A composite brake disc and its bonding enhancement method and thermal conductivity enhancement method

Abstract

The present invention discloses a composite brake disc, comprising a brake disc body and a brake ring involved in friction braking, wherein the brake ring has a first bonding surface, and the brake disc body has a second bonding surface, wherein the first bonding surface is provided with a plurality of first protrusions and / or a plurality of second protrusions, and the second bonding surface is provided with a first groove for accommodating the first protrusions and / or a second groove for accommodating the second protrusions. The composite brake disc of the present invention improves the bonding strength between the brake ring and the brake disc body, avoids separation during use that results in reduced heat conduction efficiency, and thus can improve the thermal conductivity of the brake disc. The present invention also provides a bonding enhancement method for a composite brake disc and a thermal conductivity enhancement method for a composite brake disc.

Description

Technical Field

[0001] The present invention belongs to the technical field of vehicle brake discs, and in particular, relates to a composite brake disc and a method for combining and enhancing the same and a method for enhancing the thermal conductivity thereof. Background Art

[0002] The existing floating composite brake disc is mainly composed of a brake disc body and two inner and outer brake rings. The brake disc body is made of cast aluminum, and the inner and outer brake rings are cast iron brake rings. The degree of bonding and thermal conductivity between the inner and outer brake rings and the brake disc body will directly affect the heat dissipation capacity of the brake disc, and is the key to the successful development of the composite brake disc.

[0003] Since there is thermal resistance at the joint surface between the brake ring and the brake disc body of the existing composite brake disc, the heat generated during braking cannot be transferred to the brake disc body in time, resulting in excessive temperature rise of the brake disc and reduced vehicle braking performance. Summary of the invention

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention provides a composite brake disc, the purpose of which is to improve the connection strength and thermal conductivity between composite materials.

[0005] In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is: a composite brake disc, including a brake disc body and a brake ring, the brake ring has a first bonding surface, the brake disc body has a second bonding surface, the first bonding surface is provided with a plurality of first protrusions and / or a plurality of second protrusions, the second bonding surface is provided with a first groove for accommodating the first protrusions and / or a second groove for accommodating the second protrusions.

[0006] The brake disc body is made of lightweight material.

[0007] The brake disc body is made of aluminum, and the brake ring is made of gray iron.

[0008] The present invention also provides a method for enhancing the bonding of a composite brake disc, by arranging a plurality of first protrusions and / or a plurality of second protrusions on the first bonding surface of the brake ring, and arranging a first groove for accommodating the first protrusions and / or a second groove for accommodating the second protrusions on the second bonding surface of the brake disc body, so as to improve the bonding strength between the brake ring and the brake disc body.

[0009] The brake ring comprises a friction ring body, and the first protrusion and / or the second protrusion are integrally cast with the friction ring body.

[0010] The brake disc body is made of lightweight material.

[0011] The brake disc body is made of aluminum, and the brake ring is made of gray iron.

[0012] The present invention also provides a method for enhancing the thermal conductivity of a composite brake disc. When manufacturing a casting device for a brake ring, a coating is applied to a sand core or a sand mold of the casting device, and then the sand core or the sand mold is heated to form a first cavity and / or a second cavity on the sand core or the sand mold; the first cavity is used to accommodate molten metal during the casting process to form a first protrusion, and the second cavity is used to accommodate molten metal during the casting process to form a second protrusion.

[0013] The coating is diatom mud.

[0014] The composite brake disc of the present invention improves the bonding strength between the brake ring and the brake disc body, avoids separation during use that leads to reduced heat conduction efficiency, and thus can improve the thermal conductivity of the brake disc. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] This specification includes the following drawings, which show the following contents:

[0016] Figure 1 is a cross-sectional view of the composite brake disc of the first embodiment;

[0017] Figure 2 is a cross-sectional view of the composite brake disc of the second embodiment;

[0018] Marked in the figure: 1, brake disc body; 2, brake ring; 3, friction ring body; 4, first protrusion or second protrusion. DETAILED DESCRIPTION

[0019] The specific implementation methods of the present invention are further explained in detail below by describing the embodiments with reference to the accompanying drawings, with the aim of helping those skilled in the art to have a more complete, accurate and in-depth understanding of the concept and technical solution of the present invention and facilitating its implementation.

