Carbon-ceramic brake disc with high friction layer binding force and preparation method of carbon-ceramic brake disc

Abstract

The invention provides a carbon-ceramic brake disc with strong friction layer binding force, the carbon-ceramic brake disc with strong friction layer binding force comprises a base body layer and two friction layers located on the upper surface and the lower surface of the base body layer, the base body layer comprises a mesh tire layer and a continuous fiber layer which are arranged in an overlapped mode, the surface, away from the base body layer, of the friction layer is an outer friction surface, and the surface, away from the continuous fiber layer, of the friction layer is an inner friction surface. The brake pad is characterized in that N protruding friction layer embedding areas are arranged on the face, close to the base body layer, of the friction layer, M protruding base body layer embedding areas are arranged on the face, close to the friction layer, of the base body layer, the friction layer embedding areas and the base body layer embedding areas are arranged in a staggered mode, and the side walls of the friction layer embedding areas and the side walls of the base body layer embedding areas are in contact. According to the brake disc, the base body layer embedding area and the friction layer embedding area are arranged, so that the base body layer and the friction layer are connected in a tooth-shaped structure, the binding force between the base body layer and the friction layer of the brake disc is greatly improved, and the running stability of the brake disc is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of brake disc manufacturing, and particularly relates to a carbon-ceramic brake disc with strong bonding force of the friction layer and a preparation method thereof. Background Art

[0002] A brake disc is an important component installed on vehicles such as automobiles and motorcycles for braking the vehicle. It is usually located between the wheels and works in cooperation with brake calipers, brake pads, etc. in the braking system. The brake disc mainly plays the role of decelerating or making an emergency stop during the operation of the vehicle, which is of great importance in case of emergencies and is related to people's lives. In the past decade, carbon-ceramic composites (i.e., C / SiC composites, including siliconized carbon-carbon modified silicon carbide composites, i.e., C / C-SiC composites, hereinafter uniformly referred to as carbon-ceramic composites) have developed rapidly, and their applications have been widely extended to the field of automotive brakes. Compared with the existing gray cast iron brake discs and carbon-carbon composite brake discs on the market, the carbon-ceramic composite brake discs have the advantages of light weight, excellent high-temperature friction performance, and wear resistance. Since the composite material contains 40-60% carbon and carbon fibers, its wear resistance is poor. To increase the wear resistance of the brake disc, a friction layer is often added to the surface of the brake disc to ensure its service life. Currently, a ceramic layer with a relatively high silicon carbide content is often used as the friction layer material for carbon-ceramic brake discs. Patent CN116890486A discloses a carbon fiber brake disc preform and a preparation method thereof, including a core part, two transition layers, and two friction layers; the distance between the two transition layers is equal to the thickness of the core part, and the core part is disposed between the two transition layers in a fitting manner; the two transition layers are both located between the two friction layers, and the friction layers are disposed in a fitting manner corresponding to the transition layers one by one. When setting the friction layer, the connection surface between the friction layer and the brake disc matrix is usually a plane, resulting in a not particularly firm connection between the friction layer and the matrix, and local peeling of the friction layer is likely to occur during high-load operation.

[0003] In response to this, a carbon-ceramic brake disc with strong bonding force of the friction layer is proposed, and the connection surface between the friction layer and the carbon-ceramic matrix is an uneven surface, which increases the contact area between the friction layer and the matrix of the brake disc and improves the bonding force. Summary of the Invention

[0004] The purpose of the present invention is to provide a carbon-ceramic brake disc with strong bonding force of the friction layer, improve the bonding force between the friction layer and the brake disc matrix, and avoid local peeling of the friction layer.

[0005] To achieve this goal, the present invention provides a carbon-ceramic brake disc with a strong bonding force of the friction layer. The carbon-ceramic brake disc with a strong bonding force of the friction layer includes a matrix layer and two friction layers located on the upper and lower surfaces of the matrix layer. The matrix layer includes an overlapping wire mesh layer and a continuous fiber layer. The outer surface of the friction layer away from the matrix layer is the outer friction surface. On one side of the friction layer close to the matrix layer, there are N protruding friction layer embedding areas. On one side of the matrix layer close to the friction layer, there are M protruding matrix layer embedding areas. The friction layer embedding areas and the matrix layer embedding areas are arranged in an alternating manner and the side walls of the friction layer embedding areas and the matrix layer embedding areas are in contact. The matrix layer embedding areas and the friction layer have a plurality of matrix contact surfaces parallel to the outer friction surface. The matrix contact surfaces include a matrix contact surfaces located in the wire mesh layer and b matrix contact surfaces located in the continuous fiber layer. The friction layer embedding areas and the matrix layer have a plurality of friction layer contact surfaces parallel to the outer friction surface. The friction layer contact surfaces include c friction layer contact surfaces in contact with the wire mesh layer and d friction layer contact surfaces in contact with the continuous fiber layer; it satisfies the following formula:

[0006] M = a + b

[0007] N = c + d

[0008] Where M, N, a, b, c, and d are all positive integers greater than 1.

