Luminescent ceramic insert, article and method for producing an article

Abstract

In its most general sense, the present invention relates to a product, particularly a brake disc for a disc brake, the brake disc including a light-emitting insert, and a method for manufacturing the product. Specifically, the present invention relates to a light-emitting ceramic insert fixed to a side portion of a vehicle, preferably fixed to a portion of a braking system, the light-emitting ceramic insert comprising a body formed of a light-emitting ceramic material comprising powder including SrAl4O7 or SrAl2O4 doped with rare earth elements. The present invention also relates to a method for manufacturing the insert.

Description

Technical Field

[0001] In the most general aspect of the invention, the present invention relates to a product, particularly a brake disc for a disc brake including a light-emitting insert, and to a method for producing the product. Background Technology

[0002] A crucial aspect of any vehicle on the road is its nighttime visibility, whether it's a car, motorcycle, or bicycle. Numerous accidents occur due to insufficient lighting in the dark.

[0003] While a vehicle's front and rear lighting is typically obtained effectively through headlights and position lights or brake lights, achieving good visibility of a vehicle when viewed from the side is much more difficult. This can lead to serious accidents when crossing intersections.

[0004] To overcome this problem, sidelights have not proven to be very energy efficient. Therefore, systems have been proposed that involve using luminescent materials or coatings in the manufacture of some components visible from the side of the vehicle, such as wheels or wheel sections. However, luminescent materials also suffer from poor brightness and short duration at night because they must be recharged by sunlight.

[0005] Therefore, the technical problem solved by the present invention is to overcome the above-mentioned disadvantages, thereby providing vehicles with an energy-efficient, clearly visible in the dark and long-lasting side lighting system at night. Summary of the Invention

[0006] The above-mentioned problem is solved by a light-emitting ceramic insert, which is to be fixed to the side portion of the vehicle, preferably to the braking system portion, as set forth in the appended claims.

[0007] Another object of the present invention is a brake disc for a disc brake including the luminescent ceramic insert as described below, and a method for producing the brake disc.

[0008] For purposes of full description, the subject matter of the claims forms part of this disclosure.

[0009] In particular, the object of the present invention is:

[0010] 1) A luminescent ceramic insert to be fixed to a side portion of a vehicle, preferably to a portion of a braking system, the luminescent ceramic insert comprising a body formed of a luminescent ceramic material comprising powder including SrAl4O7 or SrAl2O4 doped with rare earth elements.

[0011] 2) The insert according to point 1, wherein the rare earth element is selected from europium (Eu). 2+ 、Dy 3+ and / or neodymium (Nd) 3+ ;

[0012] 3) A method for producing an article, preferably a brake disc for a disc brake, the article comprising at least one luminescent ceramic insert, the method comprising the following steps:

[0013] a) Forming at least one insert of a luminescent ceramic material according to point 1 or point 2;

[0014] b) Pre-treat the pores in the article by cleaning, optionally treating with alcohol to remove oil and grease, and scraping the edges to increase roughness;

[0015] c) Applying a layer of high-temperature ceramic adhesive to the edge of the insert made of luminescent ceramic material and to the edge of the hole in the article;

[0016] d) Insert the insert of the luminescent ceramic material from process c) into the hole from process c);

[0017] e) Optionally, repeat steps b) to d) for at least one other hole in the brake disc;

[0018] f) Process the product at a temperature between 60°C and 80°C for a period of 2 to 3 hours.

[0019] 4) The method for producing an article according to point 3, wherein the article is preferably a brake disc for a disc brake, wherein step a) includes:

[0020] - Insert the luminescent ceramic material in powder form, as described in point 1 or point 2, into the mold of the insert;

[0021] - subject the powder in the mold to a heat-refining stage;

[0022] 5) A method for producing an article, preferably a brake disc for a disc brake, the article comprising at least one luminescent ceramic insert, the method comprising the following steps:

[0023] - Drill holes in the product using laser;

[0024] - The pores are filled with the luminescent ceramic material described in point 1 or point 2 in powder form;

[0025] - subject the powder to a heat refining stage;

[0026] 6) A method for producing an article, preferably a brake disc for a disc brake, the article comprising at least one luminescent ceramic insert, the method comprising the following steps:

[0027] - During the manufacturing stage of the article, the luminescent ceramic material described in point 1 or point 2 is introduced into the mold of the article;

[0028] - subject the powder in the mold to a heat-refining stage;

[0029] 7) The method according to any one of points 4 to 6, wherein the hot refining step is performed at a temperature between 1000°C and 1600°C and at atmospheric pressure; and preferably, the hot refining step is performed at a temperature between 1000°C and 1600°C, at atmospheric pressure and in an inert atmosphere.

[0030] 8) The method according to any one of points 4 to 7, wherein slow cooling follows the hot refining step;

[0031] 9) The method according to any one of points 3, 4, 7 and 8, wherein the ceramic binder for high temperature uses comprises a ceramic material containing a filler, the filler being selected from the following: alumina, silicon dioxide, aluminum nitride, silicon carbide, magnesium oxide and zirconium oxide.

