Wear-resistant brake disc for frequent braking

Abstract

The utility model discloses a frequent braking wear-resistant brake disc, and belongs to the technical field of brake discs, the frequent braking wear-resistant brake disc comprises a base body layer, a transition layer is mounted on one side of the base body layer, a functional layer is mounted on the side, away from the base body layer, of the transition layer, and a plurality of ventilation channels are uniformly formed in the inner walls of the base body layer, the transition layer and the functional layer; a first convex groove and a second convex groove are formed in the faces, close to each other, of the transition layer and the functional layer correspondingly, and I-shaped strips are slidably connected to the inner walls of the first convex groove and the second convex groove in an inserted mode. By arranging the base body layer, the transition layer and the functional layer, the abrasion resistance and the heat dissipation performance of the brake disc are remarkably improved, a stable working state can be kept even under the condition of frequent braking, the risk of brake failure is reduced, the heat dissipation capacity of the brake disc is further enhanced through the layout of the ventilation channels, thermal fatigue damage is delayed, and the service life of the brake disc is prolonged. Therefore, the service life of the brake disc is effectively prolonged.

Description

Technical Field

[0001] This application relates to the field of brake disc technology, and more particularly to a wear-resistant brake disc for frequent braking. Background Technology

[0002] With the acceleration of urbanization, urban traffic congestion has become a common phenomenon, especially during morning and evening rush hours. Buses, taxis, and freight vehicles are frequently starting and stopping. Under these circumstances, the wear and tear on traditional braking systems is aggravated, which not only shortens the service life of brake discs but may also lead to a decrease in braking performance due to overheating, increasing driving risks.

[0003] Currently, common solutions in the market mainly include using high-hardness alloy materials to manufacture brake discs, optimizing heat dissipation design, and enhancing surface treatment technology. While high-hardness alloy materials improve the wear resistance of brake discs, their high cost limits their large-scale commercial application. Optimizing heat dissipation design typically involves adding heat sinks or improving airflow paths, which effectively reduces brake disc temperature but places higher demands on the internal structure, increasing production difficulty. Enhanced surface treatment technology improves surface hardness and the coefficient of friction by applying special coatings or chemical treatments to the brake disc surface, but this technology is not yet mature, and its long-term reliability remains to be verified. Furthermore, these methods often focus on single-dimensional improvements and fail to comprehensively address multiple issues such as rapid wear and high temperature.

[0004] Although some improvements have been made in the market, existing technologies still have some shortcomings, such as high material costs, complex production processes, and poor long-term stability. Especially in high-intensity, frequent braking applications, how to balance cost and performance has become an urgent problem to be solved. Utility Model Content

[0005] In view of the shortcomings of the prior art, this utility model provides a wear-resistant brake disc for frequent braking, which overcomes the shortcomings of the prior art and aims to solve the problems in the background art.

[0006] To achieve the above objectives, this application adopts the following technical solution: a wear-resistant brake disc for frequent braking, comprising a base layer, a transition layer installed on one side of the base layer, a functional layer installed on the side of the transition layer away from the base layer, a plurality of ventilation channels uniformly formed on the inner walls of the base layer, the transition layer and the functional layer, and a first groove and a second groove respectively formed on the side of the transition layer and the functional layer that are close to each other, with I-shaped strips slidably inserted into the inner walls of the first groove and the second groove.

[0007] In a preferred embodiment, five mounting holes are uniformly formed on the inner walls of the substrate layer, transition layer, and functional layer.

[0008] By adopting the above technical solution, the base layer, transition layer and functional layer can be stably installed on the outer edge of the vehicle body output shaft with the help of bolts, and the base layer, transition layer and functional layer can be tightly and securely installed together to ensure that they will not easily come apart.

[0009] In a preferred embodiment, the inner wall dimensions of the first groove and the second groove are adapted to the dimensions of the I-shaped strip. The number of the first groove, the second groove, and the I-shaped strip are all two, and the two first grooves, the second groove, and the I-shaped strip are symmetrically arranged on the inner walls of the transition layer and the functional layer.

[0010] By adopting the above technical solution, the transition layer and the functional layer can be stably connected by using I-shaped strips in conjunction with groove one and groove two, so as to achieve assembly, ensure that the assembly will not easily shake, and there will be no gaps.

[0011] In a preferred embodiment, the inner wall of the I-shaped strip has a circular hole, and a rubber column is bonded to the inner wall of the circular hole.

[0012] By adopting the above technical solution, when the functional layer needs to be replaced, an auxiliary tool can be used to insert it into the inner wall of the round hole. Then, the auxiliary tool can be tapped to make the I-shaped strip slide and shake slightly on the inner wall of the first and second grooves, which facilitates the separation between the transition layer and the functional layer and avoids long-term adhesion, which would make it difficult to disassemble and separate.