[0009] Preferably, the total area of the a matrix contact surfaces is S1, the total area of the b matrix contact surfaces is S2, the total area of the c friction layer contact surfaces is S3, and the total area of the d friction layer contact surfaces is S4; the S1, S2, S3, and S4 satisfy the following relationship:

[0010]

[0011] Preferably, the side surface of the matrix layer embedding area forms a predetermined angle with the outer friction surface, and the angle is 65° - 125°.

[0012] Preferably, the sum of S1, S2, S3, and S4 is 0.8 - 1.3 times the area S of the outer friction surface.

[0013] Preferably, the average area size of the matrix contact surfaces is 10 - 900 mm 2 .

[0014] Preferably, the height of the matrix embedding area is 0.05 - 4 mm. The matrix embedding area can have one or more different heights.

[0015] Preferably, the carbon content in the web layer is 1-30 vol%, the silicon carbide content is 60-90 vol%, and the silicon content is 3-15 vol%. The carbon content in the continuous fiber layer is 40-65 vol%, the silicon carbide content is 25-50 vol%, and the silicon content is 3-15 vol%. The silicon carbide content in the friction layer is 60-95 vol% and the silicon content is 5-40 vol%.

[0016] Preferably, the thickness of the web layer is 0.2-0.6 mm, and the thickness of the continuous fiber layer is 0.2-0.5 mm.

[0017] The present invention also provides a method for preparing a carbon-ceramic brake disc with strong friction layer bonding force, which is used to prepare the carbon-ceramic brake disc with strong friction layer bonding force described above. The preparation method is as follows:

[0018] S1: Alternately stack and needle-punch a carbon fiber web and a unidirectional long fiber cloth, and repeat to obtain a needle-punched body with a predetermined thickness;

[0019] S2: Place the needle-punched body into a CVI furnace for chemical vapor deposition. The deposition temperature is 900-1100 °C and the time is 150-300 h to obtain a CVI green body;

[0020] S3: Perform industrial CT scanning on the CVI green body to confirm the distribution law of the fiber layer and the web layer within a certain depth from the upper and lower surfaces of the CVI green body, and machine out a number of matrix embedding areas according to the design to obtain a preform;

[0021] S4: Brush a friction layer slurry on the upper and lower surfaces of the preform, with a brushing thickness of 0.05-4 mm, and then perform a curing treatment to obtain a brake disc preform;

[0022] S5: Place the brake disc preform into a carbonization furnace for carbonization to obtain a carbonized body, and the carbonization temperature is 900-1100 °C;

[0023] S6: Place the carbonized body into a vacuum furnace for silicon infiltration treatment to obtain a siliconized body. The temperature is 1600-1700 °C, the holding time is 2-4 h, and the furnace pressure is less than 1000 Pa;

[0024] S7: Polish the surface and process the outer contour dimensions of the siliconized body to obtain the carbon-ceramic brake disc with strong friction layer bonding force.

[0025] Preferably, in step S4, the silicon carbide powder content in the friction layer slurry is 20-50%, the phenolic solution content is 40-60%, and the carbon powder content is 0-20%.

[0026] Beneficial effects: The carbon-ceramic brake disc with strong bonding force of the friction layer provided by the present invention has a toothed structure connection between the matrix layer and the friction layer by setting the matrix layer embedding area and the friction layer embedding area, greatly improving the bonding force between the matrix layer and the friction layer of the brake disc and enhancing the stability during the operation of the brake disc. And the fiber types in the area where the contact surface between the matrix layer embedding area and the friction layer is located are defined, reducing the damage to the fibers by the grooves and further ensuring the bonding strength of the bonding surface. Because the matrix layer embedding area is obtained by machining, the upper and lower surfaces of the matrix layer embedding area are both located in the mesh tire layer, avoiding the damage to the continuous fibers and ensuring the matrix strength in the area near the contact surface between the friction layer and the matrix, and avoiding the damage to the matrix in this area during friction. If the upper and lower surfaces of the matrix embedding area are located in the mesh tire layer, the damage to the continuous fibers is minimized, ensuring the matrix strength in the contact area. However, the strength of the mesh tire layer itself is lower than that of the continuous fiber layer. If the bonding surfaces are all in the mesh tire layer, the friction layer is also prone to falling off under the action of shear force. Therefore, it is necessary to control the proportion of the two bonding surfaces and the side contour of the matrix layer embedding area does not necessarily form a 90° angle with the brake disc, and it can also be greater than 90°. Therefore, the sum of S1, S2, S3, and S4 may be larger than the area S of the outer friction surface of the brake disc, and the non-90° side further increases the bonding force between the friction layer and the brake disc. In addition, the present invention also provides a preparation method for a carbon-ceramic brake disc with strong bonding force of the friction layer. First, a CVI blank is obtained by overlapping and needling a carbon fiber mesh tire and a carbon fiber unidirectional cloth and performing a vapor deposition treatment. Then, the matrix embedding area is prepared by machining. Then, the friction layer slurry is brushed on and cured to achieve the bonding between the matrix layer and the friction layer. The whole preparation process is simple, and the operation method is simple and easy to produce. Description of the Drawings

