Composite brake disc

Abstract

The utility model discloses a combined type brake disc, and belongs to the technical field of vehicle brake devices. The ceramic friction ring mainly comprises a ceramic friction ring body, the ceramic friction ring body comprises a first disc body and a second disc body which are coaxially arranged in parallel, a plurality of evenly-distributed ventilation ribs are arranged between the first disc body and the second disc body, a plurality of spokes are arranged on the inner end face of the first disc body or the second disc body, and the first disc body, the ventilation ribs, the second disc body and the spokes are integrally formed. And a disc cap is fixedly connected in the ceramic friction ring through spokes. The ceramic friction ring is combined with the disc cap made of the metal material, the spokes are arranged in the ceramic friction ring, the supporting columns corresponding to the spokes are arranged on the disc cap, the supporting columns and the disc cap are integrally formed through pouring, the spokes are directly embedded into the supporting columns, the connecting stability of the disc cap and the ceramic friction ring is improved, and the service life of the disc cap is prolonged. And a plurality of parts such as bolts, nuts and gaskets are not needed for connection, so that the structure is simplified.

Description

Technical Field

[0001] This utility model belongs to the technical field of vehicle braking devices, and more specifically, it relates to a composite brake disc. Background Technology

[0002] When a car brakes, the friction pads restrict the rotation of the brake disc through friction, converting the vehicle's kinetic energy into heat energy to achieve deceleration. Conventional cast iron brake discs, after years of use under various conditions, are prone to wear, rust, and deformation, resulting in short disc lifespan, abnormal brake noise, and brake vibration. Some composite brake discs incorporate fused or bonded aluminum alloy materials in the energy-absorbing area. However, aluminum alloys are not heat-resistant, leading to poor high-temperature performance of the brake disc and a high risk of detachment, stress release, and disintegration.

[0003] Some composite brake discs, such as the one disclosed in patent CN211844389U, are bidirectional floating fixing structures for carbon fiber composite brake discs. These structures include a carbon fiber composite brake disc, a metal adapter disc, a metal anti-loosening nut, a metal washer, a corrugated washer, a metal bushing, and a reamed bolt. The composite brake disc is connected to the wheel hub via the metal adapter disc. The composite brake disc and the metal adapter disc are connected to the metal anti-loosening nut via the reamed bolt. A metal bushing is fitted between the composite brake disc and the metal adapter disc, and on the reamed bolt. A corrugated washer and the metal washer are fitted along the axial direction between the metal adapter disc and the metal anti-loosening nut. This structure has a bidirectional floating effect in both the axial and radial directions, and by directly transmitting the braking force to the wheel spokes via frictional torque, it reduces the stress on the wheel hub during braking.

[0004] However, the aforementioned composite material brake discs still have the following drawbacks: 1. Although the difference in thermal expansion coefficients between the carbon fiber composite brake disc and the metal adapter disc is taken into account, and thermal stress is alleviated by designing long strip-shaped connecting through holes, the thermal expansion coefficients of the two materials differ by 8-10 times. Under extreme working conditions or long-term use, thermal stress accumulation may still lead to structural loosening and deformation, affecting braking performance and structural stability; 2. The assembly process involves multiple components such as metal anti-loosening nuts, metal washers, corrugated washers, metal bushings, and reamed hole bolts. The assembly process involves various mating relationships and dimensional requirements, which increases the difficulty and cost of processing and assembly, and the structural reliability is not high. Utility Model Content

[0005] The technical problem to be solved by this utility model is to overcome the shortcomings of the prior art and provide a composite brake disc that combines a ceramic friction ring with a metal disc cap. Spokes are set inside the ceramic friction ring, and pillars corresponding to the spokes are set on the disc cap. The pillars and the disc cap are integrally formed by casting, so that the spokes are directly embedded in the pillars, which improves the connection stability between the disc cap and the ceramic friction ring, and eliminates the need for bolts, nuts, washers and other parts, thus simplifying the structure.

