Lightweight iron and aluminum composite brake disc

Abstract

The utility model relates to the technical field of automotive light-weight brake discs, in particular to a light-weight iron and aluminum composite brake disc which comprises a composite friction ring, the composite friction ring comprises an iron ring body, the annular face of one side of the iron ring body is a flat face, and the other annular face of the iron ring body is provided with a plurality of ring body columns which are densely arranged. The aluminum alloy ring body is provided with a plurality of ring body through holes which are densely arranged; wherein the ring body columns of the iron ring body and the ring body through holes of the aluminum alloy ring body are consistent in shape and are arranged in one-to-one correspondence, and the iron ring body and the aluminum alloy ring body are combined into a whole through riveting to form the composite friction ring; an aluminum alloy disc body; provided is an aluminum alloy brazing filler metal ring. The brake disc has the benefits that the friction surface is formed by the flat surface of the iron ring body, so that the friction performance of the brake disc is improved; the heat conductivity of the brake disc composite structure is improved through brazing of the aluminum alloy brazing filler metal; the brake disc formed by compounding iron and aluminum realizes light weight.

Description

Technical Field

[0001] The utility model relates to the technical field of lightweight brake discs for vehicles, in particular to a lightweight iron and aluminum composite brake disc. Background Art

[0002] Currently, most vehicles use cast iron (or cast steel) brake discs. Since cast iron has excellent friction properties and low cost, there is currently no other suitable material to actually replace it.

[0003] However, cast iron or steel is a heavy metal material (density 7.8g / cm3). Under the current premise of reducing fuel consumption (power), mileage, reducing carbon dioxide emissions, and protecting the earth's environment, lightweight brake discs are becoming increasingly important.

[0004] Aluminum is a representative of light metals (density 2.7g / cm3). It is feasible to replace iron with aluminum, but it cannot be simply replaced by aluminum alloy because the hardness of aluminum alloy is much lower than that of iron, especially in the high temperature environment of braking. Therefore, a lot of research has been invested in ceramic particles (such as SiC, Al2O3) reinforced aluminum-based composite materials to replace cast iron materials. However, this type of material has other disadvantages, such as high-temperature friction performance. Therefore, the aluminum brake discs of the prior art are limited to the narrow range of small loads or low-speed vehicles, and the actual application and promotion are greatly restricted.

[0005] In view of the above problems, we propose a lightweight iron and aluminum composite brake disc. Utility Model Content

[0006] The purpose of the utility model is to provide a lightweight iron and aluminum composite brake disc to solve the problems raised in the above background technology.

[0007] In order to achieve the above purpose, the utility model provides the following technical solutions:

[0008] A lightweight iron-aluminum composite brake disc, comprising:

[0009] A composite friction ring, comprising:

[0010] An iron ring body, wherein one annular surface of the iron ring body is a flat surface, and the other annular surface has a plurality of densely arranged annular body columns;

[0011] An aluminum alloy ring body, wherein the aluminum alloy ring body has a plurality of densely arranged ring body through holes;

[0012] The ring body cylinder of the iron ring body and the ring body through hole of the aluminum alloy ring body have the same shape and are arranged in one-to-one correspondence. The iron ring body and the aluminum alloy ring body are combined into one by riveting to form a composite friction ring.

[0013] Aluminum alloy plate;

[0014] Aluminum alloy brazing ring;

[0015] Among them, the three are in order from top to bottom:

[0016] The first layer of the composite friction ring, the first layer of the aluminum alloy brazing material ring, the aluminum alloy disc body, the second layer of the aluminum alloy brazing material ring, and the second layer of the composite friction ring are assembled together, and the components are connected together by brazing to obtain a lightweight first composite brake disc;

[0017] Wherein, the first layer of the composite friction ring is arranged from top to bottom as an iron ring body and an aluminum alloy ring body;

[0018] The composite friction ring of the second layer is arranged from top to bottom as an aluminum alloy ring body and an iron ring body.

[0019] Preferably, one side of the iron ring body of the composite friction ring is a friction surface;

[0020] One side of the aluminum alloy ring body is a solder surface.

[0021] Preferably, the composite friction ring adopts a dense form of columns or holes, wherein the total number of columns or holes accounts for 30-70% of the total area of ​​the iron ring body or the aluminum alloy ring body, and the density of the columns or holes is 1-4 / cm 3 .

