Ceramic brake disc and method for processing thereof
By employing a method where the needle-punching path forms an angle with the center line of the unit layer during the needle-punching process of ceramic brake discs, the problem of weak fiber bonding was solved, thereby improving the shear strength and bending strength of ceramic brake discs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- BYD CO LTD
- Filing Date
- 2023-05-31
- Publication Date
- 2026-08-04
AI Technical Summary
In the traditional ceramic brake disc needle punching process, the needles and fibers are highly destructive, resulting in weak bonding between the fibers and the blank, and insufficient shear strength and bending strength.
The needle punching method is used to form an angle between the needle punching path and the center line of the unit layer, which reduces damage to the carbon fiber and increases the bonding force between the carbon fibers. The ceramic brake disc is formed by chemical vapor deposition and liquid phase silicon infiltration.
It improves the shear strength and bending strength of ceramic brake discs, enhances the bonding force between fibers and the blank, and improves processing efficiency.
Smart Images
Figure CN119058175B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of vehicles, and more specifically to a ceramic brake disc and its processing method. Background Technology
[0002] Ceramic brake discs are reinforced composite ceramics synthesized from carbon fiber and silicon carbide at high temperatures. Ceramic brake discs effectively and stably resist heat fade, exhibiting heat resistance many times higher than ordinary brake discs. They are lightweight and offer superior high-temperature braking performance, making them widely used.
[0003] Traditional ceramic brake discs are made by stacking substrates, treating them with a needle-punching process, and then subjecting the treated substrates to subsequent carbonization and chemical vapor deposition processes. In the traditional process, the needles and the surface of the brake disc are at a 90° angle, meaning the needles are inserted vertically into the brake disc. This process causes significant damage to the fibers, and the bonding force between the fibers hooked down by the needles and the preform is weak, resulting in low shear strength of the sample after silicon infiltration. Summary of the Invention
[0004] In order to solve the above-mentioned technical problems, or at least partially solve the above-mentioned technical problems, the present invention provides a ceramic brake disc and a method for processing the same.
[0005] The present invention provides a ceramic brake disc, including a ceramic brake disc body, the ceramic brake disc body including at least two stacked unit layers, the needle path of the unit layer forming an angle with the center line of the unit layer, and the needle path of the upper unit layer extending at least into the adjacent and lower unit layer.
[0006] Optionally, there are two unit layers, and the extension directions of the needle puncture paths of two adjacent unit layers may be the same or different.
[0007] Optionally, the projections of the needle paths of two adjacent unit layers onto the vertical plane intersect.
[0008] Optionally, there are multiple unit layers, and the needle path of the upper unit layer extends to the multiple unit layers below.
[0009] Optionally, the needling paths between two adjacent unit layers are different.
[0010] Optionally, the needle puncture paths are different between the multiple unit layers.
[0011] Optionally, the projections of the needle paths between at least some of the unit layers onto the vertical plane intersect.
[0012] Optionally, the angle between the needle path of the unit layer and the center line of the unit layer is 30-89°, or the angle between the needle path of the unit layer and the center line of the unit layer is -30-89°.
[0013] Optionally, the unit layer comprises two mesh layers and a unidirectional fiber layer, the unidirectional fiber layer being stacked between the two mesh layers; or
[0014] The unit layer comprises a mesh layer and two unidirectional fiber layers, wherein the mesh layer is stacked between the two unidirectional fiber layers; or
[0015] The unit layer includes multiple unidirectional fiber layers, which are stacked together; or
[0016] The unit layer includes multiple mesh layers and multiple unidirectional fiber layers, which are stacked alternately.
[0017] The present invention also provides a method for processing a ceramic brake disc, comprising the following steps:
[0018] The substrates are stacked to form multiple unit layers;
[0019] The first unit layer is needled, and the needled direction forms an angle with the centerline direction of the unit layer;
[0020] The second unit layer is stacked on top of the first unit layer. The second unit layer is needled, and the needle direction forms an angle with the center line direction of the unit layer. At the same time, the needle is inserted into the first unit layer.
