Brake disc and vehicle

Abstract

A brake disc and a vehicle, the brake disc comprising a substrate (10), a friction layer (20), and a plurality of bosses (40). The substrate (10) comprises a first surface (11). The bosses (40) are provided on the first surface (11), and the plurality of bosses (40) are periodically arranged. The friction layer (20) covers the bosses (40) and is connected to the first surface (11) to increase the contact area between the friction layer (20) and the substrate (11), thus greatly improving a binding force between the friction layer (20) and the substrate (10).

Description

Brake discs and vehicle

[0001] Priority information

[0002] This application claims priority and benefits to patent application No. 2024107097410, filed with the China National Intellectual Property Administration on May 31, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to the field of brake disc technology, specifically to a brake disc and a vehicle. Background Technology

[0004] Carbon fiber reinforced carbon / silicon carbide ceramic matrix composite (C / C-SiC, or carbon ceramic for short) combines the high strength and high toughness of carbon fiber with the high wear resistance of silicon carbide ceramic materials. It also has a low density and can replace existing metal materials as the preferred brake disc material for future lightweight electric vehicles, with huge market potential.

[0005] However, existing brake discs suffer from poor thermal stability, low coefficient of friction, and poor resistance to thermal fade. Especially during braking, the surface temperature of the brake disc rises sharply, and the exposed carbon fibers or matrix carbon on the carbon-ceramic substrate are prone to oxidation under high temperatures. Furthermore, if heat dissipation is inadequate, thermal fade can easily occur, leading to longer braking distances and reduced safety. Therefore, a friction layer is applied to the surface of the carbon-ceramic substrate in the brake disc. This friction layer protects the exposed carbon fibers or matrix carbon from oxidation, effectively meeting the braking performance requirements of the brake disc.

[0006] Currently, the friction layer of brake discs is mostly prepared using slurry or molding methods. However, most of these methods do not treat the surface structure of the substrate, resulting in a single interface layer at the junction of the substrate and the friction layer. During braking, problems such as coating chipping and peeling can easily occur, leading to disc oxidation and wear. In cases of large-area and severe peeling, the caliper brakes may experience uneven stress on the friction pads, damaging the braking system and causing safety accidents. Summary of the Invention

[0007] The purpose of this application is to provide a brake disc and a vehicle that solves the problem of wear and detachment of the friction layer on the surface of the brake disc.

[0008] To achieve the objectives of this application, the following technical solution is provided:

[0009] In a first aspect, the present invention provides a brake disc, comprising a substrate, a friction layer and a plurality of bosses, wherein the substrate comprises a first surface, the bosses are disposed on the first surface and the plurality of bosses are arranged periodically, and the friction layer covers the bosses and is connected to the first surface.

[0010] In one embodiment, the gap between two adjacent bosses is a first groove.

[0011] In one embodiment, on the axial cross-section of the brake disc, a smooth line connecting the highest point of the boss to the lowest point of the adjacent first groove satisfies the following relationship: y1=Asin(ωx); where A is 0.05mm~5mm, ω is 0.3mm~20mm, and A and ω satisfy A≤π / ω.

[0012] In one embodiment, a second groove is formed on the top surface of the boss.

[0013] In one embodiment, on the axial cross-section of the brake disc, the smooth lines connecting the highest point of the boss to the lowest point of the adjacent first groove and the highest point of the boss to the lowest point of the second groove satisfy the following relationship: y1+y2=Asin(ωx)+Bsin(βx); where B is 0.05mm~5mm and β is 0.3mm~20mm.

[0014] In one embodiment, the groove width d of the first groove satisfies d≤π / ω.

[0015] In one embodiment, the roughness Ra of the first surface on which the boss is provided satisfies the relationship: Ra = 1 / 2A.

[0016] In one embodiment, the projected area of ​​any of the bosses on the first surface is 0.01 mm. 2 ~100mm 2 .

[0017] In one embodiment, the orthographic projection of the boss along the radial direction of the brake disc is one or more of a circle, an ellipse, and a polygon.

[0018] In one embodiment, the thickness H of the friction layer satisfies: 0 < H ≤ 5 mm.

[0019] In a second aspect, the present invention provides a vehicle including a brake disc as described in various embodiments of the first aspect.

[0020] This invention, by setting multiple protrusions on the first surface of the substrate, allows the friction layer slurry to simultaneously cover the first surface and the top and side surfaces of the protrusions during the fabrication of the friction layer. After the slurry cures, the protrusions extend into the friction layer, meaning the interface between the friction layer and the substrate is not planar. This increases the contact area between the friction layer and the substrate. Furthermore, the side surfaces of the protrusions and the friction layer exert frictional forces intersecting the first surface, significantly improving the bonding strength between the friction layer and the substrate. Moreover, this invention arranges the multiple protrusions periodically, ensuring that the frictional force on each protrusion is in the same direction. This avoids stress concentration caused by uneven force distribution on the protrusions, further improving the structural strength of the substrate and the protrusions. Additionally, the frictional forces in the same direction also act in opposite directions on the friction layer, enhancing the bonding strength between the friction layer, the protrusions, and the substrate. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0022] Figure 1 is a schematic diagram of the first side of the substrate according to one embodiment;

[0023] Figure 2 is a schematic cross-sectional view of a brake disc according to one embodiment;

[0024] Figure 3 is a schematic diagram of the periodic arrangement of the bosses satisfying a sine function in one embodiment;

[0025] Figure 4 is a schematic diagram of the periodic arrangement of the bosses satisfying a sine function in another embodiment.