[0020] Embodiment 1

[0021] like Figure 1 As shown, this embodiment 1 provides a composite brake disc, including a brake disc body made of cast aluminum material and a brake ring made of cast iron material, the brake ring has a first bonding surface, the brake disc body has a second bonding surface, the first bonding surface is provided with a plurality of first protrusions and / or a plurality of second protrusions, the second bonding surface is provided with a first groove for accommodating the first protrusion and / or a second groove for accommodating the second protrusion, the cross-sectional area of ​​the first protrusion gradually decreases along its length direction, and the cross-sectional area of ​​the second protrusion gradually increases along its length direction.

[0022] Specifically, if Figure 1As shown, the brake ring is a circular ring structure, the brake disc body and the brake ring are coaxially fixedly connected, and the brake disc body is used to be installed on the wheel. The brake ring also has a braking surface, which is a plane perpendicular to the axis of the brake ring. The braking surface is used to contact the brake pad of the brake caliper assembly to generate braking force. The first bonding surface and the braking surface are coaxially arranged, and the first bonding surface and the braking surface are opposite sides of the brake ring. Two brake rings are provided and the two brake rings are symmetrically arranged. The brake disc body is located between the two brake rings and the two brake rings are fixedly connected. The two brake rings are integrally cast. The brake disc body has two second bonding surfaces, which are opposite sides of the brake disc body. The two second bonding surfaces are respectively fitted with the first bonding surfaces of the two brake rings. The first protrusion has a certain length, the length direction of the first protrusion is perpendicular to the first bonding surface or the length direction of the first protrusion and the first bonding surface have an angle less than 90 degrees, the first protrusion extends toward the outside of the first bonding surface, and the cross-sectional area of ​​the first protrusion refers to the area of ​​the cross section perpendicular to the length direction of the first protrusion, that is, the first protrusion has a large diameter end and a small diameter end, the size of the large diameter end of the first protrusion is larger than the size of the small diameter end, the cross-sectional area of ​​the large diameter end of the first protrusion is larger than the cross-sectional area of ​​the small diameter end, the large diameter end of the first protrusion is fixedly connected to the first bonding surface, the small diameter end of the first protrusion is away from the first bonding surface and the small diameter end of the first protrusion is located in the first groove. The second protrusion also has a certain length, the length direction of the second protrusion is perpendicular to the first bonding surface or the length direction of the second protrusion has an angle less than 90 degrees with the first bonding surface, the second protrusion extends toward the outside of the first bonding surface, and the cross-sectional area of ​​the second protrusion refers to the area of ​​the cross section perpendicular to the length direction of the second protrusion, that is, the second protrusion has a large diameter end and a small diameter end, the size of the large diameter end of the second protrusion is larger than the size of the small diameter end, the cross-sectional area of ​​the large diameter end of the second protrusion is larger than the cross-sectional area of ​​the small diameter end, the small diameter end of the second protrusion is fixedly connected to the first bonding surface, the large diameter end of the second protrusion is away from the first bonding surface and the large diameter end of the second protrusion is located in the second groove.

[0023] like Figure 1As shown, the brake ring includes a friction ring body, and a first protrusion and / or a second protrusion are arranged on the friction ring body, and the first protrusion and / or the second protrusion are integrally cast with the friction ring body. The friction ring body is a circular ring structure, and the brake disc body and the friction ring body are coaxially fixedly connected, and the braking surface and the first bonding surface are two opposite side surfaces of the friction ring body. The first groove matches the shape of the first protrusion and the number of the first grooves is the same as the number of the first protrusions. Each first protrusion is respectively embedded in a first groove, and the first groove is a groove formed by being recessed from the second bonding surface toward the inside of the brake disc body. The second groove matches the shape of the second protrusion and the number of the second grooves is the same as the number of the second protrusions. Each second protrusion is respectively embedded in a second groove, and the second groove is a groove formed by being recessed from the second bonding surface toward the inside of the brake disc body. Only the first protrusion may be provided on the friction ring body, and correspondingly, only the first groove may be provided on the brake disc body; only the second protrusion may be provided on the friction ring body, and correspondingly, only the second groove may be provided on the brake disc body; the first protrusion and the second protrusion may be provided on the friction ring body at the same time, and correspondingly, the first groove and the second groove may be provided on the brake disc body at the same time.