[0021] Optionally, the following steps are also included:
[0022] The third unit layer is stacked on top of the second unit layer. The third unit layer is needled, and the needle direction forms an angle with the center line direction of the unit layer. At the same time, the needle is inserted into the second unit layer, and so on.
[0023] Optionally, the following steps are also included:
[0024] The third unit layer is stacked on top of the second unit layer. The third unit layer is needled, and the needle direction forms an angle with the center line of the unit layer. At the same time, the needle is inserted into the second unit layer and the first unit layer in sequence, and so on.
[0025] Optionally, the following steps are also included:
[0026] Carbonize the embryo obtained after needle puncture;
[0027] After the carbonized preform is subjected to chemical vapor deposition, a chemical vapor deposition preform is obtained;
[0028] Chemical vapor deposition preforms are subjected to liquid phase silicon infiltration to obtain ceramic brake preforms;
[0029] Ceramic brake blanks are surface-processed to obtain carbon-ceramic brake discs.
[0030] The technical solution provided by the embodiments of the present invention has the following advantages compared with the prior art:
[0031] The ceramic brake disc provided by this invention has a certain angle between the needle and the surface of the unit layer during needle punching, so as to reduce the damage to the carbon fibers of the unit layer and increase the bonding force between the carbon fibers, thereby increasing the shear strength and bending strength of the ceramic brake disc. Attached Figure Description
[0032] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with the invention and, together with the description, serve to explain the principles of the invention.
[0033] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, those skilled in the art can obtain other drawings based on these drawings without creative effort.
[0034] Figure 1 This is a schematic diagram of an embodiment of the present invention where there are two unit layers and the needle puncture paths of the two unit layers are the same;
[0035] Figure 2 This is a schematic diagram illustrating a scenario where there are two unit layers in an embodiment of the present invention, and the needle puncture paths of the two unit layers are not the same.
[0036] Figure 3 This is a schematic diagram of an embodiment of the present invention where there are two unit layers and the projections of the needle paths of the two unit layers on the vertical plane intersect in the first manner.
[0037] Figure 4 This is a schematic diagram of an embodiment of the present invention where there are two unit layers and the projections of the needle paths of the two unit layers on the vertical plane intersect in a second manner.
[0038] Figure 5 This is a schematic diagram illustrating an embodiment of the present invention where there are multiple unit layers, and the needle path of the upper unit layer extends to the unit layer below it.
[0039] Figure 6 This is a schematic diagram illustrating a scenario where the unit layer described in this embodiment of the invention comprises multiple unit layers, and the needle path of the upper unit layer extends to the multiple unit layers below.
[0040] Figure 7 This is a schematic diagram of a unit layer in an embodiment of the present invention, which consists of two unidirectional fiber layers and a mesh layer.
[0041] Figure 8 This is a schematic diagram of a unit layer in an embodiment of the present invention, which consists of two mesh layers and one unidirectional fiber layer.
[0042] Figure 9 This is a schematic diagram of a unit layer in an embodiment of the present invention that is composed of multiple unidirectional fiber layers;
[0043] Figure 10 This is a schematic diagram of a unit layer in an embodiment of the present invention, which is composed of multiple mesh layers and multiple unidirectional fiber layers stacked alternately.
[0044] Explanation of reference numerals in the attached figures
[0045] 1. Unit layer; 2. Mesh layer; 3. Unidirectional fiber layer. Detailed Implementation
[0046] To better understand the above-mentioned objectives, features, and advantages of the present invention, the solutions of the present invention will be further described below. It should be noted that, unless otherwise specified, the embodiments and features of the present invention can be combined with each other.
[0047] The following description sets forth many specific details in order to provide a full understanding of the invention, but the invention may also be practiced in other ways different from those described herein; obviously, the embodiments described in the specification are only some, not all, of the embodiments of the invention.
[0048] Combination Figures 1 to 6 As shown, the ceramic brake disc provided in the embodiment of the present invention includes a ceramic brake disc body, which includes at least two stacked unit layers 1. The needle path of the unit layer 1 forms an angle with the center line of the unit layer 1, and the needle path of the upper unit layer 1 extends at least into the adjacent and lower unit layer 1.