[0026] Figure 5 is a schematic cross-sectional view of a brake disc according to another embodiment;

[0027] Figure 6 is a schematic cross-sectional view of a brake disc according to another embodiment;

[0028] Figure 7 is a schematic cross-sectional view of a brake disc according to another embodiment;

[0029] Figure 8 is a schematic cross-sectional view of a brake disc without a boss in one embodiment;

[0030] Figure 9 is a schematic diagram of the first side of the substrate according to one embodiment;

[0031] Figure 10 is a cross-sectional schematic diagram of a brake disc according to one embodiment;

[0032] Figure 11 is a partial cross-sectional schematic diagram of the substrate according to one embodiment;

[0033] Figure 12 is a schematic diagram of the first side of the substrate in Example 6;

[0034] Figure 13 is a schematic diagram of the first side of the substrate in Example 7;

[0035] Figure 14 is a schematic diagram of the first side of the substrate in Example 8;

[0036] Figure 15 is a cross-sectional schematic diagram of the brake disc in Comparative Example 2;

[0037] Figure 16 is a front view of the substrate according to one embodiment;

[0038] Figure 17 is a cross-sectional schematic diagram of a brake disc according to one embodiment;

[0039] Figure 18 is a front view of the substrate according to another embodiment;

[0040] Figure 19 is a schematic diagram of the rounded corners of the protrusion in one embodiment;

[0041] Figure 20 is a flowchart of a method for manufacturing a brake disc according to one embodiment;

[0042] Figure 21 is a flowchart of step S30 of the preparation method;

[0043] Figure 22 is a schematic diagram of the test samples of the brake discs provided in the embodiments and comparative examples;

[0044] Figure 23 is a schematic diagram of the substrate in one embodiment;

[0045] Figure 24 is a top view of the substrate according to an embodiment;

[0046] Figure 25 is a schematic diagram of an embodiment where the substrate cross-section is rectangular and the friction layer is shown.

[0047] Figure 26 is a top view of the substrate according to another embodiment;

[0048] Figure 27 is a schematic diagram of a substrate with a semi-circular cross-section according to one embodiment;

[0049] Figure 28 is a schematic diagram of a substrate with a triangular cross-section according to one embodiment;

[0050] Figure 29 is a schematic diagram of a trapezoidal cross-section of a substrate according to one embodiment;

[0051] Figure 30 is a schematic diagram of a substrate cross-section with various shapes in one embodiment;

[0052] Figure 31 is a schematic diagram of the cross-sectional position of one embodiment;

[0053] Figure 32 is a schematic diagram of the cross-sectional position of another embodiment;

[0054] Figure 33 is a schematic diagram of a method for fabricating a substrate according to an embodiment.

[0055] Explanation of reference numerals in the attached figures:

[0056] 10-Base, 20-Friction layer, 30A-First groove, 40-Boss, 41-Second groove; 11-First surface, 12-Second surface, 13-Inner ring, 14-Outer ring, 30-Groove, 31-First groove, 32-Second groove, A-First tangent, B-Second tangent, P-Rotation direction, X-Brake force direction; 40A-Protrusion, 41A-First fillet, 42A-Second fillet; D1-First direction; D2-Second direction. Detailed Implementation

[0057] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0058] It should be noted that when a component is said to be "fixed" to another component, it can be directly on the other component or it can be in a middle component. When a component is said to be "connected" to another component, it can be directly connected to the other component or it may be in a middle component.

[0059] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. The terminology used in the specification of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and / or" as used in this application includes any and all combinations of one or more of the associated listed items.

[0060] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0061] In a first aspect, the present invention provides a brake disc, comprising a substrate, a friction layer and a plurality of bosses, wherein the substrate comprises a first surface, the bosses are disposed on the first surface and the plurality of bosses are arranged periodically, and the friction layer covers the bosses and is connected to the first surface.

[0062] In one embodiment, the gap between two adjacent bosses is a first groove.

[0063] In one embodiment, on the axial cross-section of the brake disc, a smooth line connecting the highest point of the boss to the lowest point of the adjacent first groove satisfies the following relationship: y1=Asin(ωx); where A is 0.05mm~5mm, ω is 0.3mm~20mm, and A and ω satisfy A≤π / ω.

[0064] In one embodiment, a second groove is formed on the top surface of the boss.

[0065] In one embodiment, on the axial cross-section of the brake disc, the smooth lines connecting the highest point of the boss to the lowest point of the adjacent first groove and the highest point of the boss to the lowest point of the second groove satisfy the following relationship: y1+y2=Asin(ωx)+Bsin(βx); where B is 0.05mm~5mm and β is 0.3mm~20mm.

[0066] In one embodiment, the groove width d of the first groove satisfies d≤π / ω.

[0067] In one embodiment, the roughness Ra of the first surface on which the boss is provided satisfies the relationship: Ra = 1 / 2A.

[0068] In one embodiment, the projected area of ​​any of the bosses on the first surface is 0.01 mm. 2 ~100mm 2 .

[0069] In one embodiment, the orthographic projection of the boss along the radial direction of the brake disc is one or more of a circle, an ellipse, and a polygon.

[0070] In one embodiment, the thickness H of the friction layer satisfies: 0 < H ≤ 5 mm.

[0071] This invention, by setting multiple protrusions on the first surface of the substrate, allows the friction layer slurry to simultaneously cover the first surface and the top and side surfaces of the protrusions during the fabrication of the friction layer. After the slurry cures, the protrusions extend into the friction layer, meaning the interface between the friction layer and the substrate is not planar. This increases the contact area between the friction layer and the substrate. Furthermore, the side surfaces of the protrusions and the friction layer exert frictional forces intersecting the first surface, significantly improving the bonding strength between the friction layer and the substrate. Moreover, this invention arranges the multiple protrusions periodically, ensuring that the frictional force on each protrusion is in the same direction. This avoids stress concentration caused by uneven force distribution on the protrusions, further improving the structural strength of the substrate and the protrusions. Additionally, the frictional forces in the same direction also act in opposite directions on the friction layer, enhancing the bonding strength between the friction layer, the protrusions, and the substrate.

[0072] In a second aspect, the present invention also provides another brake disc, including a substrate and a friction layer, the substrate including a first surface having a groove formed on the first surface, the groove extending in a curved manner, the friction layer being connected to the first surface, and at least a portion of the friction layer being received in the groove.

[0073] In one embodiment, the number of grooves is multiple, and the multiple grooves are arranged in a ring-shaped interval on the first surface.

[0074] In one embodiment, the plurality of grooves are arranged in a ring at equal intervals on the first surface.

[0075] In one embodiment, in the circumferential direction of the brake disc, the minimum distance between two adjacent grooves is less than or equal to 1 / 8 of the outer circumference of the brake disc.

[0076] In one embodiment, the orthographic projection of the groove along the axial direction of the brake disc is arc-shaped.