[0024] When manufacturing the brake disc body, two brake rings are placed in the mold cavity of the casting device. During the casting process, the molten metal poured into the mold cavity is aluminum liquid, and the molten metal fills the mold cavity; during the cooling process, the brake disc body is formed in the mold cavity, the first protrusion and / or the second protrusion are embedded in the interior of the brake disc body, that is, the first groove and / or the second groove are formed on the brake disc body, the first protrusion and / or the second protrusion are fixedly connected to the brake disc body, and the brake ring and the brake disc body are combined into one to form a brake disc. With this structure, by optimizing the structure of the brake ring, the molten metal surrounds the first protrusion and / or the second protrusion during the casting process, and finally the brake disc body is connected to the brake ring, the first protrusion and / or the second protrusion as a whole, which can improve the bonding strength of aluminum and iron, and also improve the thermal conductivity of the iron-aluminum contact surface, which helps to reduce the temperature rise of the brake disc during the vehicle braking process. By improving the bonding strength between the brake ring and the brake disc body, the separation of the bonding surface between the brake ring and the brake disc body during use can be avoided, resulting in a decrease in heat conduction efficiency, thereby improving the thermal conductivity of the brake disc.

[0025] The first embodiment of the present invention also provides a method for enhancing the bonding of a composite brake disc, by providing a plurality of first protrusions and / or a plurality of second protrusions on the first bonding surface of the brake ring, and providing a first groove for accommodating the first protrusions and / or a second groove for accommodating the second protrusions on the second bonding surface of the brake disc body, so as to improve the bonding strength between the brake ring and the brake disc body.

[0026] This embodiment 1 also provides a method for enhancing the thermal conductivity of a composite brake disc. When manufacturing the brake ring, the first protrusion and / or the second protrusion are integrally cast with the friction ring body, and the two brake rings are also integrally cast, and the two brake rings are fixedly connected to form an integral structure. When manufacturing the brake disc body, the integral structure formed by connecting the two brake rings is placed in the mold cavity of the casting device. During the casting process, the molten metal poured into the mold cavity is aluminum liquid, and the molten metal fills the mold cavity; during the cooling process, the brake disc body is formed in the mold cavity, and the first protrusion and / or the second protrusion are embedded in the interior of the brake disc body, that is, the first groove and / or the second groove are formed on the brake disc body, the first protrusion and / or the second protrusion are fixedly connected to the brake disc body, and the brake ring and the brake disc body are combined into one, forming an aluminum-iron composite brake disc.

[0027] Embodiment 2

[0028] like Figure 2 As shown, the second embodiment provides a composite brake disc, including a brake disc body made of cast aluminum material and a brake ring made of cast iron material, the brake ring having a first bonding surface, the brake disc body having a second bonding surface, the first bonding surface being provided with a plurality of first protrusions and / or a plurality of second protrusions, the second bonding surface being provided with a first groove for accommodating the first protrusion and / or a second groove for accommodating the second protrusion, the cross-sectional area of ​​the first protrusion gradually decreases along its length direction, and the cross-sectional area of ​​the second protrusion gradually increases along its length direction.

[0029] Specifically, if Figure 2As shown, the brake ring is a circular ring structure, the brake disc body and the brake ring are coaxially fixedly connected, and the brake disc body is used to be installed on the wheel. The brake ring also has a braking surface, which is a plane perpendicular to the axis of the brake ring. The braking surface is used to contact the brake pad of the brake caliper assembly to generate braking force. The first bonding surface and the braking surface are coaxially arranged, and the first bonding surface and the braking surface are opposite sides of the brake ring. Two brake rings are provided and the two brake rings are symmetrically arranged. The brake disc body is located between the two brake rings and the two brake rings are fixedly connected. The brake disc body has two second bonding surfaces, which are opposite sides of the brake disc body, and the two second bonding surfaces are respectively fitted with the first bonding surfaces of the two brake rings. The first protrusion has a certain length, the length direction of the first protrusion is perpendicular to the first bonding surface or the length direction of the first protrusion and the first bonding surface have an angle less than 90 degrees, the first protrusion extends toward the outside of the first bonding surface, and the cross-sectional area of ​​the first protrusion refers to the area of ​​the cross section perpendicular to the length direction of the first protrusion, that is, the first protrusion has a large diameter end and a small diameter end, the size of the large diameter end of the first protrusion is larger than the size of the small diameter end, the cross-sectional area of ​​the large diameter end of the first protrusion is larger than the cross-sectional area of ​​the small diameter end, the large diameter end of the first protrusion is fixedly connected to the first bonding surface, the small diameter end of the first protrusion is away from the first bonding surface and the small diameter end of the first protrusion is located in the first groove. The second protrusion also has a certain length, the length direction of the second protrusion is perpendicular to the first bonding surface or the length direction of the second protrusion has an angle less than 90 degrees with the first bonding surface, the second protrusion extends toward the outside of the first bonding surface, and the cross-sectional area of ​​the second protrusion refers to the area of ​​the cross section perpendicular to the length direction of the second protrusion, that is, the second protrusion has a large diameter end and a small diameter end, the size of the large diameter end of the second protrusion is larger than the size of the small diameter end, the cross-sectional area of ​​the large diameter end of the second protrusion is larger than the cross-sectional area of ​​the small diameter end, the small diameter end of the second protrusion is fixedly connected to the first bonding surface, the large diameter end of the second protrusion is away from the first bonding surface and the large diameter end of the second protrusion is located in the second groove.