[0049] When the needle penetrates the second unit layer 1 and then extends into the first unit layer 1, it can completely penetrate all the substrates within the first unit layer 1, or it can penetrate only a portion of the substrates within the first unit layer 1, depending on the design requirements. Furthermore, the needle's piercing direction during the first piercing can be the same as or different from the piercing direction during the second piercing, and the piercing directions during both piercings can also be designed according to actual needs.
[0050] The ceramic brake disc provided by the present invention has the needle at a certain angle to the surface of the unit layer 1 during needle punching, so as to reduce the damage to the carbon fibers of the unit layer 1 and increase the bonding force between the carbon fibers, thereby increasing the shear strength and bending strength of the ceramic brake disc.
[0051] In some implementations, there are two unit layers 1, and the extension direction of the needle path of two adjacent unit layers 1 is the same. That is, the needle direction during the first needle insertion is the same as the needle direction during the second needle insertion. At this time, the needle during the second needle insertion can be inserted into the first unit layer 1 again according to the needle path during the first needle insertion, further increasing the number of needle insertions at the same position in the first unit layer 1.
[0052] In other implementations, such as Figure 1 As shown, there are two unit layers 1. The extension directions of the needle paths of two adjacent unit layers 1 are parallel but do not intersect. That is, the needle direction during the first needle insertion is parallel but does not intersect with the needle direction during the second needle insertion. At this time, the needle during the second needle insertion is inserted into the needle gap of the first unit layer 1 (the needle gap at this point is the uninserted part) to ensure that the needle density on the first unit layer 1 meets the design requirements.
[0053] This design reduces the needle density of the first unit layer 1 during the first needle punch, thereby increasing the needle punching efficiency of the first unit layer 1. Meanwhile, the second unit layer 1 only increases the needle punching depth, which has a small impact on the reduction of the needle punching process efficiency. Therefore, this needle punching method can ensure the processing efficiency of ceramic brake discs while increasing the processing efficiency of ceramic brake discs.
[0054] In other implementations, such as Figure 2 As shown, there are two unit layers 1, and the extension directions of the needle paths of two adjacent unit layers 1 are different. That is, the needle direction during the first needle insertion is different from the needle direction during the second needle insertion. Furthermore, after the needle during the second needle insertion penetrates into the first unit layer 1, the projections of the needle directions during the first needle insertion and the needle directions during the second needle insertion on the vertical plane do not intersect, so that the needle during the second needle insertion inserts into the needle gap during the first needle insertion (the needle gap at this point is the un-needled portion).
[0055] This design reduces the needle density of the first unit layer 1 during the first needle punch, thereby increasing the needle punching efficiency of the first unit layer 1. Meanwhile, the second unit layer 1 only increases the needle punching depth, having a minimal impact on the efficiency reduction of the needle punching process. Therefore, this needle punching method ensures the processing efficiency of the ceramic brake disc. Furthermore, it allows for two needle punching angles within a single unit layer 1, thereby increasing the bonding strength between the carbon fibers.
[0056] In other implementations, such as Figure 3 As shown, there are two unit layers 1. The extension directions of the needle paths of two adjacent unit layers 1 are different, that is, the needle direction during the first needle insertion is different from the needle direction during the second needle insertion. At this time, the projections of the needle paths of the two adjacent unit layers 1 on the vertical plane intersect. That is, after the needle penetrates the first unit layer 1 during the second needle insertion, the projections of the needle directions during the first needle insertion and the needle directions during the second needle insertion on the vertical plane intersect. Furthermore, the projections of the needle directions during the first needle insertion and the needle directions during the second needle insertion on the vertical direction are inclined towards one side of the centerline of unit layer 1.
[0057] This design method can increase the needle density of the first unit layer 1 and achieve two needle angles in a unit layer 1, thereby increasing the bonding force between carbon fibers. Furthermore, the projections of the two needle directions on the vertical plane intersect, enabling needles to be needled in two directions at a certain point in the first unit layer 1, further increasing the bonding force between carbon fibers.