[0077] In one embodiment, the groove includes a first tangent and a second tangent. The first tangent is perpendicular to the braking force direction of the brake disc and is tangent to the groove. The second tangent is the tangent at any point on the groove other than the first tangent. The angle α between the first tangent and the second tangent satisfies 0°≤α<90°.

[0078] In one embodiment, the relationship between the distance x between two adjacent grooves and the included angle α satisfies the following equation: Where D is the outer diameter of the brake disc and d is the inner diameter of the brake disc.

[0079] In one embodiment, the orthographic projection of the groove along the axial direction of the brake disc is wavy.

[0080] In one embodiment, the groove depth H is 0.1mm to 5mm.

[0081] In one embodiment, the groove width L satisfies: 1 / 3H≤L≤6H.

[0082] In one embodiment, along the depth direction of the groove, the groove includes a first groove and a second groove that are connected, wherein the width of the first groove is greater than the width of the second groove, or the width of the first groove is less than the width of the second groove.

[0083] In one embodiment, the thickness S of the friction layer is 0.01 mm to 6 mm. The thickness of the friction layer is the distance from the side of the friction layer facing away from the first surface to the first surface.

[0084] This invention utilizes grooves formed on the first surface to allow the friction layer slurry to penetrate into the grooves during its fabrication. After curing, at least a portion of the friction layer remains within the grooves, increasing the contact area between the friction layer and the substrate. Furthermore, the inner wall of the groove exerts a frictional force on the inserted friction layer at intersection with the first surface, significantly enhancing the bonding strength between the friction layer and the substrate. To further improve the bonding force between the inner wall of the groove and the friction layer, the groove is designed to extend in a curved manner on the first surface. This not only increases the contact area between the inner wall of the groove and the friction layer, further enhancing the frictional force, but also increases the complexity of the interlocking between the friction layer and the substrate, thus strengthening the interlocking.

[0085] Thirdly, the present invention also provides another brake disc, including a base, a protrusion and a friction layer, wherein the base includes a first surface, the protrusion is disposed on the first surface, and the friction layer covers the protrusion and is connected to the first surface.

[0086] In one embodiment, the number of protrusions is multiple, and the multiple protrusions are spaced apart from each other, with a gap between two adjacent protrusions.

[0087] In one embodiment, the plurality of protrusions are arranged in multiple rows and columns.

[0088] In one embodiment, the projected area of ​​any of the protrusions along the axial direction of the brake disc is 0.25 mm. 2 ~25mm 2 .

[0089] In one embodiment, the projected area of ​​the gap along the axial direction of the brake disc is S. dz The area of ​​the first face is S z The matrix satisfies the following relationship:

[0090] In one embodiment, the total area of ​​the plurality of sides of the protrusion is S. hz The matrix satisfies the following relationship:

[0091] In one embodiment, the height H of the protrusion is along the axial direction of the brake disc. a The thickness ranges from 0.05mm to 1.5mm.

[0092] In one embodiment, a first rounded corner is provided between the top surface of the protrusion and the side surface of the protrusion, and a second rounded corner is provided between the side surface of the protrusion and the first surface.

[0093] In one embodiment, the radius R of the first fillet bThe radius is 0.1mm to 2mm, and / or the second fillet radius is R. t The thickness ranges from 0.1mm to 2mm.

[0094] In one embodiment, the present invention provides a method for manufacturing a brake disc, comprising: machining a protrusion on a preform to make the protrusion protrude from a first surface of the preform; preparing a slurry from a precursor material for a friction layer and applying the slurry to the first surface; obtaining the brake disc by curing and sintering the slurry on the preform; wherein the precursor material for the friction layer is transformed into a friction layer, and the preform is transformed into a substrate.

[0095] The present invention provides a protrusion on the first surface, so that when the friction layer is made on the first surface, the slurry of the friction layer can simultaneously cover the first surface and the top and side surfaces of the protrusion. After the slurry is cured, the protrusion extends into the friction layer. That is, the connection interface between the friction layer and the substrate is not a plane, thereby increasing the contact area between the friction layer and the substrate. Moreover, the side surface of the protrusion has a frictional force that intersects with the friction layer on the first surface, which greatly improves the bonding force between the friction layer and the substrate.

[0096] Fourthly, the present invention also provides another brake disc, including a substrate and a friction layer, wherein the substrate includes a first surface, a plurality of grooves are formed on the first surface, the plurality of grooves are arranged in a regular manner, the friction layer is connected to the first surface, and at least the friction layer is received in the grooves.

[0097] In one embodiment, the plurality of grooves extend along a first direction, and the plurality of grooves are arranged at intervals along a second direction, wherein the first direction and the second direction intersect.

[0098] In one embodiment, all of the grooves are annular, and the grooves are arranged in concentric circles.

[0099] In one embodiment, the maximum depth H of the groove satisfies: 0.5mm≤H≤2mm; and / or, the maximum groove width L on the first surface satisfies: 0.1mm≤L≤5mm.

[0100] In one embodiment, the cross-sectional shape of the groove along the axial direction of the brake disc includes at least one of a rectangle, a semi-circle, a triangle, and a trapezoid.

[0101] In one embodiment, when the cross-sectional shape of the groove includes a rectangle, the depth H1 of the groove satisfies: 0.5mm≤H1≤2mm; and / or, the groove width L1 on the first surface satisfies: 0.1mm≤L1≤5mm.

[0102] In one embodiment, when the shape of the groove cross-section includes a semi-circle, the depth H2 of the groove satisfies: 0.5mm≤H2≤2mm; and / or, the groove width L2 on the first surface satisfies: 0.1mm≤L2≤5mm.

[0103] In one embodiment, when the shape of the groove cross-section includes a triangle, the depth H3 of the groove satisfies: 0.5mm≤H3≤2mm; and / or, the groove width L3 on the first surface satisfies: 0.1mm≤L3≤5mm.

[0104] In one embodiment, when the shape of the groove cross-section includes a trapezoid, the depth H4 of the groove satisfies: 0.5mm≤H4≤2mm; and / or, the groove width L4 on the first surface and the groove width L5 on the bottom wall of the groove satisfy: 0.1mm≤(L4+L5) / 2≤5mm.

