Automobile brake disc dust cover made of fiber reinforced resin matrix composite

Abstract

The invention discloses an automobile brake disc dust cover made of a fiber reinforced resin matrix composite. The automobile brake disc dust cover comprises a high-strength dust cover body, a bolt gasket and a mounting bolt, the dustproof cover body is made of a high-strength fiber reinforced thermoplastic resin matrix composite material; the bolt gasket is made of a non-metal polymer composite material; and the mounting bolt is made of metal. According to the material design, light weight of the automobile brake disc dust cover, reduction of automobile brake creeping noise and improvement of corrosion resistance and impact resistance can be achieved at the same time, and the automobile brake disc dust cover is low in cost, high in production efficiency and wide in application prospect.

Description

Technical Field

[0001] This invention relates to the field of automotive braking system technology, and in particular to a fiber-reinforced resin-based composite material automotive brake disc dust cover. Background Technology

[0002] The information disclosed in the background section of this invention is intended only to enhance the understanding of the overall background of the invention and is not necessarily to be construed as an admission or in any way implying that such information constitutes prior art known to those skilled in the art.

[0003] The brake disc dust cover is a crucial component of the automotive braking system. Its primary function is to protect the brake disc from flying debris such as mud and gravel, preventing these objects from getting stuck between the disc and brake pads and thus effectively avoiding damage to the braking system. During vehicle operation, the brake disc dust cover is subjected to vibration and other loads. When braking at low speeds on a flat road, during stationary or low-speed steering, or braking on an incline, the friction and micro-slip vibration between the brake pads and disc are transmitted to the dust cover through the connected bearing housing, causing the dust cover to vibrate and generate high-frequency resonance noise. This high-frequency vibration noise affects the quietness and comfort requirements of passengers and pedestrians, especially with the rapid development of new energy vehicles, where quieter electric motor systems have replaced noisier internal combustion engine systems. Therefore, the control of vibration and noise in the braking system is becoming increasingly stringent.

[0004] Traditional brake disc dust covers are mostly made of metal, such as painted steel or aluminum-magnesium alloys. Metal materials have high density and are prone to fatigue deformation. When covered by splashed dirt, sand, and water, the protective paint or layer on their surface is damaged, making them susceptible to corrosion, leading to breakage or peeling, resulting in a low safety factor. Furthermore, metal materials have high sound conductivity and poor sound attenuation, making them more prone to resonance, rapidly transmitting or amplifying sound, resulting in poor braking quietness. Currently, with the increasing proportion of new energy vehicle sales, metal brake disc dust covers no longer meet the design requirements for corrosion resistance, quietness, and lightweight design.

[0005] Using lightweight materials such as non-metallic composites to completely replace metallic materials will result in poor impact resistance and deformation resistance at high and low temperatures. Therefore, how to provide a non-metallic composite dust cover for automotive brake discs with excellent impact resistance and rigidity and that is not easily deformed is an urgent problem to be solved. Summary of the Invention

[0006] In view of this technical background, the present invention provides a fiber-reinforced resin matrix composite automotive brake disc dust cover, which has low sound conductivity, good sound decay, is not prone to resonance, and has high strength, impact resistance, and small deformation under external force, while meeting the design requirements of corrosion resistance and lightweight.

[0007] This invention provides a fiber-reinforced resin-based composite material dust cover for automotive brake discs, comprising a high-strength dust cover body, bolt washers, and mounting bolts.

[0008] The high-strength dust cover is made of high-strength fiber-reinforced thermoplastic resin-based composite material; the bolt washers are made of non-metallic polymer composite material; and the mounting bolts are made of metal.

[0009] Preferably, the high-strength dust cover is made of any one or a mixture of glass fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, basalt fiber, or nylon fiber.

[0010] Preferably, the thermoplastic resin material of the high-strength dust cover is any one or a mixture of nylon, ABS resin, polyphenylene sulfide, polyetherketone, or polyetheretherketone.

[0011] Preferably, the material of the high-strength dust cover contains 10% to 70% high-strength fiber and 30% to 90% thermoplastic resin.

[0012] Preferably, the non-metallic polymer composite bolt washer is a composite material composed of any one or a mixture of natural rubber, nitrile rubber, ethylene propylene rubber, chloroprene rubber, butyl rubber, and silicone rubber, and any one or a mixture of nylon, ABS resin, and phenolic resin.

[0013] Furthermore, in the non-metallic polymer composite bolt washer, the mass ratio of rubber to resin is 20:1 to 1:20.

[0014] Preferably, the metal mounting bolts are made of stainless steel or aluminum-magnesium alloy.

