improves the ef fectivenes s of the braking material , ensuring optimal friction performance .

[0166] . According to a further embodiment , said second separation area 17 between said inserts 1 , directed circumferentially, presents a discontinuous circumferential path 18 , or is arranged at least intermittently on di f ferent radii with respect to the theoretical axis of rotation of the braking band 2 . This configuration improves the ef fectiveness of the braking material , ensuring optimal friction performance .

[0167] . According to a further embodiment , the edge of said at least one insert 1 exhibits an undercut 19 with respect to said support structure 3 , thereby enabling said first material 37 introduced into said casting cavity 33 to encompass said at least one insert 1 and retain it within said first material 37 . This configuration enables the creation of a strong mechanical bond between the primary material and the insert , thereby enhancing the structural integrity of the brake disc .

[0168] . According to a further embodiment , said undercut 19 is an inclined chamfer 20 . This configuration enables the creation of a strong mechanical bond between the primary material and the insert , thereby enhancing the structural integrity of the brake disc .

[0169] . According to a further embodiment , said undercut 19 is a recess 21 . This configuration enables the creation of a strong mechanical bond between the primary material and the insert , thereby enhancing the structural integrity of the brake disc .

[0170] . According to a further embodiment , said undercut 19 is a perimeter recess 21 . This configuration enables the creation of astrong mechanical bond between the first material and the insert, thereby enhancing the structural integrity of the brake disc.

[0171] . According to a further embodiment, said at least one insert 1 is formed around said at least one support structure 3 so as to create a geometric coupling 22 between said at least one insert 1 and said at least one support structure 3. This configuration enables the creation of a strong mechanical bond between the primary material and the insert, thereby enhancing the structural integrity of the brake disc.

[0172] . According to a further embodiment, said at least one connecting arm 10 comprises arm ends 23. This configuration enables the inserts to be securely affixed to the support structure, thereby ensuring their stability throughout the casting process.

[0173] . According to a further embodiment, at least one of said arm ends 23 is received in an arm end seat 24 provided in said halfmould 31 or in said core 34. This configuration enables the inserts to be securely affixed to the support structure, thereby ensuring their stability throughout the casting process.

[0174] . According to a further embodiment, said arm end seat 24 is formed in a peripheral edge of said half-mould 31 or said core 34 so that, after casting or injecting said first material 37 into said casting cavity 33, at least the radially outermost of said arm ends 23 protrude from the solidified casting 25 and are subsequently removed by machining. This configuration enables the inserts to be securely affixed to the support structure, thereby ensuring their stability throughout the casting process.

[0175] . According to a further embodiment, said arm ends 23 are secured in position within the arm end seat 24 by adhesive 26. This configuration enables the inserts to be securely affixed to the support structure, thereby ensuring their stability throughout the casting process.

[0176] . According to a further embodiment, said radially outer arm ends 23 are locked in position within the arm end seat 24 by a fixing fork 27 or fixing clip 28 that externally embraces said core 34. This configuration enables the inserts to be securely affixed to the support structure, thereby ensuring their stability throughout the casting process.

[0177] . According to a further embodiment, said radially inner arm ends 23 are locked in position within the arm end seat 24 by means of a third half-mould 29 or internal fixing matrix 30. This configuration enables the inserts to be securely affixed to the support structure, thereby ensuring their stability throughout the casting process.

[0178] . According to a general embodiment , a method for manufacturing a brake disc with improved wear resistance comprises : preparing a support structure 3 with at least one insert 1 made of a second material 38 di f ferent from a first material 37 used for the brake disc body; positioning the support structure 3 with the at least one insert 1 in a casting mould 31 , wherein the support structure 3 maintains a precise position of the at least one insert 1 during the casting process ; casting the first material 37 in a liquid state into the casting mould 31 , allowing the first material 37 to flow around the at least one insert 1 and form the brake disc body; cooling the first material 37 to solidi fy and form the brake disc with the at least one insert 1 partially incorporated into the brake disc body; removing the brake disc from the casting mould 31 ; mechanically machining the brake disc to remove excess material and expose at least one surface of the at least one insert 1 or a composite zone formed by the reaction between the first material 37 and the second material 38 on the friction surface of the brake disc .

