A carbon-ceramic brake disc with strong friction layer adhesion and its preparation method

Abstract

This invention provides a carbon-ceramic brake disc with strong friction layer adhesion. The carbon-ceramic brake disc with strong friction layer adhesion includes a base layer and two friction layers located on the upper and lower surfaces of the base layer. The base layer includes overlapping mesh layers and continuous fiber layers. The friction layers have an outer friction surface away from the base layer. The invention is characterized by having N protruding friction layer embedding areas on the side of the friction layer closest to the base layer, and M protruding base layer embedding areas on the side of the base layer closest to the friction layer. The friction layer embedding areas and the base layer embedding areas are staggered, and their sidewalls are in contact. By providing the base layer embedding areas and the friction layer embedding areas, the base layer and the friction layer are connected in a toothed structure, greatly improving the adhesion between the brake disc's base layer and the friction layer, and enhancing the stability of the brake disc during operation.

Description

Technical Field

[0001] This invention relates to the field of brake disc manufacturing technology, and in particular to a carbon ceramic brake disc with strong friction layer adhesion and its preparation method. Background Technology

[0002] Brake discs are crucial components installed in vehicles such as cars and motorcycles, used for braking. They are typically located between the wheels and work in conjunction with the brake calipers and pads in the braking system. Brake discs primarily function to reduce speed or enable emergency stopping during vehicle operation, and are especially important in emergencies as they are crucial to human safety. In the past decade, carbon-ceramic composite materials (i.e., C / SiC composite materials, including carbon-carbon silicon-infiltrated modified silicon carbide composite materials, i.e., C / C-SiC composite materials, collectively referred to as carbon-ceramic composite materials) have developed rapidly, and their application has expanded significantly into the automotive braking field. Compared to existing gray cast iron brake discs and carbon-carbon composite brake discs on the market, carbon-ceramic composite brake discs have advantages such as light weight, excellent high-temperature friction performance, and wear resistance. However, because composite materials contain 40-60% carbon and carbon fibers, their wear resistance is relatively poor. To increase the wear resistance of brake discs, a friction layer is often added to the surface of the brake disc to ensure its service life. Currently, ceramic layers with a high silicon carbide content are often used as the friction layer material for carbon-ceramic brake discs. Patent CN116890486A discloses a carbon fiber brake disc preform and its preparation method, comprising a core, two transition layers, and two friction layers; the distance between the two transition layers is equal to the thickness of the core, and the core is fitted between the two transition layers; both transition layers are located between the two friction layers, and the friction layers are fitted one-to-one with the transition layers. When the friction layers are set, the connection surface between the friction layers and the brake disc substrate is usually planar, resulting in a not particularly strong connection between the friction layers and the substrate, which can easily lead to localized peeling of the friction layers under heavy loads.

[0003] To address this, a carbon-ceramic brake disc with strong friction layer adhesion is proposed. The connection surface between the friction layer and the carbon-ceramic substrate is concave and convex, which increases the contact area between the brake disc friction layer and the substrate and improves the adhesion. Summary of the Invention

[0004] The purpose of this invention is to provide a carbon ceramic brake disc with strong adhesion of the friction layer, thereby improving the bonding force between the friction layer and the brake disc substrate and preventing localized peeling of the friction layer.

[0005] To achieve this objective, the present invention provides a carbon-ceramic brake disc with strong friction layer adhesion. The carbon-ceramic brake disc with strong friction layer adhesion includes a base layer and two friction layers located on the upper and lower surfaces of the base layer. The base layer includes overlapping mesh layers and continuous fiber layers. The friction layers have an outer friction surface away from the base layer. The friction layers have N protruding friction layer embedding areas on the side near the base layer, and M protruding base layer embedding areas on the side near the friction layers. The friction layer embedding areas and the base layer embedding areas are staggered, and their sidewalls are in contact. The base layer embedding areas and the friction layers have multiple base contact surfaces parallel to the outer friction surface. These base contact surfaces include a base contact surface located in the mesh layer and b base contact surfaces located in the continuous fiber layer. The friction layer embedding area and the matrix layer have multiple friction layer contact surfaces parallel to the outer friction surface. These contact surfaces include c contact surfaces that contact the mesh layer and d contact surfaces that contact the continuous fiber layer; they satisfy 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-substrate contact surfaces is S1, the total area of ​​the b-substrate 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; wherein S1, S2, S3, and S4 satisfy the following relationship:

[0010]

[0011] Preferably, the side of the substrate layer embedding area forms a predetermined angle with the external friction surface, the angle being 65° to 125°.