[0105] In one embodiment, a cross section is obtained along the axial direction of the brake disc, the length direction of the cross section is parallel to the radial direction of the brake disc, and the length D of the cross section and the total area S of the plurality of groove cross sections satisfy: 0.2mm≤S / D≤1.5mm.

[0106] In one embodiment, the total area S of the cross-sections of the plurality of grooves satisfies the following relationship: S = N1*H1*L1 + N2*0.5*π*H2*H2 + 0.5*N3*H3*L3 + 0.5*N4*(L4+L5)*H4; where N1 is the number of grooves with rectangular cross-sections, N2 is the number of grooves with semi-circular cross-sections, N3 is the number of grooves with triangular cross-sections, and N4 is the number of grooves with trapezoidal cross-sections. H1 is the depth of the rectangular groove, L1 is the width of the rectangular groove on the first surface; H2 is the depth of the semi-circular groove; H3 is the depth of the triangular groove, L3 is the width of the triangular groove on the first surface; H4 is the depth of the trapezoidal groove, L4 is the width of the trapezoidal groove on the first surface, and L5 is the width of the bottom wall of the trapezoidal groove.

[0107] In one embodiment, the substrate is annular cylindrical; the height of the substrate is 20mm-60mm; and / or, the distance between the outer surface of the substrate and the axis of the substrate is 300mm-600mm; and / or, the distance between the inner surface of the substrate and the axis of the substrate is 40mm-300mm; and / or, the density of the substrate is 1.2g / cm³. 3 -1.6g / cm 3 ; and / or, the average surface roughness of the substrate is 1 μm-6 μm; and / or, the maximum profile height of the substrate is 5 μm-20 μm.

[0108] In one embodiment, the distance between the side of the friction layer away from the substrate and the first surface of the substrate is 0.5mm-4mm.

[0109] In one embodiment, the friction layer comprises phenolic resin, silicon carbide, and additives.

[0110] In one embodiment, the phenolic resin comprises 30%-40% by volume of the friction layer; the silicon carbide comprises 40%-50%; and the additives comprise 10%-15%.

[0111] In one embodiment, the particle size R of the silicon carbide satisfies: 0.01mm ≤ R ≤ 0.5mm.

[0112] In one embodiment, the present invention provides a method for manufacturing a brake disc, comprising: forming a plurality of grooves on a first surface of a substrate; and disposing a friction layer on the first surface of the substrate; wherein the plurality of grooves are arranged in a regular pattern, and at least the friction layer is contained in the grooves.

[0113] This invention provides a brake disc, comprising a substrate and a friction layer. The substrate includes a first surface with multiple grooves arranged in a regular pattern. The friction layer is connected to the first surface and is at least contained within the grooves. This arrangement increases the contact area between the friction layer and the substrate, creating a physical interlock between them. This provides uniform mechanical locking and contact area, thereby enhancing the bonding force and reducing the likelihood of the friction layer detaching from the substrate under high temperature and intense friction conditions.

[0114] Based on the first aspect mentioned above, the brake disc provided by the present invention, as shown in Figures 1 and 2, includes a base 10, a friction layer 20, and a plurality of bosses 40. The base 10 includes a first surface 11, the bosses 40 are disposed on the first surface 11, and the plurality of bosses 40 are arranged periodically. The friction layer 20 covers the bosses 40 and is connected to the first surface 11.

[0115] Specifically, the brake disc has a cylindrical structure (i.e., a cylinder with a hollow center). Therefore, the brake disc includes a front and a back (the top and bottom surfaces of the cylinder), as well as an inner and an outer ring. The inner ring is the inner wall of the hollow portion of the brake disc cylinder, and the outer ring is the outer circumference of the brake disc. Both the front and back of the brake disc are annular. The brake disc includes a base 10 and a friction layer 20, with friction layers 20 provided on both the front and back. Therefore, the specific structure of the brake disc should include two friction layers 20. Thus, both the front and back of the brake disc have protrusions 40, with the top surface of the protrusion 40 on the front and back of the brake disc being the top surface of the protrusion 40 on that side.

[0116] Optionally, the boss 40 located on the front side is a first boss 40, and the boss 40 located on the back side is a second boss 40. The first boss 40 is connected to the first surface 11 and protrudes from the first surface 11; the second boss 40 is connected to the second surface and protrudes from the second surface. Since the friction layer 20 on the first surface 11 and the friction layer 20 on the second surface can be configured in the same way, the friction layer 20 on the first surface 11 will be used as an example in the following invention.

[0117] The matrix 10 is made of a carbon / silicon carbide ceramic matrix composite material. This material combines the high strength and toughness of carbon fiber with the high wear resistance of silicon carbide ceramic materials, and has a low density, making it the preferred material for brake discs. The friction layer 20 can be made of a composite material, specifically a combination of silicon carbide and silicon. The silicon carbide and silicon composite friction layer 20 exhibits excellent tribological properties. When applied to the surface of the matrix 10, it protects the exposed carbon fibers or carbon in the matrix 10 from oxidation, effectively meeting the braking performance requirements of carbon-ceramic brake discs.

[0118] However, simply placing the friction layer 20 on the substrate 10 can easily lead to problems such as coating chipping and peeling during braking, causing wear and oxidation of the disc. In cases of large-area severe peeling, the caliper brakes may experience uneven stress on the friction pads, damaging the braking system and causing safety accidents. Therefore, solving this problem has become crucial.

[0119] This invention creates protrusions 40 on two opposing sides (first side 11 and second side) of a substrate 10. The material of the protrusions 40 is the same as that of the substrate 10, meaning that the protrusions 40 are a part of the substrate 10. In a specific embodiment, the protrusions 40 can be obtained by surface etching of a preform of the substrate 10. For example, etching can be performed on the front side of the preform, thinning a predetermined position on the front side to create a groove in a portion of the front side. The bottom surface of the groove is the first side 11. The protrusions 40 are retained without etching and protrude from the first side 11. It should be explained that the front side mentioned in the text refers to the top surface of the protrusions 40, and the first side 11 refers to the bottom surface of the groove.