[0058] In other implementations, such as Figure 4 As shown, there are two unit layers 1. The extension directions of the needle paths of two adjacent unit layers 1 are different, that is, the needle direction during the first needle insertion is different from the needle direction during the second needle insertion. At this time, the projections of the needle paths of the two adjacent unit layers 1 on the vertical plane intersect. That is, after the needle penetrates the first unit layer 1 during the second needle insertion, the needle path intersects with the needle path of the first unit layer 1 during the first needle insertion. Furthermore, the needle paths during the first needle insertion and the needle paths during the second needle insertion are inclined towards the corresponding sides of the centerline of the unit layer 1.
[0059] This design method can increase the needle density of the first unit layer 1 and achieve two needle angles in a unit layer 1, thereby increasing the bonding force between carbon fibers. Furthermore, the projections of the two needle directions on the vertical plane intersect, enabling needles to be needled in two directions at a certain point in the first unit layer 1, further increasing the bonding force between carbon fibers.
[0060] In this application, the needle path may be oriented toward or away from the centerline of unit layer 1, or the plane on which the needle path is located may be perpendicular to the radial direction of unit layer 1, or the plane on which the needle direction is located may be at a certain angle to the centerline of unit layer 1. The specific needle direction may be set according to actual needs.
[0061] In another embodiment, there are multiple unit layers 1, with the needle path of the upper unit layer 1 extending to the multiple unit layers 1 below. This method is suitable for ceramic brake discs with three or more unit layers 1.
[0062] In some implementations, the needling paths between two adjacent unit layers 1 are the same, that is, the needling directions between two adjacent unit layers 1 are the same. In this case, the needles used for subsequent needling can be inserted into the previous unit layer 1 again according to the needling path used for the previous unit layer 1, further increasing the number of needlings at the same position in the previous unit layer 1.
[0063] In other embodiments, the needling paths between two adjacent unit layers 1 are the same, that is, the needling directions between two adjacent unit layers 1 are the same. In this case, the needles for subsequent needling are inserted into the needling gaps of the previous unit layer 1 (the needling gaps are the unneeded parts) to ensure that the needling density on the previous unit layer 1 meets the design requirements.
[0064] This design reduces the needle density of the previous unit layer 1 during needle punching, thereby increasing the needle punching efficiency of the previous unit layer 1. Meanwhile, subsequent unit layers 1 only increase the needle punching depth, which has a small impact on the reduction of needle punching process efficiency. Therefore, this needle punching method can ensure the processing efficiency of ceramic brake discs while increasing the processing efficiency of ceramic brake discs.
[0065] In other embodiments, the needling paths between two adjacent unit layers 1 are different, that is, the needling directions between two adjacent unit layers 1 are different. Furthermore, after the needle of a subsequent needling penetrates into the previous unit layer 1, the projection of the needling direction of the previous unit layer 1 and the needling direction of the subsequent unit layer 1 onto the vertical plane does not intersect, so that the needle of the subsequent needling inserts into the needling gap of the previous needling (the needling gap at this point is the unneeded part).
[0066] This design reduces the needle density of the previous unit layer 1 during needle punching, thereby increasing needle punching efficiency. Simultaneously, subsequent unit layers 1 only increase the needle punching depth, having a minimal impact on the efficiency reduction of the needle punching process. Therefore, this needle punching method ensures the processing efficiency of ceramic brake discs. Furthermore, it allows for two needle punching angles within a single unit layer 1, thereby increasing the bonding strength between carbon fibers.
[0067] In other embodiments, the needling paths between two adjacent unit layers 1 are different, that is, the needling directions between two adjacent unit layers 1 are different. Furthermore, after the needle penetrates the previous unit layer 1 during subsequent needling, the projection of the needling direction of the previous unit layer 1 during needling intersects the projection of the needling direction of the subsequent unit layer 1 onto the vertical plane (or the needling directions between two adjacent unit layers 1 intersect), wherein, for example... Figure 5As shown, subsequent needling paths can be inclined to the corresponding sides of the centerline of unit layer 1, based on the needling path of the previous needling layer during the needling process. Alternatively, subsequent needling paths can be inclined to one side of the centerline of unit layer 1, based on the needling path of the previous needling layer during the needling process. The design can be customized according to actual needs.