[0027] Figure 1 It is a schematic structural diagram of the carbon-ceramic brake disc with strong bonding force of the friction layer of the present invention.

[0028] Figure 2 It is a schematic structural diagram of a carbon-ceramic brake disc with a 125° angle between the side surface of the matrix layer embedding area and the outer friction surface.

[0029] Figure 3 It is a schematic structural diagram of a carbon-ceramic brake disc with a 65° angle between the side surface of the matrix layer embedding area and the outer friction surface.

[0030] In the figure: 1 - matrix layer, 2 - friction layer, 3 - matrix layer embedding area, 4 - friction layer embedding area, 301 - matrix contact surface, 401 - friction layer contact surface. Detailed Embodiments

[0031] The following described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without making creative efforts fall within the protection scope of the present invention.

[0032] Reference Figures 1-3 , the present invention provides a carbon-ceramic brake disc with strong bonding force of the friction layer. The carbon-ceramic brake disc with strong bonding force of the friction layer 2 includes a matrix layer 1 and two friction layers 2 located on the upper and lower surfaces of the matrix layer 1. The matrix layer 1 includes an overlapping mesh tire layer and a continuous fiber layer. The surface of the friction layer 2 away from the matrix layer 1 is the outer friction surface. On one side of the friction layer 2 close to the matrix layer 1, there are N protruding friction layer embedding areas 4. On one side of the matrix layer 1 close to the friction layer 2, there are M protruding matrix layer embedding areas 3. The friction layer embedding areas 4 and the matrix layer embedding areas 3 are arranged in a staggered manner and the side walls of the friction layer embedding areas 4 and the matrix layer embedding areas 3 are in contact. The matrix layer embedding area 3 and the friction layer 2 have a plurality of matrix contact surfaces 301 parallel to the outer friction surface. The matrix contact surfaces 301 include a matrix contact surfaces 301 located in the mesh tire layer and b matrix contact surfaces 301 located in the continuous fiber layer. The friction layer embedding area 4 and the matrix layer 1 have a plurality of friction layer contact surfaces 401 parallel to the outer friction surface. The contact surfaces of the friction layer 2 include c friction layer contact surfaces 401 in contact with the mesh tire layer and d friction layer contact surfaces 401 in contact with the continuous fiber layer; it satisfies the following formula:

[0033] M = a + b

[0034] N = c + d

[0035] where M, N, a, b, c, and d are all positive integers greater than 1.

[0036] Among them, the total area of the a matrix contact surfaces is S1, the total area of the b matrix contact surfaces is S2, the total area of the c friction layer contact surfaces is S3, and the total area of the d friction layer contact surfaces is S4; the S1, S2, S3, and S4 satisfy the following relationship:

[0037]

[0038] The side surface of the matrix layer embedding area forms a predetermined angle with the outer friction surface, and the angle is 125° (Reference Figure 2 ) or 90° (Reference Figure 1 ) or 65° (Reference Figure 3 ). Considering the constructability, an angle less than 90° for the matrix embedding area is beneficial for the complete contact of the friction layer slurry with the matrix surface, and the increase in its side contact area is also beneficial for increasing the bonding force.

[0039] The sum of the S1, S2, S3, and S4 is 0.8 - 1.3 times the area S of the outer friction surface.

[0040] The average area of the matrix contact surface is 10 - 900 mm 2 .

[0041] The height of the matrix embedding area is 0.05 - 4 mm. The matrix embedding area can have one or more different heights.