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

[0013] Preferably, the average area of ​​the substrate contact surface is 10-900 mm². 2 .

[0014] Preferably, the height of the substrate embedding region is 0.05-4 mm. The substrate embedding region may have one or more different heights.

[0015] Preferably, the carbon content in the mesh 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%; and 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 mesh layer is 0.2-0.6 mm, and the thickness of the continuous fiber layer is 0.2-0.5 mm.

[0017] This invention also proposes a method for preparing a carbon-ceramic brake disc with strong friction layer adhesion, used to prepare the aforementioned carbon-ceramic brake disc with strong friction layer adhesion. The preparation method is as follows:

[0018] S1: Alternately stack carbon fiber mesh and unidirectional long fiber cloth and needle punch them to obtain a needled body of a predetermined thickness.

[0019] S2: The needled body is placed in a CVI furnace for vapor deposition at a temperature of 900-1100℃ for 150-300h to obtain a CVI preform.

[0020] S3: Perform industrial CT scanning on the CVI blank to confirm the distribution pattern of the fiber layer and the mesh layer within a certain depth from the upper and lower surfaces of the CVI blank, and machine several matrix embedding areas according to the design to obtain a pre-blank.

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

[0022] S5: The brake disc blank is placed in a carbonization furnace to carbonize and obtain a carbonized body at a carbonization temperature of 900-1100℃.

[0023] S6: The carbide is placed in a vacuum furnace for silicon infiltration treatment to obtain a silicide. The temperature is 1600-1700℃, the holding time is 2-4h, and the furnace pressure is less than 1000Pa.

[0024] S7: The silicide is surface-polished and its outer contour dimensions are machined to obtain a carbon ceramic brake disc with strong adhesion of the friction layer.

[0025] Preferably, 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%.

[0026] Beneficial Effects: The carbon-ceramic brake disc with strong friction layer bonding provided by this invention, by setting a substrate layer embedding area and a friction layer embedding area, connects the substrate layer and the friction layer in a toothed structure, greatly improving the bonding force between the brake disc substrate layer and the friction layer, and enhancing the stability of the brake disc during operation. Furthermore, the fiber type in the contact area between the substrate layer embedding area and the friction layer is limited, reducing the damage to the fibers caused by the grooves and further ensuring the bonding strength of the bonding surface. Because the substrate layer embedding area, obtained through mechanical processing, is located on both the upper and lower surfaces of the substrate layer, damage to the continuous fibers is avoided, ensuring the matrix strength in the area near the contact surface between the friction layer and the substrate, and preventing damage to the matrix in this area during friction. If the upper and lower surfaces of the substrate embedding area are located on the mesh layer, damage to the continuous fibers is minimized, ensuring the matrix strength of the contact area. However, the strength of the mesh layer itself is lower than that of the continuous fiber layer. If the bonding surfaces are all in the mesh layer, the friction layer is also prone to falling off under shear force. Therefore, it is necessary to control the ratio of the two bonding surfaces, and the side profile of the matrix layer embedding area does not necessarily have to be 90° with the brake disc; it can 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. The non-90° side profile further increases the bonding force between the friction layer and the brake disc. In addition, this invention also proposes a method for preparing a carbon ceramic brake disc with strong friction layer bonding force. First, carbon fiber mesh and carbon fiber unidirectional fabric are overlapped, needle-punched, and subjected to vapor deposition to obtain a CVI preform. Then, the matrix embedding area is prepared by mechanical processing. Finally, a friction layer slurry is brushed on and cured to achieve the bonding between the matrix layer and the friction layer. The entire preparation process is simple, and the operation method is simple and easy to produce. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of the carbon ceramic brake disc with strong friction layer adhesion according to the present invention.