[0068] This design method can increase the needle density of the previous unit layer 1 and achieve two needle angles in a unit layer 1, thereby increasing the bonding force between carbon fibers. Furthermore, the projections of the two needle directions on the vertical plane intersect, enabling needles to be needled in two directions at a certain point in the previous unit layer 1, further increasing the bonding force between carbon fibers.
[0069] In other embodiments, the needle-punching paths between the multiple unit layers 1 are all different, that is, the needle-punching directions between the multiple unit layers 1 are all different. This design allows the unit layers 1 to be needled in multiple directions, thereby effectively increasing the bonding force between the carbon fibers of the unit layers 1. The needle-punching direction of each unit layer 1 can be designed according to actual needs.
[0070] Further optimized, the projections of the needle-piercing paths between at least a portion of the unit layers 1 onto the vertical plane intersect, that is, the projections of the needle-piercing directions between at least a portion of the unit layers 1 onto the vertical plane intersect (or the needle-piercing directions between two adjacent unit layers 1 intersect), wherein, as Figure 6 As shown, subsequent needling paths can be inclined to the corresponding sides of the centerline of unit layer 1, based on the needling path of the previous needling layer during the needling process. Alternatively, subsequent needling paths can be inclined to one side of the centerline of unit layer 1, based on the needling path of the previous needling layer during the needling process. The design can be customized according to actual needs.
[0071] This design method can increase the needle density of the previous unit layer 1 and achieve multiple needle angles in a unit layer 1, thereby increasing the bonding force between carbon fibers. Furthermore, the projections of the two needle directions on the vertical plane intersect, enabling needles to be needled in two directions at a certain point in the previous unit layer 1, further increasing the bonding force between carbon fibers.
[0072] In this application, the angle between the needle-punching path of unit layer 1 and the centerline of unit layer 1 is 30-89°, or the angle between the needle-punching path of unit layer 1 and the centerline of unit layer 1 is -30-89°. This angle setting can reduce damage to carbon fibers, effectively improve the bonding force between the fibers hooked by the needle and the preform, and thus increase the shear strength of the sample after silicon infiltration.
[0073] In some implementations, such as Figure 7As shown, unit layer 1 includes two mesh layers 2 and one unidirectional fiber layer 3, with the unidirectional fiber layer 3 stacked between the two mesh layers 2.
[0074] In other implementations, such as Figure 8 As shown, unit layer 1 includes a mesh layer 2 and two unidirectional fiber layers 3, with the mesh layer 2 stacked between the two unidirectional fiber layers 3.
[0075] In other implementations, such as Figure 9 As shown, unit layer 1 includes multiple unidirectional fiber layers 3, which are stacked together.
[0076] In other implementations, such as Figure 10 As shown, unit layer 1 includes multiple mesh layers 2 and multiple unidirectional fiber layers 3, which are stacked alternately.
[0077] As can be seen, the configuration of unit layer 1 in this application is not limited and can be designed according to actual needs.
[0078] Combination Figures 1 to 6 As shown, the processing method for ceramic brake discs provided in this embodiment of the invention includes the following steps:
[0079] Step S1: Stack the substrates to form multiple unit layers 1.
[0080] The configuration and number of unit layers 1 are not limited and can be designed according to the schematic requirements.
[0081] Step S2: Acupuncture is performed on the first unit layer 1, and the acupuncture direction forms an angle with the centerline direction of unit layer 1.
[0082] Specifically, the first unit layer 1 is needled at a certain angle, and the needle should penetrate the entire substrate of the first unit layer 1 to increase the bonding force between the substrates.
[0083] Step S3: Place the second unit layer 1 on top of the first unit layer 1, perform needle puncture on the second unit layer 1, and form an angle between the needle puncture direction and the centerline direction of the unit layer 1. At the same time, the needle extends into the first unit layer 1.