[0042] The carbon content in the web layer is 1 - 30 vol%, the silicon carbide content is 60 - 90 vol%, and the silicon content is 3 - 15 vol%. For example, the carbon content in the web layer is 20 vol%, the silicon carbide content is 70 vol%, and the silicon content is 10 vol%; or the carbon content in the web layer is 15 vol%, the silicon carbide content is 80 vol%, and the silicon content is 5 vol%; or the carbon content in the web layer is 10 vol%, the silicon carbide content is 80 vol%, and the silicon content is 10 vol%, etc. The carbon content in the continuous fiber layer is 40 - 65 vol%, the silicon carbide content is 25 - 50 vol%, and the silicon content is 3 - 15 vol%. For example, the carbon content in the continuous fiber layer is 55 vol%, the silicon carbide content is 40 vol%, and the silicon content is 5 vol%; the carbon content in the continuous fiber layer is 45 vol%, the silicon carbide content is 40 vol%, and the silicon content is 15 vol%; or the carbon content in the continuous fiber layer is 60 vol%, the silicon carbide content is 35 vol%, and the silicon content is 5 vol%, etc. The silicon carbide content in the friction layer is 60 - 95 vol% and the silicon content is 5 - 40 vol%. For example, the silicon carbide content in the friction layer is 70 vol% and the silicon content is 30 vol%; or the silicon carbide content in the friction layer is 80 vol% and the silicon content is 20 vol%, etc.

[0043] The thickness of the web layer is 0.2 - 0.6 mm, and the thickness of the continuous fiber layer is 0.2 - 0.5 mm.

[0044] The present invention also provides a method for preparing a carbon - ceramic brake disc with strong bonding force of the friction layer, and the preparation method is as follows:

[0045] S1: Alternately stack and needle - punch a carbon fiber web and a unidirectional long - fiber cloth, and repeat to obtain a needle - punched body with a predetermined thickness;

[0046] S2: Place the needle - punched body into a CVI furnace for chemical vapor deposition, with a deposition temperature of 900 - 1100 °C and a time of 150 - 300 h to obtain a CVI green body;

[0047] S3: Perform industrial CT scanning on the CVI green body, confirm the distribution law of the fiber layer and the web layer within a certain depth from the upper and lower surfaces of the CVI green body, and machine - process a number of matrix embedding areas according to the design to obtain a pre - green body;

[0048] S4: Brush a friction layer slurry on the upper and lower surfaces of the pre - green body, with a brush - coating thickness of 0.05 - 4 mm, and then perform a curing treatment to obtain a brake - disc green body;

[0049] S5: Put the brake disc blank into a carbonization furnace for carbonization to obtain a carbonized body, and the carbonization temperature is 900 - 1100 °C;

[0050] S6: Put the carbonized body into a vacuum furnace for silicon infiltration treatment to obtain a siliconized body, the temperature is 1600 - 1700 °C, the heat preservation time is 2 - 4 h, and the furnace pressure is less than 1000 Pa;

[0051] S7: Polish the surface and process the outer contour dimensions of the siliconized body to obtain the carbon-ceramic brake disc with strong bonding force of the friction layer.

[0052] In step S4, the content of silicon carbide powder in the friction layer slurry is 20 - 50%, the content of phenolic solution is 40 - 60%, and the content of carbon powder is 0 - 20%.

[0053] Example 1

[0054] This example provides a carbon-ceramic brake disc with strong bonding force of the friction layer, and its preparation steps are as follows:

[0055] S1: Alternately stack and needle-punch the carbon fiber mesh tire and the unidirectional long fiber cloth, and repeat to obtain a needle-punched body with a predetermined thickness;

[0056] S2: Put the needle-punched body into a CVI furnace for chemical vapor deposition, the deposition temperature is 1000 °C, and the time is 400 h to obtain a CVI blank;

[0057] S3: Conduct industrial CT scanning on the CVI blank, confirm the distribution law of the fiber layer and the mesh tire layer within a certain depth from the upper and lower surfaces of the CVI blank, and mechanically process several matrix embedding areas according to the design to obtain a pre-blank. Among them, the sum of S2 and S4 is 4% of the sum of S1, S2, S3, and S4. The side of the matrix embedding area is 90° with the brake disc surface, and the average area of the matrix contact surface in the matrix embedding area is 100 mm 2 , and the height of the matrix embedding area is 0.5 mm;

[0058] S4: Brush the friction layer slurry on the upper and lower surfaces of the pre-blank. The content of silicon carbide powder in the friction layer slurry is 35%, the content of phenolic solution is 60%, the content of carbon powder is 5%, the brushing thickness is 2 mm, and then carry out curing treatment to obtain a brake disc blank;

[0059] S5: Put the brake disc blank into a carbonization furnace for carbonization to obtain a carbonized body, and the carbonization temperature is 1000 °C;

[0060] S6: Put the carbonized body into a vacuum furnace for silicon infiltration treatment to obtain a siliconized body, the temperature is 1650 °C, the heat preservation time is 3 h, and the furnace pressure is less than 1000 Pa;

[0061] S7: Polish the surface of the silicide body and process its outer contour dimensions to obtain the carbon-ceramic brake disc with strong bonding force of the friction layer.