[0028] Figure 2 This is a schematic diagram of a carbon ceramic brake disc with the side of the substrate layer embedded area at a 125° angle to the external friction surface.

[0029] Figure 3 This is a schematic diagram of a carbon ceramic brake disc with the side of the substrate layer embedded area at a 65° angle to the external friction surface.

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

[0031] The embodiments described below are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0032] refer to Figure 1-3 This invention provides a carbon-ceramic brake disc with strong friction layer adhesion. The carbon-ceramic brake disc with strong friction layer adhesion includes a base layer 1 and two friction layers 2 located on the upper and lower surfaces of the base layer 1. The base layer 1 includes overlapping mesh layers and continuous fiber layers. The friction layer 2 has an outer friction surface away from the base layer 1. The friction layer 2 has N protruding friction layer embedding areas 4 on the side near the base layer 1, and the base layer 1 has M protruding base layer embedding areas 3 on the side near the friction layer 2. The friction layer embedding areas 4 and 3 are staggered and their sidewalls are in contact. The base layer embedding areas 3 and the friction layer 2 have multiple base contact surfaces 301 parallel to the outer friction surface. The base contact surfaces 301 include a base contact surface 301 located in the mesh layer and b base contact surfaces 301 located in the continuous fiber layer. The friction layer embedding region 4 and the substrate layer 1 have multiple 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 that contact the mesh layer and d friction layer contact surfaces 401 that contact the continuous fiber layer; they satisfy 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] Wherein, the total area of ​​the a-substrate contact surfaces is S1, the total area of ​​the b-substrate 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; S1, S2, S3, and S4 satisfy the following relationship:

[0037]

[0038] The side of the substrate layer embedding area forms a predetermined angle with the external friction surface, the angle being 125° (reference). Figure 2 ) or 90° (reference) Figure 1 ) or 65° (reference) Figure 3 Considering workability, an embedding angle of less than 90° in the substrate is conducive to the complete contact of the friction layer slurry with the substrate surface, and the increase in its lateral contact area is also conducive to increasing the bonding force.

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

[0040] The average area of ​​the substrate contact surface is 10-900 mm². 2 .

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

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

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

[0044] This invention also proposes a method for preparing a carbon-ceramic brake disc with strong friction layer adhesion, the preparation method being as follows:

[0045] S1: Alternately stack carbon fiber mesh and unidirectional long fiber cloth and needle punch them to obtain a needled body of a predetermined thickness.

[0046] S2: The needled body is placed in a CVI furnace for vapor deposition at a temperature of 900-1100℃ for 150-300h to obtain a CVI preform.

[0047] S3: Perform industrial CT scanning on the CVI blank to confirm the distribution pattern of the fiber layer and the mesh layer within a certain depth from the upper and lower surfaces of the CVI blank, and machine several matrix embedding areas according to the design to obtain a pre-blank.

[0048] S4: Apply friction layer slurry to the upper and lower surfaces of the preform, with a thickness of 0.05-4mm, and then perform curing treatment to obtain the brake disc blank;

[0049] S5: The brake disc blank is placed in a carbonization furnace to carbonize and obtain a carbonized body at a carbonization temperature of 900-1100℃.

[0050] S6: The carbide is placed in a vacuum furnace for silicon infiltration treatment to obtain a silicide. The temperature is 1600-1700℃, the holding time is 2-4h, and the furnace pressure is less than 1000Pa.

[0051] S7: The silicide is surface-polished and its outer contour dimensions are machined to obtain a carbon ceramic brake disc with strong adhesion of the friction layer.

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

[0053] Example 1

[0054] This embodiment provides a carbon-ceramic brake disc with strong friction layer adhesion, and its preparation steps are as follows:

[0055] S1: Alternately stack carbon fiber mesh and unidirectional long fiber cloth and needle punch them to obtain a needled body of a predetermined thickness.

[0056] S2: The needled body is placed in a CVI furnace for vapor deposition at a temperature of 1000℃ for 400 hours to obtain a CVI preform.