[0032] 10) The method according to any one of points 3, 4, 7 to 9, wherein, in step b), the heat drying stage is performed at a temperature between 60°C and 80°C and for a time period between 6 hours and 30 minutes.

[0033] 11) The method according to any one of points 3, 4, 7 to 10, wherein in steps c) and e), spraying is performed at a distance of approximately 20 cm from the surface to be treated, and wherein, preferably, step e) is performed approximately 30 minutes after step c) ends;

[0034] 12) An article comprising an insert as described in point 1 or point 2.

[0035] 13) The article of manufacture according to point 12, wherein the article of manufacture is a brake disc for a disc brake.

[0036] It can be seen that the use of the luminescent ceramic insert according to the present invention allows for high nighttime brightness, long brightness decay time and easy recharging by both light and heat, which is an important aspect when the luminescent ceramic insert is placed on the part of the braking system that is subjected to high heat during braking. Attached Figure Description

[0037] Figure 1 A plan view of the rotor of the disc brake is shown. Detailed Implementation

[0038] This invention was inspired by the fact that a brake disc for a disc brake includes a plurality of holes on the surface of the brake disc, such as... Figure 1 As shown in the figure. However, for the purposes of this invention, it is preferable to use a dedicated hole for the light-emitting insert (instead of the original hole of the disk) to avoid impairing the cooling of the disk due to the hole that is normally present for this purpose.

[0039] Therefore, the present invention relates to a luminescent ceramic insert for fixing to a side portion of a vehicle, preferably to a portion of a braking system. The luminescent ceramic insert comprises a body formed of a luminescent ceramic material, which is composed of powder comprising SrAl4O7 or SrAl2O4 doped with rare earth elements, particularly europium (Eu). 2+ ), Dysprosium 3+ ) and / or neodymium (Nd) 3+ Examples of these materials are described in the following: CH 709020Al or Xu YF; But DK; Guan ML; Chen XA; Pan QQ; Huang SM, Controlled synthesis of single crystal SrAl2O4:Eu<2+>, Dy<3+> nanosheets with persistent phosphorescence, JOURNAL OF ALLOYS AND COMPOUNDS, Vol. 502, pp. 38-42, 06.17.2010, 0925-8388, [XP027093120].

[0040] In particular, when part of the braking system is a brake disc for a disc brake, the luminescent ceramic insert according to the invention will have a shape and size adapted to the hole provided on the brake disc.

[0041] The molded body constituting the luminescent ceramic insert is obtained by inserting the above-mentioned ceramic powder into a suitable mold and then subjecting the molded body to a firing process.

[0042] The firing process is carried out at a temperature between 1000°C and 1600°C and under atmospheric pressure. The calcination time depends on the temperature used, and at higher temperatures, the calcination time can range from several hours to several days. Preferably, the calcination is performed in an inert atmosphere.

[0043] At the end of firing, it is important to apply slow cooling to avoid cracking of the material.

[0044] The firing process is used to improve both the mechanical strength and wear resistance of luminescent ceramic materials.

[0045] The body formed of the luminescent ceramic material preferably has a thickness of 1 mm to 3 mm, and more preferably, the body formed of the luminescent ceramic material has a thickness of about 2 mm.

[0046] The portion of the braking system including the luminescent ceramic insert of the present invention is preferably the brake disc of a disc brake. In automobiles with alloy wheels, and in motorcycles or bicycles equipped with disc brakes, the brake disc is a visible portion and has a sufficiently large surface area so that it is clearly visible when illuminated by the insert of the present invention. The brake disc is also subjected to intense heating during braking, which can increase the brightness of the luminescent ceramic material.

[0047] The insert of the luminescent ceramic material according to the present invention is fixed to the side portion of the vehicle using a high-temperature resistant adhesive. Preferably, the insert of the luminescent ceramic material according to the present invention is fixed to the portion of the braking system using a high-temperature resistant adhesive. More preferably, the insert of the luminescent ceramic material according to the present invention is fixed to the brake disc for a disc brake using a high-temperature resistant adhesive.

[0048] This adhesive must possess excellent bonding ability, meaning it can bond a variety of materials, including metals, plastics, and ceramics. It must also exhibit high chemical resistance to a wide range of chemicals, including acids, alkalis, and solvents. Furthermore, the adhesive must provide good electrical insulation properties after curing.

[0049] In a preferred embodiment, the adhesive is a high-temperature ceramic adhesive comprising a ceramic material containing fillers, which may be selected from alumina, silica, aluminum nitride, silicon carbide, magnesium oxide, and zirconium oxide. Typically, the adhesive also contains a curing agent to facilitate the curing process. Examples of such adhesives include adhesives sold by Aremco, inorganic ceramic adhesive HR-8767 from Dongguan Huirui Ltd., or aluminum-based adhesive Resbond 989 from Cotronics Corp.

[0050] These adhesives maintain a stable bond at temperatures up to 1200°C and exhibit good corrosion resistance and insulation properties.