[0179] . According to one embodiment , a method for manufacturing a brake disc with improved wear resistance comprises :

[0180] . Prepare a support structure 3 with at least one insert 1 , predominantly fabricated from a second material 38 , distinct from the first material 37 employed for the brake disc body .

[0181] . Position the support structure 3 , with at least one insert 1 , within a casting mould 31 , wherein the support structure 3 maintains a precise position of the at least one insert 1 during the casting process .

[0182] . Pour the first material 37 in a liquid state into the casting mould 31 , allowing the first material 37 to flow around at least one insert 1 and form the body of the brake disc .

[0183] . Cool the first material 37 to solidi fy and form the brake disc, with at least one insert 1 partially incorporated into the brake disc body .

[0184] . Remove the brake disc from casting mould 31 .

[0185] . Mechanically machining the brake disc to remove excess material and expose at least one surface of the at least one insert 1 or a composite zone formed by the reaction between the first material 37 and the second material 38 on the friction surface of the brake disc .

[0186] . According to a further embodiment , a core 34 is provided, forming a ventilated braking band 35 .

[0187] . Position said support structure 3 connected to said core 34 .

[0188] . Insert said core 34 into said first hal f-mould 31 .

[0189] . According to a further embodiment, provide at least one first support structure 3 to which is connected at least one insert 1 made of a second material 38.

[0190] . Insert into said at least one first half-mould 31 the at least said first support structure 3 to which said at least one insert 1 is connected.

[0191] . Provide at least a second support structure 3 to which is connected at least one insert 1 made of a second material 38.

[0192] . Provide at least one core 34 forming a ventilated braking band 35.

[0193] . Position said second support structure 3 connected to said core 34.

[0194] . Insert said core 34 into said first half-mould 31, ensuring that said at least one second support structure 3, to which at least one insert 1 is connected, is positioned on the opposite side with respect to said core 34 to said at least one first support structure 3, to which at least one insert 1 is connected.

[0195] . Close the first half-mould 31 with at least one second halfmould 32, thereby forming a casting cavity 33.

[0196] . Pour or inject the first material 37 of the braking band body 2 into said casting cavity 33.

[0197] . Cooling.

[0198] . Open said half-moulds 31, 32.

[0199] . Machine said outer surface of at least one braking surface 4 so as to remove said machining allowance 36, where present, and to make flush said at least one surface of at least one insert 1 or at least one composite portion of casting metal of the body and of the insert 1 on a first outer surface of at least one first braking surface 4.

[0200] . Machine said outer surface of at least one braking surface 4 so as to remove said machining allowance 36, where present, and expose said at least one surface of at least one insert 1 or at least one composite portion of casting metal of the body and of the insert 1 on a second outer surface of at least one second braking surface 4.REFERENCE LIST1 insert2 braking band3 support structure4 braking surface5 circular crown6 circular crown sector7 Insert locations8 frame9 support ring10 connecting arm11 connecting means12 support structure locations13 counter-connection means14 screws15 rivet16 radial separation area17 circumferential separation area18 discontinuous circumferential path19undercut20 inclined chamfer2 Irecess22geometric coupling23arm extremity24arm end seat25 solidi fied casting26 adhesive27 fixing fork28 fixing clip29 third hal f-mould30 internal fixing matrix31 first hal f-mould32 second hal f-mould33mould cavity34 core35 ventilated braking band36Machining allowance37primary material38 second material39 finished brake disc40 spacerSYMBOLSX-Xaxis of rotationA-A axial directionR-R radial directionC-Ccircumf erential direction

Claims

CLAIMS1. A braking band (2) with opposing braking surfaces (4) , said braking band (2) is made of a first material (37) , said braking band (2) comprises at least one braking surface (4) suitable for cooperating with a brake pad to exert a braking action, said braking band (2) incorporates at least one support structure (3) ; wherein said support structure is a separate component and, with the braking band unworn, is completely embedded in said first material (37) , and wherein at least one insert (1) of a material suitable for increasing wear resistance is connected to said support structure, in at least one second material (38) different from said first material (37) , wherein said support structure (3) is arranged so as to maintain a precise position of the at least one insert (1) during the manufacturing process of the braking band (2) , wherein, with the brake not worn, at least one surface of at least one insert (1) or of the composite casting metal portion of the body and of the insert (1) is flush with the outer surface of at least one braking surface (4) .