[0006] The composite brake disc includes a ceramic friction ring, which includes a disc body one and a disc body two arranged in parallel and coaxially. A plurality of evenly distributed ventilation ribs are provided between the disc body one and the disc body two. A plurality of spokes are provided on the inner end face of the disc body one or the disc body two. The disc body one, the ventilation ribs, the disc body two and the spokes are integrally formed. A disc cap is fixedly connected inside the ceramic friction ring through the spokes.

[0007] Preferably, the cap is made of metal.

[0008] Preferably, the cap is made of aluminum alloy.

[0009] Preferably, the ceramic friction ring is made of ceramic or composite ceramic material.

[0010] Preferably, the center of the disc cap is provided with a central hole coaxially arranged with the ceramic friction ring, and a support column corresponding to the spokes is fixed on the outer periphery of the disc cap, with the spokes embedded in the support column.

[0011] Preferably, the disc cap is provided with assembly hole one and assembly hole two.

[0012] Preferably, the outer periphery of the first and second discs is covered by a covering ring, which is made of metal.

[0013] Preferably, the outer periphery of the first and second discs is provided with a boss, and the inner circumference of the covering ring is provided with an annular groove that fits tightly with the boss.

[0014] Preferably, the covering ring is made of titanium alloy.

[0015] Preferably, the covering ring is made of chromium alloy.

[0016] Compared with the prior art, the beneficial effects of this utility model are:

[0017] 1. This utility model combines a ceramic friction ring with a metal disc cap. When the working surface of the ceramic friction ring is heated to a high temperature, it will thermally expand. The radial expansion will release stress and deformation inward, which will be transferred to the disc cap and absorbed by its metal ductility, thus avoiding stress damage. At the same time, the intersection of the two materials at this point can prevent the brake disc from warping at high temperatures, which is conducive to ensuring the stability of the brake disc's working performance.

[0018] 2. The ceramic friction ring is made of ordinary ceramic or alumina composite ceramic through sintering, which will not cause problems such as delamination or melting due to uneven material properties when subjected to high temperature. The ceramic friction ring is equipped with ceramic ventilation ribs, which reduce the weight of the brake disc by 30-45% and increase the heat dissipation area by more than 50%, enhance the heat dissipation rate after high temperature, and help protect surrounding parts, especially resin fiber friction pads. The rapid cooling through the ventilation ribs can maintain the stability of the brake disc system.

[0019] 3. Since the density of alumina ceramic is less than 50% of that of gray cast iron, and the disc cap of this utility model is made of composite aluminum alloy material, the density is even lower, further reducing the weight. The lighter brake disc means a reduction in suspension weight, which makes the suspension system respond faster, thus improving the overall handling level of the vehicle and helping to improve the vehicle's range and NVH.

[0020] 4. Spokes are set inside the ceramic friction ring, and corresponding supports are set on the disc cap. The supports and the disc cap are integrally formed by casting, so that the spokes are directly embedded in the supports. This improves the connection stability between the disc cap and the ceramic friction ring, and eliminates the need for bolts, nuts, washers and other parts, simplifying the structure. Attached Figure Description

[0021] Figure 1 This is a front structural diagram of the present invention;

[0022] Figure 2 This is a schematic diagram of the rear structure of the present invention;

[0023] Figure 3 This is a schematic diagram of the disassembled structure of this utility model;

[0024] Figure 4 This is a cross-sectional structural diagram of the present invention;

[0025] Figure 5 for Figure 4 A magnified view of part A in the middle;

[0026] Figure 6 This is a partial structural diagram of a ceramic friction ring;

[0027] Figure 7 This is the front view of the cap;

[0028] Figure 8 for Figure 7 Sectional view along the AA direction;

[0029] Figure 9 This is a schematic diagram illustrating the trend of brake disc deformation due to heat.