[0030] like Figure 2As shown, the brake ring includes a friction ring body, and a first protrusion and / or a second protrusion are arranged on the friction ring body, and the first protrusion and / or the second protrusion are integrally cast with the friction ring body. The friction ring body is a circular ring structure, and the brake disc body and the friction ring body are coaxially fixedly connected, and the braking surface and the first bonding surface are two opposite side surfaces of the friction ring body. The first groove matches the shape of the first protrusion and the number of the first grooves is the same as the number of the first protrusions. Each first protrusion is respectively embedded in a first groove, and the first groove is a groove formed by being recessed from the second bonding surface toward the inside of the brake disc body. The second groove matches the shape of the second protrusion and the number of the second grooves is the same as the number of the second protrusions. Each second protrusion is respectively embedded in a second groove, and the second groove is a groove formed by being recessed from the second bonding surface toward the inside of the brake disc body. Only the first protrusion may be provided on the friction ring body, and correspondingly, only the first groove may be provided on the brake disc body; only the second protrusion may be provided on the friction ring body, and correspondingly, only the second groove may be provided on the brake disc body; the first protrusion and the second protrusion may be provided on the friction ring body at the same time, and correspondingly, the first groove and the second groove may be provided on the brake disc body at the same time.

[0031] When manufacturing the brake disc body, two brake rings are placed in the mold cavity of the casting device. During the casting process, the molten metal poured into the mold cavity is aluminum liquid, and the molten metal fills the mold cavity; during the cooling process, the brake disc body is formed in the mold cavity, the first protrusion and / or the second protrusion are embedded in the interior of the brake disc body, that is, the first groove and / or the second groove are formed on the brake disc body, the first protrusion and / or the second protrusion are fixedly connected to the brake disc body, and the brake ring and the brake disc body are combined into one to form a brake disc. With this structure, by optimizing the structure of the brake ring, the molten metal surrounds the first protrusion and / or the second protrusion during the casting process, and finally the brake disc body is connected to the brake ring, the first protrusion and / or the second protrusion as a whole, which can improve the bonding strength of aluminum and iron, and also improve the thermal conductivity of the iron-aluminum contact surface, which helps to reduce the temperature rise of the brake disc during the vehicle braking process. By improving the bonding strength between the brake ring and the brake disc body, the separation of the bonding surface between the brake ring and the brake disc body during use can be avoided, resulting in a decrease in heat conduction efficiency, thereby improving the thermal conductivity of the brake disc.

[0032] The second embodiment also provides a method for enhancing the bonding of a composite brake disc, by providing a plurality of first protrusions and / or a plurality of second protrusions on the first bonding surface of the brake ring, and providing a first groove for accommodating the first protrusions and / or a second groove for accommodating the second protrusions on the second bonding surface of the brake disc body, so as to improve the bonding strength between the brake ring and the brake disc body.

[0033] The second embodiment also provides a method for enhancing the thermal conductivity of a composite brake disc. When manufacturing the brake ring, the first protrusion and / or the second protrusion are integrally cast with the friction ring body. When manufacturing the brake disc body, two brake rings are placed in a mold cavity of a casting device. During the casting process, the molten metal poured into the mold cavity is aluminum liquid, and the molten metal fills the mold cavity. During the cooling process, a brake disc body is formed in the mold cavity, and the first protrusion and / or the second protrusion are embedded in the inside of the brake disc body, that is, the first groove and / or the second groove are formed on the brake disc body, the first protrusion and / or the second protrusion are fixedly connected to the brake disc body, and the brake ring and the brake disc body are combined into one, forming an aluminum-iron composite brake disc.