[0057] S3: Perform industrial CT scanning on the CVI blank to confirm the distribution pattern of the fiber layer and mesh layer within a certain depth from the upper and lower surfaces of the CVI blank. Machining several matrix embedding zones according to the design yields a pre-blank. The sum of designs S2 and S4 is 4% of the sum of S1, S2, S3, and S4. The side of the matrix embedding zone is at a 90° angle to the brake disc surface, and the average area of ​​the matrix contact surface in the matrix embedding zone is 100 mm². 2 The height of the substrate embedding area is 0.5 mm;

[0058] S4: A friction layer slurry is brushed onto 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 2mm. Then, a curing treatment is performed to obtain the brake disc preform.

[0059] S5: The brake disc blank is placed in a carbonization furnace to carbonize and obtain a carbonized body at a carbonization temperature of 1000℃.

[0060] S6: The carbide is placed in a vacuum furnace for silicon infiltration treatment to obtain a silicide. The temperature is 1650℃, the holding time is 3h, and the furnace pressure is less than 1000Pa.

[0061] S7: The silicide is surface-polished and its outer contour dimensions are machined to obtain a carbon ceramic brake disc with strong adhesion of the friction layer.

[0062] Example 2

[0063] This embodiment provides a carbon-ceramic brake disc with strong friction layer adhesion, and its preparation steps are as follows:

[0064] S1: Alternately stack carbon fiber mesh and unidirectional long fiber cloth and needle punch them to obtain a needled body of a predetermined thickness.

[0065] S2: The needled body is placed in a CVI furnace for vapor deposition at a temperature of 1000℃ for 400 hours to obtain a CVI preform.

[0066] S3: Perform industrial CT scanning on the CVI blank to confirm the distribution pattern of the fiber layer and mesh layer within a certain depth from the upper and lower surfaces of the CVI blank. Machining several matrix embedding zones according to the design yields a pre-blank. The sum of designs S2 and S4 is 25% of the sum of S1, S2, S3, and S4. The side of the matrix embedding zone is at a 90° angle to the brake disc surface, and the average area of ​​the matrix contact surface in the matrix embedding zone is 100 mm². 2 The height of the substrate embedding area is 0.5 mm;

[0067] S4: A friction layer slurry is brushed onto 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 2mm. Then, a curing treatment is performed to obtain the brake disc preform.

[0068] S5: The brake disc blank is placed in a carbonization furnace to carbonize and obtain a carbonized body at a carbonization temperature of 1000℃.

[0069] S6: The carbide is placed in a vacuum furnace for silicon infiltration treatment to obtain a silicide. The temperature is 1650℃, the holding time is 3h, and the furnace pressure is less than 1000Pa.

[0070] S7: The silicide is surface-polished and its outer contour dimensions are machined to obtain a carbon ceramic brake disc with strong adhesion of the friction layer.

[0071] Example 3

[0072] This embodiment provides a carbon-ceramic brake disc with strong friction layer adhesion, and its preparation steps are as follows:

[0073] S1: Alternately stack carbon fiber mesh and unidirectional long fiber cloth and needle punch them to obtain a needled body of a predetermined thickness.

[0074] S2: The needled body is placed in a CVI furnace for vapor deposition at a temperature of 1000℃ for 400 hours to obtain a CVI preform.

[0075] S3: Perform industrial CT scanning on the CVI blank to confirm the distribution pattern of the fiber layer and mesh layer within a certain depth from the upper and lower surfaces of the CVI blank. Machining several matrix embedding zones according to the design yields a pre-blank. The sum of designs S2 and S4 is 4% of the sum of S1, S2, S3, and S4. The side of the matrix embedding zone is at a 65° angle to the brake disc surface, and the average area of ​​the matrix contact surface in the matrix embedding zone is 100 mm². 2 The height of the substrate embedding area is 0.5 mm;

[0076] S4: A friction layer slurry is brushed onto 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 2mm. Then, a curing treatment is performed to obtain the brake disc preform.

[0077] S5: The brake disc blank is placed in a carbonization furnace to carbonize and obtain a carbonized body at a carbonization temperature of 1000℃.