[0030] In the figure, 1. Disc cap; 101. Center hole; 102. Support column; 103. Assembly hole one; 104. Assembly hole two; 2. Ceramic friction ring; 201. Disc body one; 202. Ventilation rib; 203. Disc body two; 204. Spoke; 205. Boss; 3. Covering ring; 301. Ring groove. Detailed Implementation

[0031] The present invention will be further described below with reference to the accompanying drawings:

[0032] The directional terms used in the detailed description paragraphs are only for the convenience of those skilled in the art to understand the technical solutions described in this application based on the visual orientation shown in the accompanying drawings. Unless otherwise expressly specified and limited, the terms "setting," "installation," "connection," etc., should be interpreted broadly, and those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0033] like Figures 1 to 8 As shown, a composite brake disc includes a ceramic friction ring 2, a disc cap 1, and a covering ring 3. The ceramic friction ring 2 is made of ordinary ceramic or alumina composite ceramic material. Ceramic has a melting point above 2000℃, while cast iron has a melting point of around 1100℃, and aluminum alloy has a melting point of around 600℃. Compared to cast iron and aluminum alloy, ceramic materials have a higher heat load capacity. The ventilation rib structure can achieve a weight reduction effect (30~45%) and increase the heat dissipation area by more than 50%. The integral friction ring will not experience problems such as delamination or melting due to uneven material properties when subjected to high temperatures.

[0034] The ceramic friction ring 2 includes a first disc 201 and a second disc 203 arranged parallel and coaxially. Multiple evenly distributed ventilation ribs 202 are provided between the first disc 201 and the second disc 203. This structure, on the one hand, creates a good heat dissipation channel between adjacent ventilation ribs 202, which is beneficial for heat dissipation; on the other hand, the ventilation rib structure can achieve a weight reduction of 30-45% and an increase in heat dissipation area of ​​more than 50%, enhancing the heat dissipation rate after high temperatures, which is beneficial for protecting surrounding parts, especially the friction pads (the friction pads are mostly composed of resin fibers, which gradually begin to decompose above 300℃). Since the coefficient of friction decreases with higher temperatures, rapid cooling can maintain the stability of the brake disc system.

[0035] The inner end face of disc body 1 201 or disc body 203 is provided with multiple spokes 204, which are evenly distributed. Disc body 1 201, ventilation rib 202, disc body 203 and spokes 204 are integrally sintered from ceramic material, which effectively improves the heat resistance temperature of the brake disc and greatly improves the stability of the brake disc's working performance. Moreover, the integral ceramic friction ring 2 will not experience problems such as delamination or melting due to uneven material properties when subjected to high temperatures.

[0036] In this embodiment, a disc cap 1 is fixedly connected to the ceramic friction ring 2 via spokes 204. The disc cap 1 is made of metal, preferably aluminum alloy. The aluminum alloy disc cap 1 has relatively low hardness and a certain degree of metallic elasticity, which can absorb the thermal expansion of the ceramic friction ring 2 and avoid the adverse condition of thermal deformation of the one-piece cast iron disc. During processing, after the ceramic friction ring 2 is placed, the disc cap 1 is formed by casting aluminum alloy through a mold. The cast aluminum alloy will wrap around the spokes 204 of the ceramic structure. After cooling, the disc cap 1 and the ceramic friction ring 2 are integrated. The aluminum alloy disc cap 1 reduces the overall weight of the brake disc. At the same time, because aluminum alloy has better ductility than ceramic, the assembly and operation of the brake disc assembly are more reliable.

[0037] The disc cap 1 has a central hole 101 coaxially arranged with the ceramic friction ring 2 in its center. The central hole 101 can be used to mate with components such as the vehicle's wheel hub shaft, serving a positioning and connection function. A support post 102 corresponding to the spokes 204 is fixed to the outer periphery of the disc cap 1. The support post 102 and the disc cap 1 are integrally formed by casting, with the spokes 204 embedded within the support post 102. The support post 102 improves the connection stability between the disc cap 1 and the ceramic friction ring 2, and eliminates the need for bolts, nuts, washers, and other connecting parts, simplifying the structure. Furthermore, the disc cap 1 has a first mounting hole 103 and a second mounting hole 104, which can be used to install other related braking components or for further fixing.