2. The braking band according to claim 1, wherein at least one insert (1) is a plurality of inserts (1) ; or wherein at least one insert (1) is a circular crown (5) . or wherein at least one insert (1) is a circular crown sector (6) . or wherein at least one insert (1) is a plurality of inserts (1) forming concentric circular crowns. or wherein at least one insert (1) is a plurality of inserts (1) forming concentric circular crowns, each comprising a plurality of circular crown sectors (6) .

3. The braking band according to any one of claims 1 to 2, wherein at least one support structure (3) is a frame (8) comprising at least one support ring (9) and at least one connecting arm (10) ;and / or wherein said support structure (3) is constructed from a third material, distinct from both said first material (37) and said second material ( 38 ) ; or wherein said support structure (3) is constructed from a third material, for example steel, which is distinct from both said first material(37) , for example spheroidal cast iron, and said second material(38) , for example a composite material comprising silicon carbides .

4. The braking band according to any one of claims 1 to 3, wherein at least one support structure (3) is a frame (8) comprising a plurality of support rings (9) concentric with each other and a plurality of connecting arms (10) ; and / or wherein the connecting arms (10) are circumferentially equidistant.

5. The braking band according to claim 3 or 4, wherein at least one connecting arm (10) is connected to at least one support ring (9) ; or wherein at least one connecting arm (10) is welded to the support ring (9) ; or wherein at least one connecting arm (10) is integrally formed with at least one support ring (9) .

6. The braking band according to any one of claims 1 to 5, wherein said at least one support structure ( 3 ) is a frame ( 8 ) .

7. The braking band according to any one of claims 4 to 6, wherein at least one of at least one support ring (9) and at least one connecting arm (10) comprises connecting means (11) for connecting to at least one insert (1) .

8. The braking band according to claim 7, wherein these connecting means (11) are seats for screws (12) ;or wherein these connecting means (11) are rivet seats (12) .

9. The braking band according to any one of claims 1 to 8, wherein at least one insert (1) comprises counter-connection means (13) .

10. The braking band according to claim 9, wherein these counterconnection means (13) are insert screw seats (7) alignable with screw seats (12) provided in the at least one support structure (3) .

11. The braking band according to claim 9, wherein these counterconnection means (13) are seats for insert rivets (7) alignable with seats for rivets (12) provided in at least one support structure (3) .

12. The braking band according to any one of claims 1 to 11, wherein said at least one insert (1) is connected to said at least one support structure (3) by means of at least one screw (14) ; or wherein said at least one insert (1) is connected to said at least one support structure (3) by means of at least one rivet (15) .

13. The braking band according to any one of claims 1 to 12, wherein said at least one insert (1) is a plurality of inserts (1) arranged so as to create at least a first separation area (16) between said inserts (1) directed radially, so that the change of material between said first material (37) and said second material (38) creates edges suitable for reviving the braking material of a pad that cooperates with the braking surface (4) of said braking band ( 2 ) .

14. The braking band according to any one of claims 1 to 13, wherein said at least one insert (1) is a plurality of inserts (1) arranged so as to create at least a second separation area (17) between said inserts (1) directed circumferentially; or wherein said at least one insert (1) is a plurality of inserts (1) arranged so as to create at least a second separation area (17)between said inserts (1) directed circumferentially; said second separation area (17) between said inserts (1) directed circumferentially has a discontinuous circumferential path (18) or is arranged at least in sections on different radii with respect to the theoretical axis of rotation of the braking band (2) .

15. The braking band according to any one of claims 1 to 14, wherein the edge of said at least one insert (1) exhibits an undercut (19) with respect to said support structure (3) , thereby enabling said first material (37) introduced into said casting cavity (33) to encompass said at least one insert (1) at least along its edge and retain it within said first material (37) .

16. The braking band according to claim 15, wherein said undercut (19) is an inclined chamfer (20) ; or wherein said undercut (19) is a recess (21) ; or wherein said undercut (19) is a perimeter recess (21) .