[0078] S6: The carbide is placed in a vacuum furnace for silicon infiltration treatment to obtain a silicide. The temperature is 1650℃, the holding time is 3h, and the furnace pressure is less than 1000Pa.

[0079] S7: The silicide is surface-polished and its outer contour dimensions are machined to obtain a carbon ceramic brake disc with strong adhesion of the friction layer.

[0080] Example 4

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

[0082] S1: Alternately stack carbon fiber mesh and unidirectional long fiber cloth and needle punch them to obtain a needled body of a predetermined thickness.

[0083] S2: The needled body is placed in a CVI furnace for vapor deposition at a temperature of 1000℃ for 400 hours to obtain a CVI preform.

[0084] S3: Perform industrial CT scanning on the CVI blank to confirm the distribution pattern of the fiber layer and mesh layer within a certain depth from the upper and lower surfaces of the CVI blank. Machining several matrix embedding zones according to the design yields a pre-blank. The sum of designs S2 and S4 is 4% of the sum of S1, S2, S3, and S4. The side of the matrix embedding zone is at a 125° angle to the brake disc surface, and the average area of ​​the matrix contact surface in the matrix embedding zone is 100 mm². 2 The height of the substrate embedding area is 0.5 mm;

[0085] S4: A friction layer slurry is brushed onto 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 2mm. Then, a curing treatment is performed to obtain the brake disc preform.

[0086] S5: The brake disc blank is placed in a carbonization furnace to carbonize and obtain a carbonized body at a carbonization temperature of 1000℃.

[0087] S6: The carbide is placed in a vacuum furnace for silicon infiltration treatment to obtain a silicide. The temperature is 1650℃, the holding time is 3h, and the furnace pressure is less than 1000Pa.

[0088] S7: The silicide is surface-polished and its outer contour dimensions are machined to obtain a carbon ceramic brake disc with strong adhesion of the friction layer.

[0089] Example 5

[0090] This embodiment provides a carbon-ceramic brake disc with strong friction layer adhesion, and its preparation steps are as follows:

[0091] S1: Alternately stack carbon fiber mesh and unidirectional long fiber cloth and needle punch them to obtain a needled body of a predetermined thickness.

[0092] S2: The needled body is placed in a CVI furnace for vapor deposition at a temperature of 1000℃ for 400 hours to obtain a CVI preform.

[0093] S3: Perform industrial CT scanning on the CVI blank to confirm the distribution pattern of the fiber layer and mesh layer within a certain depth from the upper and lower surfaces of the CVI blank. Machining several matrix embedding zones according to the design yields a pre-blank. The sum of designs S2 and S4 is 40% of the sum of S1, S2, S3, and S4. The side of the matrix embedding zone is at a 90° angle to the brake disc surface, and the average area of ​​the matrix contact surface in the matrix embedding zone is 100 mm². 2 The height of the substrate embedding area is 0.5 mm;

[0094] S4: A friction layer slurry is brushed onto 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 2mm. Then, a curing treatment is performed to obtain the brake disc preform.

[0095] S5: The brake disc blank is placed in a carbonization furnace to carbonize and obtain a carbonized body at a carbonization temperature of 1000℃.

[0096] S6: The carbide is placed in a vacuum furnace for silicon infiltration treatment to obtain a silicide. The temperature is 1650℃, the holding time is 3h, and the furnace pressure is less than 1000Pa.

[0097] S7: The silicide is surface-polished and its outer contour dimensions are machined to obtain a carbon-ceramic brake disc with strong adhesion of the friction layer.

[0098] Comparative Example 1

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

[0100] S1: Alternately stack carbon fiber mesh and unidirectional long fiber cloth and needle punch them to obtain a needled body of a predetermined thickness.

[0101] S2: The needled body is placed in a CVI furnace for vapor deposition at a temperature of 1000℃ for 400 hours to obtain a CVI preform.