[0062] Example 2

[0063] This example provides a carbon-ceramic brake disc with strong bonding force of the friction layer, and its preparation steps are as follows:

[0064] S1: Alternately laminate the carbon fiber mesh tire and the unidirectional long fiber cloth and perform needling treatment, and repeat to obtain a needled body with a predetermined thickness;

[0065] S2: Put the needled body into a CVI furnace for chemical vapor deposition, the deposition temperature is 1000 °C, and the time is 400 h to obtain a CVI green body;

[0066] S3: Perform industrial CT scanning on the CVI green body to confirm the distribution law of the fiber layer and the mesh tire layer within a certain depth from the upper and lower surfaces of the CVI green body, and mechanically process a number of matrix embedding areas according to the design to obtain a preform, where the sum of S2 and S4 is 25% of the sum of S1, S2, S3, and S4. The side of the matrix embedding area is 90° with the brake disc surface, and the average area of the matrix contact surface in the matrix embedding area is 100 mm 2 , and the height of the matrix embedding area is 0.5 mm;

[0067] S4: Brush the friction layer slurry on the upper and lower surfaces of the preform. The content of silicon carbide powder in the friction layer slurry is 35%, the content of phenolic solution is 60%, the content of carbon powder is 5%, the brushing thickness is 2 mm, and then perform curing treatment to obtain a brake disc preform;

[0068] S5: Put the brake disc preform into a carbonization furnace for carbonization to obtain a carbonized body, and the carbonization temperature is 1000 °C;

[0069] S6: Put the carbonized body into a vacuum furnace for silicon infiltration treatment to obtain a silicide body, the temperature is 1650 °C, the holding time is 3 h, and the furnace pressure is less than 1000 Pa;

[0070] S7: Polish the surface of the silicide body and process its outer contour dimensions to obtain the carbon-ceramic brake disc with strong bonding force of the friction layer.

[0071] Example 3

[0072] This example provides a carbon-ceramic brake disc with strong bonding force of the friction layer, and its preparation steps are as follows:

[0073] S1: Alternately laminate the carbon fiber mesh tire and the unidirectional long fiber cloth and perform needling treatment, and repeat to obtain a needled body with a predetermined thickness;

[0074] S2: Place the needle-punched body into a CVI furnace for chemical vapor deposition at a deposition temperature of 1000 °C for 400 h to obtain a CVI green body;

[0075] S3: Conduct an industrial CT scan on the CVI green body to confirm the distribution patterns of the fiber layer and the wire mesh layer within a certain depth from the upper and lower surfaces of the CVI green body. Machine a number of matrix embedding areas according to the design to obtain a preform, where the sum of designs S2 and S4 is 4% of the sum of S1, S2, S3, and S4. The side surface of the matrix embedding area makes an angle of 65° with the brake disc surface, and the average area of the matrix contact surface in the matrix embedding area is 100 mm 2 , and the height of the matrix embedding area is 0.5 mm;

[0076] S4: Brush a friction layer slurry on the upper and lower surfaces of the preform. The friction layer slurry contains 35% silicon carbide powder, 60% phenolic solution, and 5% carbon powder, and the brushing thickness is 2 mm. Then, perform a curing treatment to obtain a brake disc preform;

[0077] S5: Place the brake disc preform into a carbonization furnace for carbonization to obtain a carbonized body at a carbonization temperature of 1000 °C;

[0078] S6: Place the carbonized body into a vacuum furnace for silicon infiltration treatment to obtain a siliconized body at a temperature of 1650 °C, with a holding time of 3 h and a furnace pressure less than 1000 Pa;

[0079] S7: Polish the surface and machine the outer contour dimensions of the siliconized body to obtain the carbon-ceramic brake disc with a strong friction layer bonding force.