17. The braking band according to any one of claims 1 to 16, wherein said at least one insert (1) is formed around said at least one support structure (3) so as to create a geometric coupling (22) between said at least one insert (1) and said at least one support structure (3) .

18. The braking band according to any one of claims 1 to 17, wherein said at least one connecting arm (10) comprises arm ends (23) .

19. The braking band according to claim 18, wherein at least one of said arm ends (23) is received in an arm end seat (24) provided in said half-mould (31) or in said core (34) .

20. The braking band according to claim 19, wherein said arm end seat (24) is formed in a peripheral edge of said half-mould (31) or said core (34) so that, after casting or injecting said first material (37) into said casting cavity (33) , at least the radially outermost of said arm ends (23) protrude from the solidified casting (25) and are subsequently removed by machining.

21. The braking band according to claim 19 or 20, wherein said arm ends (23) are secured in position within the arm end seat (24) by adhesive (26) .

22. The braking band according to claim 19, 20, or 21, wherein said radially outer arm ends (23) are locked in position within the arm end seat (24) by a fixing fork (27) or fixing clip (28) that externally embraces said core (34) .

23. The braking band according to any one of claims 19 to 22, wherein said radially inner arm ends (23) are locked in position within the arm end seat (24) by means of a third half-mould (29) and / or internal fixing matrix (30) .

24. A disc brake disc comprising a braking band (2) according to any one of claims 1 to 23.

25. A method for manufacturing a brake disc with improved wear resistance, the method comprising:-preparing a support structure (3) with at least one insert (1) made of a second material (38) different from a first material (37) used for the brake disc body;- positioning the support structure (3) with at least one insert (1) in a casting mould (31) , wherein the support structure (3) maintains a precise position of the at least one insert (1) during the casting process;- Pouring the first material (37) in a liquid state into the casting mould (31) , allowing the first material (37) to flow around the at least one insert (1) and form the body of the brake disc;-cooling the first material (37) to solidify and form the brake disc with at least one insert (1) partially incorporated into the brake disc body;-removing the brake disc from the casting mould (31) ;- mechanically machining the brake disc to remove excess material and expose at least one surface of the at least one insert (1) or a composite zone formed by the reaction between the first material (37) and the second material (38) on the friction surface of the brake disc.

26. A method according to claim 25, wherein:- providing a core (34) forming a ventilated braking band (35) ;-positioning said support structure (3) connected to said core (34) ;-insert said core (34) into said first half-mould (31) prior to proceeding with the closing phase with a second half-mould and proceeding with the casting or injection.

27. A method according to claim 25 or 26, wherein :- providing at least said first support structure (3) to which at least one insert (1) made of a second material (38) is connected;-inserting into said at least one first half-mould (31) the at least said first support structure (3) to which said at least one insert (1) is connected;- providing at least a second support structure (3) to which at least one insert (1) made of a second material (38) is connected;- providing at least one core (34) forming a ventilated braking band ( 35 ) ;-positioning said second support structure (3) connected to said core ( 34 ) ;-insert said core (34) into said first half-mould (31) , ensuring that said at least one second support structure (3) , to which at least one insert (1) is connected, is positioned on the opposite side with respect to said core (34) to said at least one first support structure (3) , to which at least one insert (1) is connected;-closing the first half-mould (31) with at least one second halfmould (32) , thereby forming a casting cavity (33) ;- casting or injecting the first material (37) of the braking band body (2) into said casting cavity (33) ;-cooling;- open said half-moulds (31, 32) ;- machining said outer surface of at least one braking surface (4) so as to remove said machining allowance (36) , where present, and to make flush said at least one surface of at least one insert (1) or at least one composite portion of casting metal of the body andof the insert (1) on a first outer surface of at least one first braking surface (4) ;- machining said outer surface of at least one braking surface (4) so as to remove said machining allowance (36) , where present, and to make flush said at least one surface of at least one insert (1) or at least one composite portion of casting metal of the body and of the insert (1) on a second outer surface of at least one second braking surface (4) . Brake Band and Brake Disc with improved friction performance

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