[0120] Furthermore, there are multiple bosses 40, all with identical structural dimensions, and these bosses 40 are arranged periodically on the first surface 11. As shown in Figure 2, the periodic arrangement of the multiple bosses 40 on the first surface 11 can be observed by examining the cross-section of the brake disc. Specifically, by cutting the brake disc along its axial direction, a cross-section of the brake disc can be obtained, in which the cross-sections of the multiple bosses 40 are arranged periodically along the radial direction of the brake disc.

[0121] Optionally, the multiple bosses 40 extend radially along the first surface 11 of the brake disc. As shown in Figure 1, the bosses 40 extend radially along the first surface 11 in a straight line or a curve. Therefore, the cross-section through the extension direction of the bosses 40 (i.e., the axial direction of the brake disc) shows that the cross-sections of the multiple bosses 40 are periodically arranged radially along the brake disc. Thus, the multiple bosses 40 are arranged side by side on the first surface 11.

[0122] This invention provides multiple protrusions 40 on the first surface 11 of the substrate 10. This allows the slurry of the friction layer 20 to simultaneously cover both the first surface 11 and the top and side surfaces of the protrusions 40 during the fabrication of the friction layer 20. After the slurry cures, the protrusions 40 extend into the friction layer 20, meaning the interface between the friction layer 20 and the substrate 10 is not planar. This increases the contact area between the friction layer 20 and the substrate 10. Furthermore, the side surfaces of the protrusions 40 exert frictional forces on the friction layer 20 intersecting the first surface 11, significantly improving the bonding strength between the friction layer 20 and the substrate 10. Moreover, the invention arranges the protrusions 40 periodically, ensuring that the frictional force from the friction layer 20 on each protrusion 40 is in the same direction. This avoids stress concentration caused by uneven force distribution on the protrusions 40, further improving the structural strength of the substrate 10 and the protrusions 40. Additionally, the frictional forces in the same direction also act in opposite directions on the friction layer 20, enhancing the bonding strength between the friction layer 20, the protrusions 40, and the substrate 10.

[0123] In one embodiment, referring to Figures 1 and 2, the gap between two adjacent bosses 40 is the first groove 30A. Specifically, the gap between two adjacent bosses 40 is the first groove 30A obtained after etching the preform. In a specific embodiment, since all bosses 40 extend radially along the brake disc, and the shape and extension direction of the bosses 40 restrict the shape and extension direction of the first groove 30A, the extension direction of the first groove 30A between two adjacent bosses 40 is also radially along the brake disc.

[0124] In one embodiment, referring to Figures 2 and 3, on the axial cross-section of the brake disc, the smooth line connecting the highest point of the boss 40 to the lowest point of the adjacent first groove 30A satisfies the following relationship: y1=Asin(ωx); where A is 0.05mm~5mm, ω is 0.3mm~20mm, and A and ω satisfy A≤π / ω.

[0125] Specifically, based on the above implementation method, a cross-section (section P) is obtained by cutting along the axial direction of the brake disc. As shown in Figure 2, section P includes a base section 10, multiple periodically arranged bosses section 40, and a friction layer section 20. Among them, the multiple periodically arranged bosses section 40 satisfy the above-mentioned relationship.

[0126] It should be explained that the highest point of the boss 40 can be one or more, and the lowest point of the first groove 30A can be one or more. In a specific embodiment, when the highest point of the boss 40 is one, the cross-sectional shape of the boss 40 can be triangular, as shown in Figure 3. Therefore, the highest point of the boss 40 is the vertex of the triangle that faces away from the first surface 11 (point N1 in the figure). Similarly, the cross-sectional shape of the first groove 30A can be an inverted triangle, so the lowest point of the first groove 30A is the vertex of the inverted triangle (point M1 in the figure). Therefore, the smooth line connecting the two is shown by the dashed line in Figure 3.

[0127] In other embodiments, the highest point of the boss 40 can be in multiple cases, and the cross-sectional shape of the boss 40 can be a quadrilateral (rectangular), as shown in Figure 4. Therefore, the highest point of the boss 40 is any point on the top edge of the quadrilateral away from the first surface 11 (point N2 in the figure). Similarly, the cross-sectional shape of the first groove 30A can be a quadrilateral (rectangular), so the lowest point of the first groove 30A is any point on the bottom edge of the quadrilateral (point M2 in the figure). Therefore, the smooth connecting line between the two is shown by the dashed line in Figure 4.

[0128] Optionally, since the cross-sectional shape of the boss 40 is quadrilateral, any point on the top edge is the farthest point from the first surface 11. Therefore, the point satisfying the relationship can be the midpoint or the endpoint of the top edge. Of course, in order to be relevant to the point taken from the top edge of the boss 40, the point on the bottom edge of the first groove 30A that satisfies the relationship should be the midpoint or the endpoint of the bottom edge. That is, as shown in Figure 4, when the boss 40 is taken as point N21, the first groove 30A is taken as point M21; or when the boss 40 is taken as point N22, the first groove 30A is taken as point M22; or when the boss 40 is taken as point N23, the first groove 30A is taken as point M23.

[0129] After obtaining the highest point of the boss 40 and the lowest point of the groove in the above manner, a rectangular coordinate system can be established in section P, where the X-axis of the rectangular coordinate system is the tangent to the first surface 11, and the Y-axis of the rectangular coordinate system is parallel to the axial direction of the brake disc. Optionally, the origin O of the coordinate system is the lowest point of one of the first grooves 30A. Then, the smoothed line connecting the highest points of the remaining bosses 40 and the lowest points of the first grooves 30A satisfies the above relationship, that is, it satisfies the relationship of a sine function.

[0130] Furthermore, the boss 40 and the first groove 30A of the brake disc should satisfy the sinusoidal function relationship, and the period of the boss 40 is T=(2π) / |ω|, where ω is the coefficient before x. Moreover, since the value of y in the basic relationship y=sinx is [-1,1], the relationship y1 provided by this invention takes the value [-A,A]. However, since the X-axis is the tangent to the first surface 11, and the bosses 40 are all located on the first surface 11, while the base 10 is below the first surface 11, the actual value of y1 is [0,A]. This is because A is the amplitude of the sinusoidal function, i.e., the groove depth of the first groove 30A.