[0102] S3: Perform industrial CT scanning on the CVI blank to confirm the distribution pattern of the fiber layer and mesh layer within a certain depth from the upper and lower surfaces of the CVI blank. Machining several matrix embedding zones according to the design yields a pre-blank, where the sum of designs S2 and S4 is 50% of the sum of S1, S2, S3, and S4. The side of the matrix embedding zone is at a 90° angle to the brake disc surface, and the average area of ​​the matrix contact surface in the matrix embedding zone is 100 mm². 2 The height of the substrate embedding area is 0.5 mm;

[0103] S4: A friction layer slurry is brushed onto 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 2mm. Then, a curing treatment is performed to obtain the brake disc preform.

[0104] S5: The brake disc blank is placed in a carbonization furnace to carbonize and obtain a carbonized body at a carbonization temperature of 1000℃.

[0105] S6: The carbide is placed in a vacuum furnace for silicon infiltration treatment to obtain a silicide. The temperature is 1650℃, the holding time is 3h, and the furnace pressure is less than 1000Pa.

[0106] S7: The silicide is surface-polished and its outer contour dimensions are machined to obtain a carbon ceramic brake disc with strong adhesion of the friction layer.

[0107] Comparative Example 2

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

[0109] S1: Alternately stack carbon fiber mesh and unidirectional long fiber cloth and needle punch them to obtain a needled body of a predetermined thickness.

[0110] S2: The needled body is placed in a CVI furnace for vapor deposition at a temperature of 1000℃ for 400 hours to obtain a CVI preform.

[0111] S3: Perform industrial CT scanning on the CVI blank to confirm the distribution pattern of the fiber layer and mesh layer within a certain depth from the upper and lower surfaces of the CVI blank. Machining several matrix embedding zones according to the design yields a pre-blank. The sum of designs S2 and S4 is 60% of the sum of S1, S2, S3, and S4. The side of the matrix embedding zone is at a 90° angle to the brake disc surface, and the average area of ​​the matrix contact surface in the matrix embedding zone is 100 mm². 2 The height of the substrate embedding area is 0.5 mm;

[0112] S4: A friction layer slurry is brushed onto 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 2mm. Then, a curing treatment is performed to obtain the brake disc preform.

[0113] S5: The brake disc blank is placed in a carbonization furnace to carbonize and obtain a carbonized body at a carbonization temperature of 1000℃.

[0114] S6: The carbide is placed in a vacuum furnace for silicon infiltration treatment to obtain a silicide. The temperature is 1650℃, the holding time is 3h, and the furnace pressure is less than 1000Pa.

[0115] S7: The silicide is surface-polished and its outer contour dimensions are machined to obtain a carbon ceramic brake disc with strong adhesion of the friction layer.

[0116] The carbon-ceramic brake discs prepared in Examples 1-5 and Comparative Examples 1-2 were tested. The test method was as follows:

[0117] To check for flaking of the friction layer, conduct the test according to the test method specified in QC / T 316. Use a braking torque equivalent to 0.6g and perform 20 × 10 braking cycles. 4 Each time, the corresponding area is checked once every 50,000 times, for a total of 300,000 cycles.

[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] The test data above shows that the friction layer and the substrate layer are connected by a toothed structure. By rationally designing the ratio of the substrate contact surface to the friction layer contact surface, the bonding force between the two layers can be increased, which plays a crucial role in improving the wear resistance of carbon-ceramic brake discs. The angle between the side of the substrate embedding area and the brake disc surface also has a certain effect on improving the bonding force between the substrate layer and the friction layer. Increasing the contact area between the sidewalls of the friction layer embedding area and the substrate layer embedding area is beneficial for improving the bonding force. An angle of less than 90° between the side of the substrate layer embedding area and the outer friction surface can increase the contact area, which is more beneficial for increasing the bonding force than 90°. However, an angle greater than 90° not only increases the contact area but also provides additional mechanical engagement, further enhancing the bonding force. However, machining angles greater than 90° requires higher precision and is more difficult.

[0122] The above-disclosed embodiments are merely some preferred embodiments of the present invention and should not be construed as limiting the scope of the present invention. Therefore, any equivalent variations made in accordance with the claims of the present invention are still within the scope of the present invention.