[0022] Preferably, the composite friction ring is composed of a plurality of composite friction nodes spliced ​​together, and the composite friction ring, the aluminum alloy disc body, and the two layers of aluminum alloy brazing rings constitute the second composite brake disc.

[0023] Compared with the prior art, the beneficial effects of the utility model are:

[0024] The utility model improves the friction performance of the brake disc by forming the friction surface with the flat surface of the iron ring body; improves the thermal conductivity of the brake disc structure by brazing with aluminum alloy brazing material; and realizes lightweighting by forming the brake disc with iron / aluminum composite. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a perspective view of the aluminum alloy ring body of the composite friction ring of Example 1 of the utility model, wherein the aluminum alloy ring body has a plurality of densely arranged through holes.

[0026] Figure 2 It is a perspective view of the iron ring body of the composite friction ring of Example 1 of the utility model, wherein one annular surface of the iron ring body is a flat surface, and the other annular surface has a plurality of densely arranged columns.

[0027] Figure 3It is a partial cutaway perspective view of the composite friction ring of Example 1 of the utility model, showing Figure 1 The through hole of the aluminum alloy ring Figure 2 The columns of the iron ring body have the same shape and are arranged in one-to-one correspondence. The iron ring body and the aluminum alloy ring body are combined into one by riveting to form a composite friction ring.

[0028] Figure 4 It is a partial cutaway perspective view of the iron / aluminum composite brake disc of Example 1 of the utility model, showing that in order from top to bottom: composite friction ring (iron ring body-aluminum alloy ring body)-aluminum alloy brazing ring-aluminum alloy disc body-aluminum alloy brazing ring-composite friction ring (aluminum alloy ring body-iron ring body) are assembled together, and the components are connected together by brazing to obtain the iron / aluminum composite brake disc.

[0029] Figure 5 It is a perspective view of an aluminum alloy node of a composite friction node in Example 2 of the utility model, wherein the node has a plurality of densely arranged through holes.

[0030] Figure 6 It is a perspective view of an iron node of a composite friction node in Example 2 of the utility model, wherein one side of the iron node is a flat surface, and the other side has a plurality of densely arranged columns.

[0031] Figure 7 It is a perspective view of the composite friction block of Example 2 of the utility model, showing Figure 5 Aluminum alloy block through hole and Figure 6 The columns of the iron segments have the same shape and are arranged in one-to-one correspondence. The iron segments and the aluminum alloy segments are combined into one by riveting to form a composite friction segment.

[0032] Figure 8 It indicated Figure 7 The 12 composite segments shown are spliced ​​into a complete ring.

[0033] Fig. 9 It is a partial cutaway perspective view of a segmented iron / aluminum composite brake disc of Example 2 of the utility model.

[0034] In the figure:

[0035] 1. Aluminum alloy ring body; 2. Ring body through hole; 3. Iron ring body; 4. Ring body column; 5. Aluminum alloy segment; 6. Segment through hole; 7. Iron segment; 8. Segment column; 11. Aluminum alloy disc body; 12. Aluminum alloy brazing ring; 10. Composite friction ring; 20. First composite brake disc; 30. Composite segment; 40. Second composite brake disc. DETAILED DESCRIPTION

[0036] The preferred technical solutions of the present invention will be described clearly and completely in the following in the form of drawings. Obviously, the described technical solutions are only part of the technical solutions of the present invention, rather than all of the technical solutions.

[0037] Embodiment 1:

[0038] The utility model relates to a lightweight iron and aluminum composite brake disc. In the utility model, the first composite brake disc 20 of embodiment 1 comprises: a pair of composite friction rings 10, an aluminum alloy brazing material ring 12, an aluminum alloy disc body 11 ( Figure 4 ).

[0039] See attached figure, Figure 1 1 is a perspective view of an aluminum alloy ring body 1 of a composite friction ring 10 according to Example 1 of the present utility model, wherein the aluminum alloy ring body 1 has a plurality of densely arranged through holes 2; Figure 2 It is a perspective view of the iron ring body 3 of the composite friction ring 10, wherein one side annular surface of the iron ring body 3 is a flat surface, and the other annular surface has a plurality of densely arranged columns 4; wherein the through hole 2 of the aluminum alloy ring body 1 is consistent in shape with the columns 4 of the iron ring body 3 and their arrangement positions correspond one to one, and the aluminum alloy ring body 1 and the iron ring body 3 are combined into one by riveting to form the composite friction ring 10.