[0080] Example 4

[0081] This example provides a carbon-ceramic brake disc with a strong friction layer bonding force, and its preparation steps are as follows:

[0082] S1: Alternately stack and needle-punch a carbon fiber wire mesh and unidirectional long fiber cloth, and repeat to obtain a needle-punched body with a predetermined thickness;

[0083] S2: Place the needle-punched body into a CVI furnace for chemical vapor deposition at a deposition temperature of 1000 °C for 400 h to obtain a CVI green body;

[0084] S3: Conduct an industrial CT scan on the CVI green body to confirm the distribution patterns of the fiber layer and the wire mesh layer within a certain depth from the upper and lower surfaces of the CVI green body. Machine a number of matrix embedding areas according to the design to obtain a preform, where the sum of designs S2 and S4 is 4% of the sum of S1, S2, S3, and S4. The side surface of the matrix embedding area makes an angle of 125° with the brake disc surface, and the average area of the matrix contact surface in the matrix embedding area is 100 mm 2 , and the height of the matrix embedding area is 0.5 mm;

[0085] S4: Brush the friction layer slurry on the upper and lower surfaces of the preform. The content of silicon carbide powder in the friction layer slurry is 35%, the content of phenolic solution is 60%, the content of carbon powder is 5%, the brushing thickness is 2 mm, and then carry out curing treatment to obtain the brake disc preform;

[0086] S5: Put the brake disc preform into a carbonization furnace for carbonization to obtain a carbonized body, and the carbonization temperature is 1000 °C;

[0087] S6: Put the carbonized body into a vacuum furnace for silicon infiltration treatment to obtain a siliconized body, the temperature is 1650 °C, the holding time is 3 h, and the furnace pressure is less than 1000 Pa;

[0088] S7: Carry out surface grinding and external contour dimension processing on the siliconized body to obtain the carbon-ceramic brake disc with strong bonding force of the friction layer.

[0089] Example 5

[0090] This example provides a carbon-ceramic brake disc with strong bonding force of the friction layer, and its preparation steps are as follows:

[0091] S1: Alternately stack and needling process the carbon fiber mesh tire and the unidirectional long fiber cloth, and repeat to obtain a needled body with a predetermined thickness;

[0092] S2: Put the needled body into a CVI furnace for chemical vapor deposition, the deposition temperature is 1000 °C, and the time is 400 h to obtain a CVI preform;

[0093] S3: Carry out industrial CT scanning on the CVI preform, confirm the distribution law of the fiber layer and the mesh tire layer within a certain depth from the upper and lower surfaces of the CVI preform, and machine out several matrix embedding areas according to the design to obtain a preform, where the sum of the designs of S2 and S4 is 40% of the sum of S1, S2, S3, and S4. The side of the matrix embedding area is 90° with the brake disc surface, and the average area of the matrix contact surface in the matrix embedding area is 100 mm 2 , and the height of the matrix embedding area is 0.5 mm;

[0094] S4: Brush the friction layer slurry on the upper and lower surfaces of the preform. The content of silicon carbide powder in the friction layer slurry is 35%, the content of phenolic solution is 60%, the content of carbon powder is 5%, the brushing thickness is 2 mm, and then carry out curing treatment to obtain the brake disc preform;

[0095] S5: Put the brake disc preform into a carbonization furnace for carbonization to obtain a carbonized body, and the carbonization temperature is 1000 °C;

[0096] S6: Put the carbonized body into a vacuum furnace for silicon infiltration treatment to obtain a siliconized body, the temperature is 1650 °C, the holding time is 3 h, and the furnace pressure is less than 1000 Pa;

[0097] S7: Polish the surface of the siliconized body and process the outer contour dimensions to obtain the carbon-ceramic brake disc with strong bonding force of the friction layer.

[0098] Comparative Example 1

[0099] This comparative example provides a carbon-ceramic brake disc, and its preparation steps are as follows:

[0100] S1: Alternately stack and needling process the carbon fiber mesh tire and the unidirectional long fiber cloth, and repeat to obtain a needled body with a predetermined thickness.

[0101] S2: Put the needled body into a CVI furnace for chemical vapor deposition, the deposition temperature is 1000 °C, and the time is 400 h to obtain a CVI green body.

[0102] S3: Perform industrial CT scanning on the CVI green body, confirm the distribution law of the fiber layer and the mesh tire layer within a certain depth from the upper and lower surfaces of the CVI green body, and machine out several matrix embedding areas according to the design to obtain a preform, where the sum of S2 and S4 is 50% of the sum of S1, S2, S3, and S4. The side surface of the matrix embedding area is 90° with the brake disc surface, and the average area of the matrix contact surface in the matrix embedding area is 100 mm 2 , and the height of the matrix embedding area is 0.5 mm;

[0103] S4: Brush the friction layer slurry on the upper and lower surfaces of the preform. The content of silicon carbide powder in the friction layer slurry is 35%, the content of phenolic solution is 60%, and the content of carbon powder is 5%. The brushing thickness is 2 mm, and then curing treatment is carried out to obtain a brake disc preform.