[0051] The following describes a method for manufacturing a brake disc for a disc brake, the brake disc comprising at least one luminescent ceramic insert according to the invention.

[0052] A method for manufacturing a brake disc for a disc brake, the brake disc comprising at least one luminescent ceramic insert according to the invention, the method comprising the following steps:

[0053] a) Manufacture at least one insert made of luminescent ceramic material as described above;

[0054] b) Provide brake discs for disc brakes;

[0055] c) The holes of the brake disc are pretreated by cleaning, using alcohol to remove oil and grease, and scraping the edges to increase roughness.

[0056] d) Apply a layer of ceramic adhesive for high temperature to the edge of the at least one insert made of luminescent ceramic material and to the edge of the hole in the brake disc;

[0057] e) Insert a luminescent ceramic material insert from process d) into the hole of process d);

[0058] f) Optionally, repeat steps b) to e) for at least one other hole in the brake disc;

[0059] g) Treat the brake disc at a temperature of 60°C to 80°C for a period of 2 to 3 hours.

[0060] Another object of the present invention is an article of manufacture, particularly a caliper for a disc brake, said article comprising at least one luminescent ceramic insert as described above.

[0061] In other embodiments, the ceramic insert can be directly inserted into the disk material during the CCB forming process; or holes can be laser-drilled in the pre-formed disk, and then these holes can be filled with the aforementioned particulate material to form the insert directly onto the disk.

[0062] For the preferred embodiments described above, in order to meet specific needs, those skilled in the art will be able to make numerous modifications, adjustments and substitutions to the elements with other functionally equivalent elements without departing from the scope of the appended claims.

Claims

1. A luminescent ceramic insert, the luminescent ceramic insert being fixed to a side portion of a vehicle, preferably, the luminescent ceramic insert being fixed to a portion of a braking system, the luminescent ceramic insert comprising a body formed of a luminescent ceramic material, the luminescent ceramic material being composed of powder comprising SrAl4O7 or SrAl2O4 doped with rare earth elements.

2. The luminescent ceramic insert according to claim 1, wherein, The rare earth element is selected from europium (Eu). 2+ 、Dy 3+ and neodymium Nd 3+ .

3. A method for producing an article, preferably a brake disc for a disc brake, the article comprising at least one luminescent ceramic insert according to claim 1 or 2, the method comprising the following steps: a) Forming at least one insert of luminescent ceramic material; b) The pores in the article are pretreated by cleaning, optionally by treating with alcohol to remove oil and grease, and scraping the edges to increase roughness; c) Applying a layer of high-temperature ceramic adhesive to the edge of the insert made of luminescent ceramic material and to the edge of the hole in the article; d) Insert the insert made of luminescent ceramic material from process c) into the hole of process c); e) Optionally, steps b) through d) may be repeated for at least one other hole in the article; f) The article is treated at a temperature between 60°C and 80°C for a period of 2 to 3 hours.

4. The method for producing an article according to claim 3, wherein the article is preferably a brake disc for a disc brake, wherein, Step a) includes: - Insert the luminescent ceramic material in powder form into the mold of the luminescent ceramic insert according to claim 1 or 2; - subject the powder in the mold to a heat-refining stage.

5. A method for producing an article, preferably a brake disc for a disc brake, the article comprising at least one luminescent ceramic insert according to claim 1 or 2, the method comprising the following steps: - Laser drilling is performed on the product; - The pores are filled with a luminescent ceramic material in powder form; - subject the powder to a heat refining stage.

6. A method for producing an article, preferably a brake disc for a disc brake, the article comprising at least one luminescent ceramic insert according to claim 1 or 2, the method comprising the following steps: - During the manufacturing stage of the article, luminescent ceramic material is introduced into the mold of the article; - subject the powder in the mold to a heat-refining stage.

7. The method according to any one of claims 4 to 6, wherein, The hot refining process is carried out at a temperature between 1000°C and 1600°C and under atmospheric pressure. as well as Preferably, the hot refining step is performed at a temperature between 1000°C and 1600°C, under atmospheric pressure, and in an inert atmosphere.

8. The method according to any one of claims 4 to 7, wherein, The process is followed by slow cooling.

9. The method according to any one of claims 3, 4, 7 and 8, wherein, The high-temperature ceramic binder includes a ceramic material containing fillers, which can be selected from the following: alumina, silicon dioxide, aluminum nitride, silicon carbide, magnesium oxide, and zirconium oxide.

10. The method according to any one of claims 3, 4, 7 to 9, wherein, In step b), the heat drying stage is performed at a temperature between 60°C and 80°C and for a time between 6 hours and 30 minutes.

11. The method according to any one of claims 3, 4, 7 to 10, wherein, In steps c) and e), spraying is performed at a distance of approximately 20 cm from the surface to be treated, and preferably, step e) is performed approximately 30 minutes after step c) ends.

12. An article comprising a luminescent ceramic insert according to any one of claims 1 or 2.

13. The article of claim 12, wherein, The product is a brake disc used in disc brakes.

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