[0040] The material used for the aluminum alloy ring body 1 in the utility model is not limited, and it can be pure aluminum or any aluminum alloy, preferably an aluminum alloy with high temperature strength, such as Al-Fe alloy; the material used for the iron ring body 3 in the utility model is not limited, and it can be cast iron or cast steel, preferably an iron material with good friction properties, such as gray cast iron HT250.

[0041] Figure 3 A partial cutaway perspective view of a composite friction ring 10 of Example 1 of the utility model is shown. After riveting, the column 4 of the iron ring body 3 and the through hole 2 of the aluminum alloy ring body 1 form a tightly combined two-layer structure. The iron ring body layer 3 of the two-layer structure constitutes a surface layer, and its side surface (flat surface) will serve as the friction surface of the composite friction ring 10; while the aluminum alloy ring body layer 1 constitutes a substrate layer, and its side surface (perforated surface, in which the aluminum alloy ring body 1 is flush with the top surface of the column 4 of the iron ring body 3) will serve as the brazing surface of the composite friction ring 10.

[0042] Figure 4It is a partial cutaway perspective view of the first composite brake disc 20 of Example 1 of the utility model. As shown in the figure, in order from top to bottom: composite friction ring 10 (iron ring body upward) - aluminum alloy brazing ring 12 - aluminum alloy disc body 11 - aluminum alloy brazing ring 12 - composite friction ring 10 (iron ring body downward) are assembled together, wherein the material of the aluminum alloy brazing ring 12 is Al-Si alloy with a Si content of 6-10%. The Al-Si alloy is melted by brazing, and the components are brazed together to obtain the first composite brake disc 20.

[0043] The material used for the aluminum alloy disc 11 in the present invention is not limited, and it can be pure aluminum or any aluminum alloy, preferably an aluminum alloy with high temperature strength, such as Al-Fe alloy.

[0044] The first composite brake disc 20 of Example 1 of the utility model has the following benefits: since the iron ring body 3 of the composite friction ring 10 constitutes the inner and outer friction surfaces of the brake disc 20, the brake disc 20 has good friction performance; since the aluminum alloy ring body 2 and the iron ring body 3 of the composite friction ring 10 adopt dense column / hole meshing riveting, not only the connection strength is high, but also the heat transfer efficiency between the iron ring body 3 (friction layer) and the aluminum alloy ring body (substrate layer) is improved; since the aluminum alloy ring body 1 of the composite friction ring 10 and the aluminum alloy disc body are brazed and connected by an aluminum alloy brazing ring 12, a metal-to-metal connection strength that can withstand a high-temperature braking environment is formed; since the volume proportion of iron in the first composite brake disc 20 is less than 10%, the brake disc (and the unsprung mass of the vehicle) is lightweight, thereby achieving.

[0045] The dense form of the columns 4 / holes 2 used in the composite friction ring 10 means that the total number of columns 4 / holes 2 accounts for 30-70% of the total area of ​​the ring (1 or 3); and the density of the columns 4 / holes 2 is 1-4 / cm 3 .

[0046] It should be understood that although the shape of the column 4 / hole 2 is circular in the figures, it is not limited to an angular shape, such as a triangle, rectangle, oblong, pentagon, rhombus, etc.

[0047] Although the columns 4 / holes 2 are shown in the figures as being arranged in concentric circles in a ring, they may also be arranged in other ways, such as a grid, a mesh, etc.

[0048] Although the cylindrical shapes or holes of the posts 4 / holes 2 are shown as having the same diameter, they may also have different diameters, for example, the diameter may gradually increase in the outward circumferential direction and may gradually decrease in the inward circumferential direction.

[0049] Embodiment 2:

[0050] Figure 5It is a perspective view of an aluminum alloy node 5 of a composite node 30 of Example 2 of the utility model, wherein the node 5 has a plurality of node through holes 6 that are densely arranged.

[0051] Figure 6 It is a perspective view of an iron segment 7 of a composite segment 30 of Example 2 of the utility model, wherein one side of the iron segment 7 is a flat surface, and the other side has a plurality of segment columns 8 densely arranged.

[0052] Figure 7 is a perspective view of the composite friction node 30 of embodiment 2 of the present utility model, showing Figure 5 The through hole 6 of the aluminum alloy block 5 is Figure 6 The columns 5 of the iron segment 7 have the same shape and are arranged in one-to-one correspondence. The iron segment 7 and the aluminum alloy segment 5 are combined into one by riveting to form a composite friction segment 30 .