[0084] Specifically, the second unit layer 1 is punctured by a needle at a certain angle, and the needle should penetrate all the substrate of the second unit layer 1. At the same time, the needle extends into the first unit layer 1 to puncture at least a portion of the substrate in the first unit layer 1 again. This increases the bonding force between the substrates of the second unit layer 1, further increases the bonding force between the substrates of the first unit layer 1, and increases the bonding force between adjacent substrates of the first and second unit layers 1, ensuring the strength of the finished ceramic brake disc.
[0085] In this process, after the needle passes through the second unit layer 1, when it extends into the first unit layer 1, the needle can completely penetrate all the substrate within the first unit layer 1, or it can penetrate only part of the substrate within the first unit layer 1; this can be designed according to requirements. Furthermore, the needle's piercing direction during the first piercing can be the same as or different from the piercing direction during the second piercing, and the piercing directions during both piercings can also be designed according to actual needs. This processing method is suitable for ceramic brake discs where unit layer 1 has two layers.
[0086] The processing method of ceramic brake disc provided by the present invention involves the needle being at a certain angle to the surface of unit layer 1 during needle punching, so as to reduce the damage to the carbon fibers of unit layer 1 and increase the bonding force between carbon fibers, thereby increasing the shear strength and bending strength of the finished ceramic brake disc.
[0087] In other embodiments, when the number of unit layers 1 in the ceramic brake disc is three or more, such as Figure 5 As shown, the processing method of the ceramic brake disc of this application includes the following steps:
[0088] Step S1: Stack the substrates to form multiple unit layers 1.
[0089] Step S2: Acupuncture is performed on the first unit layer 1, and the acupuncture direction forms an angle with the centerline direction of unit layer 1.
[0090] Step S3: Place the second unit layer 1 on top of the first unit layer 1, perform needle puncture on the second unit layer 1, and form an angle between the needle puncture direction and the centerline direction of the unit layer 1. At the same time, the needle extends into the first unit layer 1.
[0091] Steps S1, S2, and S3 here are the same as those described above, and will not be described in detail here.
[0092] Step S4: The third unit layer 1 is stacked on top of the second unit layer 1. The third unit layer 1 is needled, with the needle direction forming an angle with the centerline direction of the unit layer 1. Simultaneously, the needle extends into the second unit layer 1, and so on. Here, "so-so" means that when there are more than three unit layers 1, the needle of the next unit layer 1 will be inserted into the previous unit layer 1 during needled treatment to increase the bonding force between adjacent unit layers 1.
[0093] In other embodiments, when the number of unit layers 1 in the ceramic brake disc is three or more, such as Figure 6 As shown, the processing method of the ceramic brake disc of this application includes the following steps:
[0094] Step S1: Stack the substrates to form multiple unit layers 1.
[0095] Step S2: Acupuncture is performed on the first unit layer 1, and the acupuncture direction forms an angle with the centerline direction of unit layer 1.
[0096] Step S3: Place the second unit layer 1 on top of the first unit layer 1, perform needle puncture on the second unit layer 1, and form an angle between the needle puncture direction and the centerline direction of the unit layer 1. At the same time, the needle extends into the first unit layer 1.
[0097] Steps S1, S2, and S3 here are the same as those described above, and will not be described in detail here.
[0098] Step S4: The third unit layer 1 is stacked on top of the second unit layer 1. The third unit layer 1 is needled, with the needle direction forming an angle with the centerline direction of the unit layer 1. Simultaneously, the needle is inserted into the second unit layer 1 and the first unit layer 1 in sequence, and so on. Here, "in sequence" means that when there are more than three unit layers 1, the needle of the next unit layer 1 will be inserted into all the previous unit layers 1 during needled treatment, thereby increasing the bonding force between adjacent unit layers 1 and further increasing the needle density of the previous unit layers 1.
[0099] In other embodiments, the processing method of the ceramic brake disc of this application further includes the following steps:
[0100] Step S1: Stack the substrates to form multiple unit layers 1.