Claims

1. A carbon-ceramic brake disc with strong friction layer adhesion, the carbon-ceramic brake disc comprising a base layer and two friction layers located on the upper and lower surfaces of the base layer, the base layer comprising overlapping mesh layers and continuous fiber layers, the friction layers having an outer friction surface away from the base layer surface, characterized in that, The friction layer has N protruding friction layer embedding areas on the side near the matrix layer, and the matrix layer has M protruding matrix layer embedding areas on the side near the friction layer. The friction layer embedding areas and the matrix layer embedding areas are staggered and their sidewalls are in contact. The matrix layer embedding areas have multiple matrix contact surfaces parallel to the outer friction surface with the friction layer, including a matrix contact surfaces located in the mesh layer and b matrix contact surfaces located in the continuous fiber layer. The friction layer embedding areas have multiple friction layer contact surfaces parallel to the outer friction surface with the matrix layer, including c friction layer contact surfaces in contact with the mesh layer and d friction layer contact surfaces in contact with the continuous fiber layer. This satisfies the following formula: M = a + b N=c+d Where M, N, a, b, c, and d are all positive integers greater than 1.

2. The carbon ceramic brake disc with strong friction layer adhesion as described in claim 1, characterized in that, The total area of ​​the substrate contact surfaces is S1, the total area of ​​the substrate contact surfaces is S2, the total area of ​​the friction layer contact surfaces is S3, and the total area of ​​the friction layer contact surfaces is S4; wherein S1, S2, S3, and S4 satisfy the following relationship: 。 3. The carbon ceramic brake disc with strong friction layer adhesion as described in claim 2, characterized in that, The side of the substrate layer embedded area forms a predetermined angle with the external friction surface, the angle being 65°~125°.

4. The carbon ceramic brake disc with strong friction layer adhesion as described in claim 3, characterized in that, The sum of S1, S2, S3, and S4 is 0.8 to 1.3 times the area S of the external friction surface.

5. The carbon ceramic brake disc with strong friction layer adhesion as described in claim 1, characterized in that, The average area of ​​the substrate contact surface is 10-900 mm². 2 .

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

7. The carbon ceramic brake disc with strong friction layer adhesion as described in claim 1, characterized in that, The mesh layer contains 1-30 vol% carbon, 60-90 vol% silicon carbide, and 3-15 vol% silicon; the continuous fiber layer contains 40-65 vol% carbon, 25-50 vol% silicon carbide, and 3-15 vol% silicon; and the friction layer contains 60-95 vol% silicon carbide and 5-40 vol% silicon.

8. The carbon ceramic brake disc with strong friction layer adhesion as described in claim 7, characterized in that, The thickness of the mesh layer is 0.2-0.6 mm, and the thickness of the continuous fiber layer is 0.2-0.5 mm.

9. A method for preparing a carbon-ceramic brake disc with strong friction layer adhesion, used to prepare a carbon-ceramic brake disc with strong friction layer adhesion as described in any one of claims 1-8, characterized in that, The preparation method is as follows: S1: Alternately stack carbon fiber mesh and unidirectional long fiber cloth and needle punch them to obtain a needled body of a predetermined thickness. S2: The needled body is placed in a CVI furnace for vapor deposition at a temperature of 900-1100℃ for 150-300h to obtain a CVI preform. S3: Perform industrial CT scanning on the CVI blank to confirm the distribution pattern of the fiber layer and the mesh layer within a certain depth from the upper and lower surfaces of the CVI blank, and machine several matrix embedding areas according to the design to obtain a pre-blank. S4: Apply friction layer slurry to the upper and lower surfaces of the preform, with a thickness of 0.05-4mm, and then perform curing treatment to obtain the brake disc blank; S5: The brake disc blank is placed in a carbonization furnace to carbonize and obtain a carbonized body at a carbonization temperature of 900-1100℃. S6: The carbide is placed in a vacuum furnace for silicon infiltration treatment to obtain a silicide. The temperature is 1600-1700℃, the holding time is 2-4h, and the furnace pressure is less than 1000Pa. S7: The silicide is surface-polished and its outer contour dimensions are machined to obtain a carbon ceramic brake disc with strong adhesion of the friction layer.

Images