[0013] In a preferred embodiment, the base layer uses HT250 high-strength cast iron as the base material, the transition layer uses NiCrBSi nickel-based self-fluxing alloy, and the functional layer is formed by sintering tungsten carbide-graphite mixed powder. The surface of the functional layer is laser-hardened to form a micron-level hardened layer.

[0014] By adopting the above technical solution, good strength and toughness are provided. The transition layer, made of NiCrBSi nickel-based self-fluxing alloy, plays a buffering and bonding role, enhancing the bonding force between the matrix layer and the functional layer. The functional layer is made of tungsten carbide-graphite mixed powder sintering, which gives the structure excellent wear resistance and thermal conductivity. The hardening layer further improves the surface hardness and friction performance.

[0015] In a preferred embodiment, the substrate layer is about 5 mm thick, the transition layer is about 1 mm thick, the functional layer is about 3 mm thick, the material is WC-Gr, and the surface roughness of the hardened layer is Ra≤0.4μm and the surface hardness is HRC≥65.

[0016] By adopting the above technical solution, the combination of the base layer, transition layer and functional layer can ensure the overall strength and friction performance, and guarantee the service life.

[0017] The beneficial effects of this application are:

[0018] 1. This wear-resistant brake disc for frequent braking significantly improves wear resistance and heat dissipation performance by setting a base layer, a transition layer and a functional layer. It can maintain a stable working state even under frequent braking, reducing the risk of brake failure. The layout of ventilation channels further enhances the heat dissipation capacity of the brake disc, delays the occurrence of thermal fatigue damage, and thus effectively extends the service life of the brake disc.

[0019] 2. This wear-resistant brake disc for frequent braking, by inserting an auxiliary tool into the inner wall of a circular hole, can then be struck to cause the I-shaped strip to slide and slightly shake on the inner walls of groove one and groove two, thereby transmitting the vibrational force to the transition layer and the functional layer. This facilitates the separation between the transition layer and the functional layer. The innovative multi-layer composite material structure design makes the product more economical and maintainable, allowing for the replacement of only the worn functional layer during a single maintenance, rather than the entire disc being scrapped, thus greatly reducing the user's maintenance costs. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of this application;

[0021] Figure 2 This is a schematic diagram of the side view of the structure of this application;

[0022] Figure 3 For the purposes of this application Figure 2 Enlarged structural diagram at point A in the middle;

[0023] Figure 4 This is a schematic diagram of the partially unfolded structure of this application.

[0024] The following are labeled in the diagram: 1. Substrate layer; 2. Transition layer; 3. Functional layer; 4. Ventilation channel; 5. Mounting hole; 6. Groove one; 7. Groove two; 8. I-shaped strip; 9. Round hole; 10. Rubber column. Detailed Implementation

[0025] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0026] Reference Figure 1-4A wear-resistant brake disc for frequent braking includes a base layer 1, a transition layer 2 installed on one side of the base layer 1, and a functional layer 3 installed on the side of the transition layer 2 away from the base layer 1. The inner walls of the base layer 1, the transition layer 2 and the functional layer 3 are evenly provided with a plurality of ventilation channels 4. The transition layer 2 and the functional layer 3 are respectively provided with a first groove 6 and a second groove 7 on the side close to each other. I-shaped strips 8 are slidably inserted into the inner walls of the first groove 6 and the second groove 7.

[0027] See Figure 1 The inner walls of the base layer 1, transition layer 2 and functional layer 3 are evenly provided with five mounting holes 5, which can be used with bolts to stably install the base layer 1, transition layer 2 and functional layer 3 on the outer edge of the vehicle output shaft, and can tightly and securely install the base layer 1, transition layer 2 and functional layer 3 together, ensuring that they will not easily come apart.

[0028] See Figure 4 The inner wall dimensions of groove 6 and groove 7 are adapted to the dimensions of I-shaped strip 8. There are two grooves 6, two grooves 7 and two I-shaped strips 8. The two grooves 6, two grooves 7 and two I-shaped strips 8 are symmetrically arranged on the inner walls of transition layer 2 and functional layer 3. This allows the I-shaped strips 8 to be used in conjunction with grooves 6 and two grooves 7 to firmly connect transition layer 2 and functional layer 3, realize assembly, and ensure that there will be no easy shaking after assembly and no gaps.

[0029] See Figure 3 and Figure 4 The inner wall of the I-shaped strip 8 has a round hole 9, and a rubber column 10 is bonded to the inner wall of the round hole 9. When the functional layer 3 needs to be replaced, an auxiliary tool can be used to insert it into the inner wall of the round hole 9. Then, the auxiliary tool can be tapped to make the I-shaped strip 8 slide and shake slightly on the inner wall of the first groove 6 and the second groove 7, which facilitates the separation between the transition layer 2 and the functional layer 3 and avoids long-term bonding, which makes it difficult to disassemble and separate.