[0101] Step S2: Acupuncture is performed on the first unit layer 1, and the acupuncture direction forms an angle with the centerline direction of unit layer 1.
[0102] Step S3: Place the second unit layer 1 on top of the first unit layer 1, perform needle puncture on the second unit layer 1, and form an angle between the needle puncture direction and the centerline direction of the unit layer 1. At the same time, the needle extends into the first unit layer 1.
[0103] Steps S1, S2, and S3 here are the same as those described above, and will not be described in detail here.
[0104] Step S4 involves carbonizing the preform obtained after needle punching. Carbonization involves heating the sample under inert or vacuum conditions to remove the sizing agent from the carbon fiber surface. Generally, carbon fibers are impregnated with a sizing agent at the factory to prevent separation between fiber bundles during use, thus better preserving the shape of the carbon fiber bundles. However, the sizing agent needs to be removed before chemical vapor deposition to ensure good adhesion of the deposited carbon to the carbon fiber surface.
[0105] Step S5: After the carbonized preform undergoes chemical vapor deposition (CVD), a CVD preform is obtained. Specifically, the carbonized preform is placed in a CVD furnace, and a mixture of propylene and argon gas is introduced. The deposition temperature is 900-1000℃, the deposition pressure is 3-5 kPa, and the deposition time is 80 hours. This CVD process is a conventional technique and therefore will not be described in detail here.
[0106] Step S6: The chemical vapor deposition preform is subjected to liquid-phase silicon infiltration to obtain a ceramic brake preform. Specifically, the chemical vapor deposition preform is subjected to liquid-phase silicon infiltration in a vacuum atmosphere at 1600-1700 degrees Celsius to obtain the ceramic brake preform.
[0107] Step S7: The ceramic brake blank undergoes surface processing to obtain a carbon-ceramic brake disc. Specifically, the finished carbon-ceramic brake disc is obtained by precision grinding the end face of the carbon-ceramic brake disc blank.
[0108] The following description uses specific embodiments and comparative examples:
[0109] Example 1
[0110] The processing method for ceramic brake discs includes the following steps:
[0111] Step S1: Stack the substrates to form two unit layers 1.
[0112] Step S2: The first unit layer 1 is needled, and the angle between the needled direction and the centerline direction of unit layer 1 is 70°.
[0113] Step S3: Place the second unit layer 1 on top of the first unit layer 1, perform needle puncture on the second unit layer 1, and make an angle of 70 degrees between the needle puncture direction and the centerline direction of the unit layer 1. At the same time, the needle is inserted into the first unit layer 1.
[0114] Step S4: Carbonize the embryo obtained after needle puncture.
[0115] Step S5: After the carbonized preform undergoes chemical vapor deposition, a chemical vapor deposition preform is obtained.
[0116] Step S6: The chemical vapor deposition preform is subjected to liquid phase silicon infiltration to obtain a ceramic brake preform.
[0117] Step S7: The ceramic brake blank is surface-processed to obtain a carbon ceramic brake disc.
[0118] Example 2
[0119] The processing method for ceramic brake discs includes the following steps:
[0120] Example 1
[0121] The processing method for ceramic brake discs includes the following steps:
[0122] Step S1: Stack the substrates to form two unit layers 1.
[0123] Step S2: The first unit layer 1 is needled, and the angle between the needled direction and the centerline direction of unit layer 1 is 70°.
[0124] Step S3: Place the second unit layer 1 on top of the first unit layer 1, perform needle puncture on the second unit layer 1, and form an angle of -70 degrees between the needle puncture direction and the centerline direction of the unit layer 1. At the same time, the needle is inserted into the first unit layer 1.
[0125] Step S4: Carbonize the embryo obtained after needle puncture.
[0126] Step S5: After the carbonized preform undergoes chemical vapor deposition, a chemical vapor deposition preform is obtained.
[0127] Step S6: The chemical vapor deposition preform is subjected to liquid phase silicon infiltration to obtain a ceramic brake preform.