[0104] S5: Put the brake disc preform into a carbonization furnace for carbonization to obtain a carbonized body, and the carbonization temperature is 1000 °C.

[0105] S6: Put the carbonized body into a vacuum furnace for silicon infiltration treatment to obtain a siliconized body, the temperature is 1650 °C, the holding time is 3 h, and the furnace pressure is less than 1000 Pa.

[0106] S7: Polish the surface of the siliconized body and process the outer contour dimensions to obtain the carbon-ceramic brake disc with strong bonding force of the friction layer.

[0107] Comparative Example 2

[0108] This comparative example provides a carbon-ceramic brake disc, and its preparation steps are as follows:

[0109] S1: Alternately stack and needling process the carbon fiber mesh tire and the unidirectional long fiber cloth, and repeat to obtain a needled body with a predetermined thickness.

[0110] S2: Place the needling body into a CVI furnace for chemical vapor deposition at a deposition temperature of 1000 °C for 400 h to obtain a CVI green body;

[0111] S3: Conduct an industrial CT scan on the CVI green body to confirm the distribution law of the fiber layer and the mesh tire layer within a certain depth from the upper and lower surfaces of the CVI green body. Machine a number of matrix embedding areas according to the design to obtain a preform. Among them, the sum of S2 and S4 is 60% of the sum of S1, S2, S3, and S4. The side of the matrix embedding area is at a 90° angle to the brake disc surface, and the average area of the matrix contact surface in the matrix embedding area is 100 mm 2 , and the height of the matrix embedding area is 0.5 mm;

[0112] S4: Brush the friction layer slurry on the upper and lower surfaces of the preform. The friction layer slurry contains 35% silicon carbide powder, 60% phenolic solution, and 5% carbon powder. The brushing thickness is 2 mm, and then curing treatment is carried out to obtain a brake disc preform;

[0113] S5: Place the brake disc preform into a carbonization furnace for carbonization to obtain a carbonized body at a carbonization temperature of 1000 °C;

[0114] S6: Place the carbonized body into a vacuum furnace for silicon infiltration treatment to obtain a siliconized body at a temperature of 1650 °C, with a holding time of 3 h, and the furnace pressure is less than 1000 Pa;

[0115] S7: Polish the surface and machine the outer contour dimensions of the siliconized body to obtain the carbon-ceramic brake disc with strong bonding force of the friction layer.

[0116] Test the carbon-ceramic brake discs prepared in the above Examples 1-5 and Comparative Examples 1-2. The test method is as follows:

[0117] Detect whether the friction layer falls off: Conduct the test according to the test method specified in QC / T 316. With a braking torque equivalent to 0.6 g, the number of braking times is 20×10 4 times, and check the corresponding area every 50,000 times, with a total of 300,000 times of circulation.

[0118] The test data is shown in Table 1 below.

[0119] Table 1 Test data of carbon-ceramic brake discs in Examples 1-5 and Comparative Examples 1-2

[0120]

[0121] From the above test data, it can be seen that the friction layer and the matrix layer are connected in a toothed structure. By reasonably designing the ratio of the matrix contact surface to the friction layer contact surface, it can increase the bonding force between the matrix layer and the friction layer, which is of great importance for improving the wear resistance of the carbon-ceramic brake disc. The setting of the angle between the side of the matrix embedding area and the brake disc surface also has a certain effect on improving the bonding force between the matrix layer and the friction layer. Increasing the contact area between the side walls of the friction layer embedding area and the matrix layer embedding area is beneficial to improving the bonding force. When the angle between the side of the matrix layer embedding area and the outer friction surface is less than 90°, the contact area can be increased, which is more beneficial to increasing the bonding force compared to 90°; however, when it is greater than 90°, not only the contact area is increased, but also additional mechanical interlocking is provided, further enhancing the bonding force. It's just that the processing requirements for angles greater than 90° are higher and the difficulty is greater.

[0122] The above-disclosed are only several preferred embodiments of the present invention. Of course, the scope of the rights of the present invention cannot be limited thereby. Therefore, equivalent changes made according to the scope of the patent application of the present invention still fall within the scope covered by the present invention.