[0015] Preferably, the high-strength dust cover, the non-metallic polymer composite bolt washer, and the metal mounting bolts are connected by an anti-loosening mechanical connection.

[0016] Compared with the prior art, the present invention has achieved the following beneficial effects:

[0017] The dust cover of this invention uses high-strength, impact-resistant fibers, which significantly improves the impact resistance and deformation resistance of thermoplastic resin. Simultaneously, the high-strength fiber-reinforced resin matrix composite material greatly reduces the transmission of braking noise and increases its attenuation. The bolts are connected to the dust cover using non-metallic polymer composite gaskets, significantly improving the absorption of high-frequency vibrations from the bearing housing during braking, reducing resonance and noise caused by vibration transmission to the dust cover. The use of stainless steel or aluminum-magnesium alloy fixing bolts reduces bolt damage and loosening due to metal corrosion, improving safety. Therefore, through the material design of this invention, the use of metal is reduced, and the shortcomings of metal brake disc dust covers in reducing braking noise are improved. At the same time, it achieves low cost, lightweight, impact-resistant, deformation-resistant, and corrosion-resistant brake disc dust covers, with broad application prospects. Attached Figure Description

[0019] The accompanying drawings, which form part of this specification, are used to provide a further understanding of the invention. The illustrative embodiments and descriptions of the invention are used to explain the invention and do not constitute an undue limitation thereof. Obviously, those skilled in the art can obtain other drawings based on these drawings without any inventive effort.

[0020] Figure 1 These are schematic diagrams of the fiber-reinforced resin-based composite material automotive brake disc dust cover bodies of Embodiments 1-4 of the present invention.

[0021] Figure 2 These are schematic diagrams illustrating the installation of fiber-reinforced resin-based composite automotive brake disc dust covers according to Embodiments 1-4 of the present invention.

[0022] In Figure 2, 1 is a fiber-reinforced thermoplastic resin-based automotive dust cover; 2 is a non-metallic polymer composite bolt washer; and 3 is a stainless steel or aluminum-magnesium alloy bolt. Detailed Implementation

[0024] It should be noted that the following detailed descriptions are exemplary and intended to provide further illustration of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0025] The technical solution of the present invention will be further described in conjunction with specific embodiments.

[0026] Example 1

[0027] This embodiment provides a fiber-reinforced resin-based composite material dust cover for automotive brake discs, such as... Figure 2As shown, it includes: 1. Fiber-reinforced thermoplastic resin-based automotive dust cover; 2. Non-metallic polymer composite bolt washers; 3. Stainless steel or aluminum-magnesium alloy bolts.

[0028] 1. The high-strength fiber in the fiber-reinforced thermoplastic resin-based automotive dust cover is 50% chopped glass fiber, and the thermoplastic resin matrix is ​​nylon 66, with a mass content of 50%. The material designed according to this specification has a tensile strength of 180 MPa, an ultimate tensile rate of 4%, a flexural strength of 300 MPa, and a notched impact strength of 14.5 kJ / m at 23°C. 2 The notched impact strength at -30℃ is 9.5 kJ / m. 2 .

[0029] 2. Non-metallic polymer composite bolt washers, 90% nitrile rubber, 10% thermoplastic phenolic resin, initial Shore D hardness of 49, compression set of 5%.

[0030] 3. Stainless steel or aluminum-magnesium alloy fixing bolts, with 304 stainless steel as the material.

[0031] Example 2

[0032] This embodiment provides a fiber-reinforced resin-based composite material dust cover for automotive brake discs, such as... Figure 2 As shown, it includes: 1. Fiber-reinforced thermoplastic resin-based automotive dust cover; 2. Non-metallic polymer composite bolt washers; 3. Stainless steel or aluminum-magnesium alloy bolts.

[0033] 1. The fiber-reinforced thermoplastic resin-based automotive dust cover body contains 20% chopped glass fiber and 10% glass microspheres by mass; the thermoplastic resin matrix is ​​nylon 66, with a mass content of 70%. The material designed according to this specification has a tensile strength of 85 MPa, an ultimate tensile rate of 10%, a flexural strength of 205 MPa, and a notched impact strength of 9.5 kJ / m² at 23°C. 2 The notched impact strength at -30℃ is 4.5 kJ / m. 2 .

[0034] 2. Non-metallic polymer composite bolt washers, 90% neoprene rubber, 10% thermoplastic phenolic resin, initial Shore D hardness of 45, compression set of 7%.

[0035] 3. Stainless steel or aluminum-magnesium alloy fixing bolts, with 5052 aluminum-magnesium alloy as the material.