[0128] Step S7: The ceramic brake blank is surface-processed to obtain a carbon ceramic brake disc.
[0129] Comparative Example 1
[0130] The processing method for ceramic brake discs includes the following steps:
[0131] Step S1: Stack the substrates to form two unit layers 1.
[0132] Step S2: Stack the two unit layers 1 together and insert the needle vertically into the two unit layers 1.
[0133] Step S3: Carbonize the embryo obtained after needle puncture.
[0134] Step S4: After the carbonized preform undergoes chemical vapor deposition, a chemical vapor deposition preform is obtained.
[0135] Step S5: The chemical vapor deposition preform is subjected to liquid phase silicon infiltration to obtain a ceramic brake preform.
[0136] Step S6: The ceramic brake blank is surface-processed to obtain a carbon ceramic brake disc.
[0137] The bending strength and shear strength of ceramic brake discs manufactured using the ceramic brake disc processing method of this application and conventional ceramic brake disc processing methods are as follows:
[0138]
[0139]
[0140] As can be seen from the above, the ceramic brake discs obtained by the processing method of this application have improved bending strength and shear strength compared with ceramic brake discs made by traditional processing methods.
[0141] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.
[0142] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments described herein, but is to be accorded the widest scope consistent with the principles and novel features of the invention herein.
Claims
1. A ceramic brake disc, characterized in that, The device includes a ceramic brake disc body, which comprises multiple stacked unit layers (1). The needle path of each unit layer (1) forms an angle with the center line of the unit layer (1). The needle path of the upper unit layer (1) extends into the multiple unit layers (1) below it. The needle path of each unit layer (1) has the same direction. The needle paths of the multiple unit layers (1) are different. The needle paths of two adjacent unit layers (1) intersect. The needle paths of two adjacent unit layers (1) are inclined toward the corresponding sides of the center line of the unit layer (1).
2. The ceramic brake disc according to claim 1, characterized in that, The angle between the needle puncture path of the unit layer (1) and the center line of the unit layer (1) is 30-89°, or the angle between the needle puncture path of the unit layer (1) and the center line of the unit layer (1) is -30-89°.
3. The ceramic brake disc according to claim 1, characterized in that, The unit layer includes two mesh layers (2) and a unidirectional fiber layer (3), the unidirectional fiber layer (3) being stacked between the two mesh layers (2); or The unit layer includes a mesh layer (2) and two unidirectional fiber layers (3), wherein the mesh layer (2) is stacked between the two unidirectional fiber layers (3); or The unit layer includes multiple unidirectional fiber layers (3), and the multiple unidirectional fiber layers (3) are stacked; or The unit layer includes multiple mesh layers (2) and multiple unidirectional fiber layers (3), which are stacked alternately.
4. A method for processing a ceramic brake disc, said method being used to process a ceramic brake disc according to any one of claims 1-3, characterized in that, Includes the following steps: The substrates are stacked to form multiple unit layers (1); The first unit layer (1) is needled, and the needled direction forms an angle with the centerline direction of the unit layer (1); The second unit layer (1) is stacked on the first unit layer (1), and the second unit layer (1) is needled, with the needle direction forming an angle with the center line direction of the unit layer (1). At the same time, the needle is inserted into the first unit layer (1) and intersects the needle path of the first unit layer (1) and tilts towards the corresponding sides of the center line of the unit layer (1). The third unit layer (1) is stacked on the second unit layer (1), and the third unit layer (1) is needled, with the needle direction forming an angle with the center line direction of the unit layer (1). At the same time, the needle is inserted into the second unit layer (1) and the first unit layer (1) in sequence, and so on.
5. The processing method of the ceramic brake disc according to claim 4, characterized in that, It also includes the following steps: Carbonize the embryo obtained after needle puncture; After the carbonized preform is subjected to chemical vapor deposition, a chemical vapor deposition preform is obtained; Chemical vapor deposition preforms are subjected to liquid phase silicon infiltration to obtain ceramic brake preforms; Ceramic brake blanks are surface-processed to obtain carbon-ceramic brake discs.