[0053] Figure 8 It indicated Figure 7 The 12 composite segments 30 shown are spliced ​​into a complete ring. The composite segment 30 shown in this embodiment is a quadrilateral shape, that is, the four sides are arc sides, however, it should be understood that the shape can be any shape, for example, a fan shape, as long as it can be spliced ​​into a complete ring (i.e., forming an annular friction surface); although 12 composite segments 30 are shown, it can be any number of segments, as long as it can be spliced ​​into a complete ring (i.e., forming an annular friction surface); although the composite segments 30 shown are the same shape, it can be a combination of different shapes, as long as it can be spliced ​​into a complete ring (i.e., forming an annular friction surface). In a sense, the shape, quantity and combination of the composite segments 30 largely depend on the processing equipment, processing cost and required performance requirements.

[0054] Fig. 9 The diagram is a partial cutaway perspective view of a second composite brake disc 40 of the second embodiment of the present invention. The structure is similar to that of the first embodiment of the present invention, except that the first embodiment is in a complete ring shape, while the present embodiment is in a ring shape of spliced ​​segments, achieving the same purpose. In the second composite brake disc 40, the splicing of the composite segments 30 can reserve gaps as required, which also serves to release thermal stress.

[0055] It can be understood from the description of Examples 1 and 2 of the utility model that the composite friction ring 10 of Example 1 and the composite segment 30 of Example 2 actually constitute an iron material layer and an aluminum substrate layer (i.e., a friction layer and a brazing layer), except that the composite segment 30 of Example 2 is actually spliced ​​into a ring shape. Therefore, Example 1 and Example 2 can be combined with each other, i.e., the aluminum alloy ring body 1 is combined with the iron segment 7; the iron ring body 3 is combined with the aluminum alloy segment 5, to obtain substantially the same effect.

[0056] In this specification, although a solid brake disc is shown, it can also be applied to a duct type brake disc.

[0057] Although the utility model shows the application of a disc brake disc, the same principle can also be applied to a brake drum or other mechanical brake devices.

Claims

1. A lightweight iron-aluminum composite brake disc, characterized in that: The brake disc includes: A composite friction ring (10), the composite friction ring (10) comprising: An iron ring body (3), wherein one annular surface of the iron ring body (3) is a flat surface, and the other annular surface is provided with a plurality of densely arranged annular body columns (4); An aluminum alloy ring body (1), wherein the aluminum alloy ring body (1) has a plurality of densely arranged ring body through holes (2); The ring body column (4) of the iron ring body (3) and the ring body through hole (2) of the aluminum alloy ring body (1) have the same shape and are arranged in one-to-one correspondence. The iron ring body (3) and the aluminum alloy ring body (1) are combined into one by riveting to form a composite friction ring (10); Aluminum alloy plate (11); Aluminum alloy brazing ring (12); Among them, the three are in order from top to bottom: The first layer of the composite friction ring (10), the first layer of the aluminum alloy brazing material ring (12), the aluminum alloy disc body (11), the second layer of the aluminum alloy brazing material ring (12), and the second layer of the composite friction ring (10) are assembled together, and the components are connected together by brazing to obtain a lightweight first composite brake disc (20); Wherein, the first layer of the composite friction ring (10) is arranged from top to bottom as an iron ring body (3) and an aluminum alloy ring body (1); The second layer of the composite friction ring (10) is arranged from top to bottom as an aluminum alloy ring body (1) and an iron ring body (3).

2. A lightweight iron-aluminum composite brake disc according to claim 1, characterized in that: One side of the iron ring body (3) of the composite friction ring (10) is a friction surface; One side of the aluminum alloy ring body (1) is a brazing filler metal surface.

3. A lightweight iron-aluminum composite brake disc according to claim 1, characterized in that: The composite friction ring (10) adopts a dense form of columns or holes, wherein the total number of columns or holes accounts for 30-70% of the total area of ​​the iron ring body (3) or the aluminum alloy ring body (1), and the density of the columns or holes is 1-4 / cm 3 .

4. A lightweight iron-aluminum composite brake disc according to claim 1, characterized in that: The composite friction ring (10) is composed of a plurality of composite friction nodes (30) spliced ​​together, and the composite friction ring (10), the aluminum alloy disc body (11), and the two-layer aluminum alloy brazing material ring (12) form a second composite brake disc (40).

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