[0036] Example 3

[0037] This embodiment provides a fiber-reinforced resin-based composite material dust cover for automotive brake discs, such as... Figure 2 As shown, it includes: 1. Fiber-reinforced thermoplastic resin-based automotive dust cover; 2. Non-metallic polymer composite bolt washers; 3. Stainless steel or aluminum-magnesium alloy bolts.

[0038] 1. The high-strength fiber in the fiber-reinforced thermoplastic resin-based automotive dust cover is 30% chopped glass fiber; the thermoplastic resin matrix in the fiber-reinforced thermoplastic resin-based automotive dust cover is 70% nylon 66. The material designed according to this specification has a tensile strength of 155 MPa, an ultimate tensile strength of 4.3%, a flexural strength of 240 MPa, and a notched impact strength of 20 kJ / m at room temperature (23℃). 2 The notched impact strength at -30℃ is 12kJ / m. 2 .

[0039] 2. Non-metallic polymer composite bolt washers, 80% EPDM rubber, 10% thermoplastic phenolic resin, 10% natural rubber, initial Shore D hardness of 48, compression set of 5%.

[0040] 3. Stainless steel or aluminum-magnesium alloy fixing bolts, with 5052 aluminum-magnesium alloy as the material.

[0041] Example 4

[0042] This embodiment provides a fiber-reinforced resin-based composite material dust cover for automotive brake discs, such as... Figure 2 As shown, it includes: 1. Fiber-reinforced thermoplastic resin-based automotive dust cover; 2. Non-metallic polymer composite bolt washers; 3. Stainless steel or aluminum-magnesium alloy bolts.

[0043] 1. The fiber-reinforced thermoplastic resin-based automotive dust cover body contains 50% chopped glass fiber as high-strength fiber; the thermoplastic resin matrix is ​​35% Nylon 66 and 15% Nylon 6I / X. The material designed according to this specification has a tensile strength of 220 MPa, an ultimate tensile rate of 2.5%, a flexural strength of 210 MPa, and a notched impact strength of 13 kJ / m at 23°C. 2 The notched impact strength at -30℃ is 8kJ / m 2 .

[0044] 2. Non-metallic polymer composite bolt washers, 90% neoprene rubber, 10% ABS resin, initial Shore D hardness of 46, compression set of 7%.

[0045] 3. Stainless steel or aluminum-magnesium alloy fixing bolts, with 5052 aluminum-magnesium alloy as the material.

[0046] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

[0047] According to the embodiments described above, the material design can meet the mechanical performance requirements of corrosion resistance and non-metallic dust covers, reduce low-speed braking noise on flat roads by 1dB-5dB, reduce braking noise on ramps by 3dB-10dB, and reduce weight by 15%-35% compared to metal parts.

Claims

1. A fiber-reinforced resin-based composite material dust cover for automotive brake discs, characterized in that, It includes a high-strength dust cover, bolt washers, and mounting bolts; the high-strength dust cover is made of high-strength fiber-reinforced thermoplastic resin-based composite material; the bolt washers are made of non-metallic polymer composite material; and the mounting bolts are made of metal.

2. The fiber-reinforced resin-based composite automotive brake disc dust cover as described in claim 1, characterized in that, The high-strength dust cover is made of any one or a mixture of glass fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, basalt fiber, or nylon fiber.

3. The fiber-reinforced resin-based composite material automotive brake disc dust cover as described in claim 2, characterized in that, The high-strength fiber content is 10% to 70%.

4. The fiber-reinforced resin-based composite automotive brake disc dust cover as described in claim 1, characterized in that, The high-strength dust cover is made of thermoplastic resin, which is any one or a mixture of nylon, ABS resin, polyphenylene sulfide, polyetherketone, or polyetheretherketone.

5. The fiber-reinforced resin-based composite material automotive brake disc dust cover as described in claim 4, characterized in that, The content of the thermoplastic resin material is 30% to 90%.

6. The bolt washer as claimed in claim 1, characterized in that, The non-metallic polymer composite material is a composite material composed of any one or a mixture of natural rubber, nitrile rubber, ethylene propylene rubber, chloroprene rubber, butyl rubber, and silicone rubber, and any one or a mixture of nylon, ABS resin, and phenolic resin.

7. The bolt washer as claimed in claim 1, characterized in that, The non-metallic polymer composite material is a composite material composed of any one or a mixture of natural rubber, nitrile rubber, ethylene propylene rubber, chloroprene rubber, butyl rubber, and silicone rubber, and any one or a mixture of nylon, ABS resin, and phenolic resin.

8. The mounting bolt as described in claim 1, characterized in that, The bolts are made of stainless steel or aluminum-magnesium alloy and are used to fix bolt washers and high-strength dust covers to the automotive bearing housing.

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