Claims

1. A carbon-ceramic brake disc with a strong friction layer bonding force, the carbon-ceramic brake disc with a strong friction layer bonding force comprises a base layer and two friction layers located on the upper and lower surfaces of the base layer, the base layer comprises an overlapping web layer and a continuous fiber layer, the friction layer is away from the base layer as an outer friction surface, characterized in that: The friction layer is provided with N protruding friction layer embedding areas on one side close to the base layer, and the base layer is provided with M protruding base layer embedding areas on one side close to the friction layer. The friction layer embedding areas and the base layer embedding areas are arranged alternately, and the friction layer embedding areas and the base layer embedding areas are in contact with the side walls; the base layer embedding areas and the friction layer have a plurality of base contact surfaces parallel to the external friction surface, and the base contact surfaces include a base contact surface located in the web layer and b base contact surfaces located in the continuous fiber layer; the friction layer embedding areas and the base layer have a plurality of friction layer contact surfaces parallel to the external friction surface, and the friction layer contact surfaces include c friction layer contact surfaces in contact with the web layer and d friction layer contact surfaces in contact with the continuous fiber layer; it satisfies the following formula: M=a+b N=c+d Wherein M, N, a, b, c, and d are all positive integers greater than 1.

2. The carbon-ceramic brake disc with strong friction layer bonding force as claimed in claim 1, characterized in that: The total area of ​​a substrate contact surface is S1, the total area of ​​b substrate contact surfaces is S2, the total area of ​​c friction layer contact surfaces is S3, and the total area of ​​d friction layer contact surfaces is S4; S1, S2, S3, S4 satisfy the following relationship:

3. The carbon-ceramic brake disc with strong friction layer bonding force as claimed in claim 2, characterized in that: The side surface of the embedded area of ​​the base layer forms a predetermined angle with the outer friction surface, and the angle is 65° to 125°.

4. The carbon-ceramic brake disc with strong friction layer bonding force as claimed in claim 3, characterized in that: The sum of S1, S2, S3, and S4 is 0.8-1.3 times the area S of the outer friction surface.

5. The carbon-ceramic brake disc with strong friction layer bonding force as claimed in claim 1, characterized in that: The average area of ​​the substrate contact surface is 10-900 mm 2 .

6. The carbon-ceramic brake disc with strong friction layer bonding force as claimed in claim 1, characterized in that: The height of the substrate embedding area is 0.05-4 mm.

7. The carbon-ceramic brake disc with strong friction layer bonding force as claimed in claim 1, characterized in that: The carbon content of the web layer is 1-30 vol%, the silicon carbide content is 60-90 vol% and the silicon content is 3-15 vol%, the carbon content of the continuous fiber layer is 40-65 vol%, the silicon carbide content is 25-50 vol% and the silicon content is 3-15 vol%; the silicon carbide content of the friction layer is 60-95 vol% and the silicon content is 5-40 vol%.

8. The carbon-ceramic brake disc with strong friction layer bonding force as claimed in claim 7, characterized in that: The web layer has a thickness of 0.2-0.6 mm, and the continuous fiber layer has a thickness of 0.2-0.5 mm.

9. A method for preparing a carbon-ceramic brake disc with a strong friction layer bonding force, used for preparing a carbon-ceramic brake disc with a strong friction layer bonding force as claimed in any one of claims 1 to 8, characterized in that: The preparation method is as follows: S1: alternately stacking carbon fiber webs and unidirectional long fiber cloths and performing needle punching, and repeating the process to obtain a needle punched body of a predetermined thickness; S2: placing the needle-pierced body into a CVI furnace for vapor deposition at a deposition temperature of 900-1100° C. for 150-300 h to obtain a CVI body; S3: performing industrial CT scanning on the CVI blank to confirm the distribution pattern of the fiber layer and the web layer within a certain depth from the upper and lower surfaces of the CVI blank, and machining a plurality of matrix embedding areas according to the design to obtain a preform; S4: brushing the friction layer slurry on the upper and lower surfaces of the preform to a thickness of 0.05-4 mm, and then performing a curing treatment to obtain a brake disc blank; S5: placing the brake disc blank into a carbonization furnace for carbonization to obtain a carbonized body, the carbonization temperature being 900-1100° C.; S6: placing the carbide into a vacuum furnace for siliconizing treatment to obtain a silicide, the temperature is 1600-1700° C., the heat preservation time is 2-4 hours, and the furnace pressure is less than 1000 Pa; S7: grinding the surface of the silicide and processing the outer contour dimensions to obtain a carbon-ceramic brake disc with a strong friction layer bonding force.

10. The method for preparing a carbon-ceramic brake disc with a strong friction layer bonding force as claimed in claim 9, characterized in that: In step S4, the silicon carbide powder content in the friction layer slurry is 25-50%, the phenolic solution content is 40-60%, and the carbon powder content is 0-20%.

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