[0131] Optionally, in addition to satisfying the above sinusoidal function relationship, A ≤ π / ω must also be satisfied. This ensures that the surface of the substrate 10 (the first surface 11 with the boss 40) has a uniform roughness, which decomposes the radial force on the friction layer 20 during brake disc braking and transfers some stress to the substrate 10, thus improving the bonding strength of the product. When A is much greater than π / ω, the interface between the friction layer 20 and the substrate 10 cannot provide sufficient friction force, increasing the risk of the friction layer 20 detaching.

[0132] In one embodiment, referring to Figure 6, a second groove 41 is formed on the top surface of the boss 40. Specifically, a second groove 41 is also formed on the side of the boss 40 facing away from the first surface 11. The cross-sectional shape of the second groove 41 is not limited, and the depth of the second groove 41 is not limited (it can be less than or equal to the depth of the first groove 30A). In a specific embodiment, the cross-sectional shape of the boss 40 is quadrilateral, so the second groove 41 can be formed on the top surface of the boss 40.

[0133] In one embodiment, on the axial cross-section of the brake disc, the smooth lines connecting the highest point of the boss 40 to the lowest point of the adjacent first groove 30A, and the highest point of the boss 40 to the lowest point of the second groove 41 satisfy the following relationship: y1+y2=Asin(ωx)+Bsin(βx); where B is 0.05mm~5mm and β is 0.3mm~20mm.

[0134] Specifically, based on the above implementation method, the relationship y2 = Bsin(βx) can also be calculated in the same way as the function of y1, which will not be repeated here. It can be understood that the second groove 41 is opened on the boss 40 so that the boss 40 will form a composite of multiple rectangles of different sizes, and the smooth connection of the composite of multiple rectangles of different sizes can be a superposition of sine functions.

[0135] In one embodiment, referring to Figure 2, the groove width d of the first groove 30A satisfies d≤π / ω. Specifically, the groove width of the first groove 30A is half of the period of the sine function relationship calculated in the above embodiment (using the above method to set up a rectangular coordinate system, the period T of the boss 40 is (2π) / |ω|), and the groove width of the first groove 30A needs to be less than or equal to half of the period T of the boss 40.

[0136] It should be noted that in a specific embodiment, when the boss 40 is triangular, the first groove 30A is a constricted shape (from top to bottom). Therefore, the maximum value of the groove width of the first groove 30A should be the diameter of the opening of the first groove 30A, that is, the distance between the two vertices of the boss 40.

[0137] By ensuring that the ratio of the groove width d to the period ω of the first groove 30A is within the aforementioned range, it is possible to avoid the groove width d being too large or too small, thus preventing an impact on the number of bosses 40 and reducing the influence of the groove width d on the surface area of ​​the substrate 10. It is understandable that, with the area of ​​the first surface remaining constant, a greater number of periods for the bosses 40 indicates a larger number of bosses 40; and the bosses 40 affect the design of the groove width d, meaning a smaller groove width d corresponds to a smaller groove width d, and vice versa. Therefore, configuring the relationship between the two within the aforementioned range ensures that the groove width d and the period ω are within a suitable range, thereby maximizing the increase in the surface area of ​​the substrate 10 through the bosses 40, and thus improving the contact between the friction layer 20 and the substrate 10.

[0138] In one embodiment, the surface roughness Ra of the first surface 11 with the boss 40 satisfies the relationship: Ra = 1 / 2A. Specifically, based on the range of A provided in the above embodiment, the surface roughness Ra satisfies the range of 0.1 to 10. Specifically, the surface roughness Ra can be 0.1, 0.2, 0.4, 0.8, 1.6, 3.2, or 6.3.

[0139] The surface roughness Ra of the first surface 11 is within the aforementioned range, ensuring that the surface roughness obtained by setting the boss 40 on the first surface 11 is within a reasonable range. When the roughness Ra is less than the aforementioned range, it indicates that the value of A is too large, the boss 40 is too high (the groove is too deep), which affects the stability of the surface of the substrate 10, resulting in a thinner internal layer (the part forming the groove) and damage to the overall structure of the substrate 10. When the roughness Ra is greater than the aforementioned range, it indicates that the value of A is too small, i.e., the boss 40 is too low (the groove is too shallow), which is not conducive to increasing the surface area of ​​the substrate 10, leading to a weakening of the connection strength between the friction layer 20 and the substrate 10.

[0140] In one embodiment, the projected area of ​​any boss 40 on the first surface 11 is 0.01 mm². 2 ~100mm 2Optionally, the projected area of ​​the boss 40 on the first surface 11 is 0.01 mm². 2 0.05mm 2 0.1mm 2 0.5mm 2 1mm 2 5mm 2 10mm 2 20mm 2 40mm 2 60mm 2 80mm 2 100mm 2 .

[0141] Understandably, along the axial direction of the brake disc, the orthographic projection of the boss 40 is the same as its orthographic projection onto the first surface 11. When the area of ​​a single boss 40 is within the aforementioned range, the size of the boss 40 can be kept within a suitable range. On the first surface 11 of equal area, as many bosses 40 as possible can be provided, thereby increasing the contact area between the substrate 10 and the friction layer 20 (the more bosses 40 there are, the larger the total side surface area of ​​the bosses 40). Furthermore, with the same number of bosses 40, a suitable boss 40 area can control the width of the first groove 30A, preventing the first groove 30A from being too wide or too narrow.

[0142] When the projected area of ​​the boss 40 is smaller than the above range, the manufacturing difficulty of the boss 40 increases. Furthermore, if the boss 40 is too small, the connection strength between the boss 40 and the friction layer 20 weakens, and the strength of the boss 40 itself also deteriorates, making it prone to breakage due to stress concentration. When the projected area of ​​the boss 40 is larger than the above range, the number of bosses 40 decreases, resulting in a smaller contact area between the substrate 10 and the friction layer 20.

[0143] In one embodiment, referring to Figures 2, 5 to 7, the orthographic projection of the boss 40 along the radial direction of the brake disc is one or more of a circle, an ellipse, and a polygon. Optionally, the orthographic projection of the boss 40 along the radial direction of the brake disc can be a triangle, a square, a rectangle, a pentagon, or a hexagon.

[0144] In one embodiment, the orthographic projection of the bottom wall of the first groove 30A along the radial direction of the brake disc is a straight line or an arc. Specifically, it can be a circular arc or an elliptical arc.