[0034] Embodiment 3

[0035] The third embodiment of the present invention provides a method for enhancing the thermal conductivity of an aluminum-iron composite brake disc, by providing a plurality of first protrusions and / or a plurality of second protrusions on a first mating surface of a brake ring, and providing a first groove for accommodating the first protrusions and / or a second groove for accommodating the second protrusions on a second mating surface of a brake disc body, so as to improve the bonding strength between the brake ring and the brake disc body.

[0036] Specifically, the main difference between the method for enhancing the thermal conductivity of the aluminum-iron composite brake disc provided in the third embodiment and the method for enhancing the thermal conductivity of the aluminum-iron composite brake disc provided in the first, second and third embodiments is that the method for forming the first protrusion and / or the second protrusion is added, and the rest of the contents are the same, and the same parts will not be repeated here.

[0037] The brake ring is cast by a casting device, which mainly includes a lower box, an upper box matched with the lower box, and a sand core or sand mold arranged in the mold cavity and used to form the brake ring casting, and the upper box and the lower box constitute a sand box. In this embodiment, when manufacturing the casting device of the brake ring, a coating is applied on the sand core or sand mold of the casting device to form a coating layer on the surface of the sand core or sand mold, and then the sand core or sand mold is heated to form a first cavity and / or a second cavity on the sand core or sand mold; the first cavity is used to contain molten metal during the casting process to form a first protrusion, and the second cavity is used to contain molten metal during the casting process to form a second protrusion.

[0038] The coating applied on the surface of the sand core or sand mold of the casting device is preferably diatom mud. When the sand core or sand mold is heated, the diatom mud can form a cavity on the surface of the sand core or sand mold after the water evaporates, that is, the first cavity and / or the second cavity are formed on the surface of the sand core or sand mold. Then, when making the brake ring, after the molten metal (molten iron) is smelted, the molten metal is poured from the pouring port of the casting device, or into the first cavity and / or the second cavity on the surface of the sand mold; during the cooling process, a friction ring body is formed in the mold cavity, a first protrusion is formed in the first cavity, and a second protrusion is formed in the second cavity. The first protrusion and / or the second protrusion are fixedly connected to the friction ring body to form a brake ring.

[0039] Through this method, various irregular or even barbed shaped cavities are formed on the surface of the sand core or sand mold, and various protrusions or pits are formed accordingly after the metal liquid is poured. In the subsequent secondary pouring process, the aluminum liquid will fill between the protrusions and pits, so that a good interlocking connection is formed between the bonding surfaces of the composite material, the bonding strength is improved, and the relatively large thermal resistance formed between the bonding surfaces due to poor bonding is reduced. It is difficult to form such irregular or even barbed shaped cavities on the surface of the sand core or sand mold by machining.

[0040] The present invention is described above by way of example in conjunction with the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-mentioned methods. As long as various non-substantial improvements are made using the method concept and technical solution of the present invention; or the above concept and technical solution of the present invention are directly applied to other occasions without improvement, they are all within the protection scope of the present invention.

Claims

1. A method for enhancing the thermal conductivity of a composite brake disc, the composite brake disc comprising a brake disc body and a brake ring, the brake ring having a first bonding surface, the brake disc body having a second bonding surface, the first bonding surface being provided with a plurality of first protrusions and / or a plurality of second protrusions, the second bonding surface being provided with a first groove for accommodating the first protrusions and / or a second groove for accommodating the second protrusions; It is characterized in that When making a casting device for a brake ring, a coating is applied to a sand core or a sand mold of the casting device, and then the sand core or the sand mold is heated to form a first cavity and / or a second cavity on the sand core or the sand mold; the first cavity is used to accommodate molten metal during the casting process to form a first protrusion, and the second cavity is used to accommodate molten metal during the casting process to form a second protrusion.

2. The method for enhancing the thermal conductivity of a composite brake disc according to claim 1, characterized in that: The coating is diatom mud.

3. The method for enhancing the thermal conductivity of a composite brake disc according to claim 1, characterized in that: The brake disc body is made of lightweight material.

4. The method for enhancing the thermal conductivity of a composite brake disc according to claim 2, characterized in that: The brake disc body is made of aluminum, and the brake ring is made of gray iron.

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