[0038] Both disc body 201 and disc body 203 are surrounded by a covering ring 3, which is made of metal. The covering ring 3 forms a high-temperature resistant metal strip. Since ceramic is resistant to pressure but not to tension, the covering ring 3 can improve the overall strength of the ceramic friction ring 2 and prevent the ceramic from being damaged by wheel bumps and impacts or centrifugal disintegration under high-speed rotation. During manufacturing, the covering ring 3 is preferably made of titanium alloy or chromium alloy, which has the characteristics of high temperature resistance and corrosion resistance, and can greatly improve the mechanical strength of the brake disc.

[0039] In this embodiment, the outer periphery of disc body 1 201 and disc body 203 is provided with bosses 205, and the inner circumference of the covering ring 3 is provided with an annular groove 301 that fits tightly with the bosses 205. This fit between the bosses 205 and the annular groove 301 can ensure that the covering ring 3 is tightly bonded to the ceramic friction ring 2, preventing the covering ring 3 from loosening or shifting during braking.

[0040] When this invention is in use, if the vehicle needs to brake, the braking system applies pressure to the invention through the brake caliper, causing the friction pads to come into close contact with the surfaces of the first disc 201 and the second disc 203 of the ceramic friction ring 2. Because the ceramic friction ring 2 has high hardness and good frictional properties, a strong frictional force is generated between the friction pads and the ceramic friction ring 2, thereby hindering the rotation of the brake disc and achieving vehicle deceleration or stopping.

[0041] During braking, the brake disc generates a significant amount of heat due to friction. For example... Figure 9 As shown, when the working surface of the ceramic friction ring 2 reaches high temperatures, it undergoes thermal expansion. This radial expansion releases stress and deformation inwards, which is then transferred to the disc cap 1 and absorbed by its metallic ductility, preventing stress damage. The intersection of these two materials at this point also prevents high-temperature warping, thus ensuring the stability of the brake disc's performance. Furthermore, during braking, as the brake disc rotates, air flows rapidly through the channels formed by the ventilation ribs 202, carrying away heat and providing excellent heat dissipation. The covering ring 3 tightly encloses the ceramic friction ring 2, effectively preventing it from disintegrating under ultra-high speeds, further improving the overall stability of the brake disc.

[0042] Finally, although this specification describes embodiments, not every embodiment contains only one independent technical solution. This way of describing the specification is only for clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A composite brake disc, characterized in that: The ceramic friction ring (2) includes a first disc (201) and a second disc (203) arranged in parallel and coaxially. Multiple evenly distributed ventilation ribs (202) are provided between the first disc (201) and the second disc (203). Multiple spokes (204) are provided on the inner end face of the first disc (201) or the second disc (203). The first disc (201), ventilation ribs (202), second disc (203) and spokes (204) are integrally formed. A disc cap (1) is fixedly connected inside the ceramic friction ring (2) through the spokes (204).

2. The composite brake disc according to claim 1, characterized in that: The cap (1) is made of metal.

3. A composite brake disc according to claim 2, characterized in that: The cap (1) is made of aluminum alloy.

4. A composite brake disc according to claim 1, characterized in that: The ceramic friction ring (2) is made of ceramic or composite ceramic materials.

5. A composite brake disc according to claim 1, characterized in that: The center hole (101) is provided in the middle of the disc cap (1) and is coaxially arranged with the ceramic friction ring (2). A support column (102) corresponding to the spoke (204) is fixed on the outer periphery of the disc cap (1), and the spoke (204) is embedded in the support column (102).

6. A composite brake disc according to claim 5, characterized in that: The cap (1) is provided with assembly hole one (103) and assembly hole two (104).

7. A composite brake disc according to any one of claims 1 to 6, characterized in that: The outer periphery of the first disk (201) and the second disk (203) is covered by a covering ring (3), which is made of metal.

8. A composite brake disc according to claim 7, characterized in that: The outer periphery of the first disc (201) and the second disc (203) is provided with a boss (205), and the inner periphery of the covering ring (3) is provided with an annular groove (301) that fits tightly with the boss (205).

9. A composite brake disc according to claim 7, characterized in that: The covering ring (3) is made of titanium alloy.

10. A composite brake disc according to claim 7, characterized in that: The covering ring (3) is made of chromium alloy.

Images