[0145] In one embodiment, referring to Figure 2, the thickness H of the friction layer 20 satisfies: 0 < H ≤ 5 mm. Optionally, the thickness H of the friction layer 20 can be 0.5 mm, 1 mm, 1.5 mm, 2 mm, 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, or 5 mm. Optionally, the thickness H of the friction layer 20 can be the distance from the highest point of the boss 40 to the surface of the friction layer 20.

[0146] By ensuring that the thickness of the friction layer 20 is within the aforementioned range, excessive thickness of the friction layer 20 can be avoided from affecting the performance of the brake disc. When the thickness of the friction layer 20 exceeds the aforementioned range, the friction layer 20 becomes too thick. On the one hand, this results in an excessively thick overall brake disc, making it difficult to fit the wheel. On the other hand, excessive thickness of the friction layer 20 also affects the high strength and high toughness performance advantages of the carbon ceramic matrix.

[0147] Based on the second aspect mentioned above, the brake disc provided by the present invention is specifically a carbon-ceramic brake disc. Referring to Figures 9 and 10, the brake disc includes a substrate 10 and a friction layer 20. The substrate 10 includes a first surface 11, on which a groove 30 is formed. The groove 30 extends in a curved manner. The friction layer 20 is connected to the first surface 11, and at least a portion of the friction layer 20 is housed in the groove 30.

[0148] Specifically, the brake disc has a cylindrical structure (i.e., a cylinder with a hollow center), so it includes a front and a back (the top and bottom surfaces of the cylinder), as well as an inner ring 13 and an outer ring 14. The front is the first surface 11, and the back is the second surface 12; the inner ring 13 is the inner wall surface of the hollow portion of the brake pad cylinder, and the outer ring 14 is the outer peripheral wall of the brake disc. Both the first surface 11 and the second surface 12 of the brake disc are annular. The brake disc includes a base 10 and a friction layer 20, with friction layers 20 provided on both the first surface 11 and the second surface 12. Therefore, the specific structure of the brake disc should include two friction layers 20. Since the friction layers 20 on the first surface 11 and the second surface 12 can be arranged in the same way, this invention will use the friction layer 20 on the first surface 11 as an example.

[0149] The matrix 10 is made of a carbon / silicon carbide ceramic matrix composite material. This material combines the high strength and toughness of carbon fiber with the high wear resistance of silicon carbide ceramic materials, and has a low density, making it the preferred material for brake discs. The friction layer 20 can be made of a composite material, specifically a combination of silicon carbide and silicon. The silicon carbide and silicon composite friction layer 20 exhibits excellent tribological properties. When applied to the surface of the matrix 10, it protects the exposed carbon fibers or carbon in the matrix 10 from oxidation, effectively meeting the braking performance requirements of carbon-ceramic brake discs.

[0150] However, simply placing the friction layer 20 on the first layer can easily lead to problems such as coating chipping and peeling during braking, causing disc oxidation and wear. In cases of large-area severe peeling, the caliper brakes may experience uneven stress on the friction pads, damaging the braking system and causing safety accidents. Therefore, solving this problem has become crucial.

[0151] The present invention provides a groove 30 on the first surface 11, which allows the slurry of the friction layer 20 to penetrate into the groove 30 when the friction layer 20 is formed on the first surface 11. After the slurry is cured, at least part of the friction layer 20 will be contained in the groove 30, thereby increasing the contact area between the friction layer 20 and the substrate 10. Moreover, the inner wall of the groove 30 has a frictional force on the inserted friction layer 20 that intersects with the first surface 11, which greatly improves the bonding force between the friction layer 20 and the substrate 10.

[0152] Furthermore, in order to improve the bonding force between the inner wall of the groove 30 and the friction layer 20, the present invention also designs the groove 30 in a curved extension manner on the first surface 11. On the one hand, this can increase the contact area between the inner wall of the groove 30 and the friction layer 20, thereby further improving the friction force; on the other hand, the curved extension of the groove 30 increases the complexity of the interlocking structure (interlocking of the friction layer 20 and the substrate 10) and increases the firmness of the interlocking.

[0153] In one embodiment, there are multiple grooves 30, which are arranged in a ring-shaped interval on the first surface 11. Specifically, there can be multiple grooves 30, and the multiple grooves 30 have the same structural dimensions. The multiple grooves 30 are arranged in a ring-shaped interval on the first surface 11. It can be understood that the first surface 11 is annular, and the multiple grooves 30 can be arranged in a ring-shaped interval on the first surface 11 with the center point of the annulus as the center of rotation.

[0154] By creating multiple curved and extending grooves 30 on the first surface 11, the present invention not only increases the total contact area between the friction layer 20 and the substrate 10 on the first surface 11, but also increases the interlocking structure between the substrate 10 and the friction layer 20, which greatly improves the bonding between the friction layer 20 and the substrate 10.

[0155] In one embodiment, a plurality of grooves 30 are arranged in a ring at equal intervals on the first surface 11. It should be explained that the arrangement of the plurality of grooves 30 at equal intervals means that the line connecting any two adjacent grooves 30 at the same position is of the same length, and the connecting line segment can be arc-shaped.

[0156] In a specific embodiment, the first surface 11 includes adjacent first groove, second groove, and third groove. An arc A (not shown in the figure) connects the end of the first groove near the center of the ring to the end of the second groove near the center of the ring, and an arc B (not shown in the figure) connects the end of the second groove near the center of the ring to the end of the third groove near the center of the ring. Arc A is equal to arc B. Both arcs A and B are arcs with the same radius, centered on the ring.

[0157] By setting multiple grooves 30 at equal intervals, on the one hand, the force between the substrate 10 and the friction layer 20 in the grooves 30 can be ensured; on the other hand, the equally distributed grooves 30 can stabilize the bonding force between the friction layer 20 and the substrate 10, ultimately achieving the goal of avoiding stress concentration problems.

[0158] In one embodiment, in the circumferential direction of the brake disc, the minimum distance between two adjacent grooves 30 is less than or equal to 1 / 8 of the outer circumference of the brake disc. Specifically, when multiple grooves 30 are arranged at equal intervals, the number of grooves 30 should be greater than or equal to eight.