[0030] See Figure 1 - Figure 4 The base layer 1 uses HT250 high-strength cast iron as the basic material, the transition layer 2 uses NiCrBSi nickel-based self-fluxing alloy, and the functional layer 3 is made of tungsten carbide-graphite mixed powder sintering. The surface of the functional layer 3 is laser-hardened to form a micron-level hardened layer. The use of HT250 high-strength cast iron as the base material of the base layer 1 provides good strength and toughness. The use of NiCrBSi nickel-based self-fluxing alloy in the transition layer 2 plays a buffering and bonding role, enhancing the bonding force between the base layer 1 and the functional layer 3. The use of tungsten carbide-graphite mixed powder sintering in the functional layer 3 gives the structure excellent wear resistance and thermal conductivity. The hardened layer further improves the surface hardness and friction performance.

[0031] See Figures 1-4 The substrate layer 1 is approximately 5 mm thick, the transition layer 2 is approximately 1 mm thick, and the functional layer 3 is approximately 3 mm thick. The material is WC-Gr 80% tungsten carbide + 20% graphite, and the surface roughness of the hardened layer Ra≤0.4μm and the surface hardness HRC≥65. This combination of substrate layer 1, transition layer 2 and functional layer 3 can ensure the overall strength and friction performance, and guarantee the service life.

[0032] Working principle: When the vehicle needs to brake, the braking force is transmitted to the brake caliper, pushing the brake pads to press against the brake disc to generate friction and decelerate. During this process, due to the presence of functional layer 3, the heat generated by friction can be quickly conducted to the overall structure of the brake disc and dissipated quickly through the ventilation channel 4, avoiding thermal deformation and thermal cracking caused by local high temperature. At the same time, the mixture of tungsten carbide and graphite maintains a sufficient coefficient of friction while greatly reducing wear. By inserting the auxiliary tool into the inner wall of the round hole 9, the auxiliary tool can be tapped, causing the I-shaped strip 8 to slide and slightly shake on the inner wall of the first groove 6 and the second groove 7, thereby transmitting the vibration force to the transition layer 2 and the functional layer 3, which facilitates the separation between the transition layer 2 and the functional layer 3, avoiding long-term adhesion that makes disassembly and separation difficult. This means that only the worn functional layer 3 needs to be replaced in a single maintenance, rather than the entire layer being scrapped, greatly reducing the user's maintenance costs.

[0033] In the description of this utility model, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0034] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0035] The present invention has been described above with reference to specific embodiments. However, those skilled in the art should understand that these descriptions are exemplary and not intended to limit the scope of protection of the present invention. Those skilled in the art can make various modifications and variations to the present invention based on its spirit and principles, and these modifications and variations are also within the scope of the present invention.

Claims

1. A wear-resistant brake disc for frequent braking, comprising a substrate layer (1), characterized in that, A transition layer (2) is installed on one side of the substrate layer (1), and a functional layer (3) is installed on the side of the transition layer (2) away from the substrate layer (1). A plurality of ventilation channels (4) are evenly provided on the inner walls of the substrate layer (1), the transition layer (2) and the functional layer (3). A first groove (6) and a second groove (7) are respectively provided on the side of the transition layer (2) and the functional layer (3) that are close to each other. I-shaped strips (8) are slidably inserted into the inner walls of the first groove (6) and the second groove (7).

2. The wear-resistant brake disc for frequent braking according to claim 1, characterized in that, The inner walls of the substrate layer (1), transition layer (2) and functional layer (3) are uniformly provided with five mounting holes (5).

3. The wear-resistant brake disc for frequent braking according to claim 1, characterized in that, The inner wall dimensions of the first groove (6) and the second groove (7) are adapted to the dimensions of the I-shaped strip (8). There are two of each of the first groove (6), the second groove (7) and the I-shaped strip (8), and the two first grooves (6), the second groove (7) and the I-shaped strip (8) are symmetrically arranged on the inner walls of the transition layer (2) and the functional layer (3).

4. The wear-resistant brake disc for frequent braking according to claim 1, characterized in that, The inner wall of the I-shaped strip (8) is provided with a circular hole (9), and a rubber column (10) is bonded to the inner wall of the circular hole (9).

5. A wear-resistant brake disc for frequent braking according to claim 1, characterized in that, The base layer (1) uses HT250 high-strength cast iron as the base material, the transition layer (2) uses NiCrBSi nickel-based self-fluxing alloy, and the functional layer (3) is made of sintered tungsten carbide-graphite mixed powder. The surface of the functional layer (3) is laser-quenched to form a micron-level hardened layer.

6. A wear-resistant brake disc for frequent braking according to claim 1, characterized in that, The substrate layer (1) has a thickness of about 5 mm, the transition layer (2) has a thickness of about 1 mm, and the functional layer (3) has a thickness of about 3 mm. The material is WC-Gr, and the surface roughness of the hardened layer is Ra≤0.4μm and the surface hardness is HRC≥65.

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