[0159] By limiting the minimum distance between two adjacent grooves 30 to limit the number of grooves 30 on the first surface 11, it is possible to avoid having too few grooves 30, which would make it difficult to achieve the interlocking effect, and also to avoid having too many grooves 30, which would affect the structural stability of the substrate 10.

[0160] In one embodiment, referring to Figure 9, the orthographic projection of the groove 30 along the axial direction of the brake disc is arc-shaped. Specifically, an arc is a portion of a circle or ellipse, so the orthographic projection shape of the groove 30 can be a circular arc or an elliptical arc, without any specific limitation. The arc-shaped design effectively alleviates stress concentration during friction braking and prevents coating cracking.

[0161] Understandably, when the groove 30 is arc-shaped, the groove 30 includes an inner arc and an outer arc. The inner arc is the side of the inner wall of the groove 30 that faces inward into the groove 30, and the outer arc is the side of the inner wall of the groove 30 that faces outward into the groove 30.

[0162] In one embodiment, referring to Figures 9 and 10, the groove 30 includes a first tangent A and a second tangent B. The first tangent A is perpendicular to the braking force direction X of the brake disc and is tangent to the groove 30. The second tangent B is the tangent at any point on the groove 30 other than the first tangent A. The included angle α between the first tangent A and the second tangent B satisfies 0°≤α<90°.

[0163] Specifically, during vehicle braking, the brake disc has a rotation direction P and a braking force direction X, as shown in Figure 9. With the vehicle's travel surface as a reference, the braking force direction X of the brake disc is parallel to the direction of the travel surface, and the rotation direction P of the disc is the circumferential direction of the brake disc.

[0164] Of course, when the brake disc is upright on the reference surface as shown in Figure 9, and the disc body is not rotating, the braking force direction X of the brake disc is parallel to the reference surface. In this case, two tangents can be made on the outer arc of the groove 30, namely the first tangent A and the second tangent B. The first tangent A is perpendicular to the braking force direction X of the brake disc and has a point of tangency; the second tangent B is the tangent at any point on the groove 30 other than the point of tangency A. The included angle α of the first tangent A and the second tangent B satisfies 0°≤α<90°. In a specific embodiment, the included angle α of the first tangent A and the second tangent B is 5°, 10°, 15°, 20°, 25°, 30°, 35°, 40°, 45°, 50°, 55°, 60°, 65°, 70°, 75°, 80°, and 85°.

[0165] Understandably, the angle α between the first tangent A and the second tangent B can be used to represent the curvature of the arc-shaped groove 30. The greater the curvature, the greater the degree of bending of the curve, that is, the more curved the groove 30 is. When the angle α between the first tangent A and the second tangent B is equal to 0°, the groove 30 can be a straight line (along the radial direction of the brake disc). However, the angle α between the first tangent A and the second tangent B cannot be 90°, because at 90°, the groove 30 is a straight line and is in the same direction as the braking force X of the brake disc, which cannot satisfy the design of the grooves 30 arranged in a ring at intervals on the first surface 11 in this invention.

[0166] In one embodiment, referring to Figures 9 and 10, the relationship between the distance x between two adjacent grooves 30 and the included angle α satisfies the following equation: Where D is the diameter of the outer ring 14 of the brake disc, and d is the diameter of the inner ring 13 of the brake disc. In a specific embodiment, the diameter D of the outer ring 14 of the brake disc can be 480 mm, and the diameter d of the inner ring 13 of the brake disc can be 184 mm.

[0167] It needs to be explained that the distance x between two adjacent grooves 30 is actually the shortest distance between two adjacent grooves 30, and it is the shortest distance on an arc. Because the grooves 30 are arranged in a ring-shaped interval, the distance between two grooves 30 should not be a straight line, but an arc (as shown in Figure 9).

[0168] Satisfying the aforementioned relationship between the spacing x between two adjacent grooves 30 and the included angle α is to rationally balance the curvature of the groove 30 and the distance between the two grooves 30. It should be explained that the larger the included angle α, the greater the curvature of the groove 30, causing the shape of the groove 30 to more closely resemble a horizontal line (a horizontal line relative to the radial direction of the base 10). This results in a reduction in the number of grooves 30 that can be provided on the fixed area of ​​the first surface (or the same number of grooves 30 will be too close together), leading to an unreasonable arrangement of the grooves 30. Therefore, by satisfying the above relationship, the spacing between two grooves 30 can be rationally configured using the included angle α formed by the grooves 30, thereby maximizing the number of grooves 30 on the first surface and increasing the surface area of ​​the base 10.

[0169] In one embodiment, the orthographic projection of the groove 30 along the axial direction of the brake disc is wavy. Specifically, the groove 30 can extend in a wavy curve from the side near the inner ring 13 to the outer ring 14. The wavy groove 30 has a more complex structure, which can increase the contact area, thereby increasing the friction and enhancing the bonding force between the substrate 10 and the friction layer 20.

[0170] In one embodiment, referring to Figure 10, the groove depth H of the groove 30 is 0.1mm to 5mm. Optionally, the groove depth H of the groove 30 can be 0.1mm, 0.5mm, 1mm, 1.5mm, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, or 5mm. In a specific embodiment, the groove depth H of the groove 30 can be 1mm.

[0171] In one embodiment, referring to Figure 10, the groove width L of the groove 30 satisfies: 1 / 3H ≤ L ≤ 6H. Optionally, the groove width L of the groove 30 can be 1 / 3H, 1 / 2H, 2 / 3H, H, 2H, 3H, 4H, 5H, or 6H. In a specific embodiment, the distance x between two adjacent grooves 30 is the same as the groove width L of the groove 30. Alternatively, in a specific embodiment, the groove width L of the groove 30 is the same as the groove depth H of the groove 30. By satisfying that the groove width L of the groove 30 is within the above range, the ratio of the groove width L to the groove depth H can be kept within a suitable range, avoiding the groove width L being too narrow relative to the groove depth H, so as to avoid the slurry of the friction layer 20 being difficult to fill into the groove 30; it can also avoid the groove width L being too wide relative to the groove depth, so as to avoid damaging the surface structure of the substrate 10.

[0172] In one embodiment, referring to Figure 11a), along the depth direction of the groove 30, the groove 30 includes a connected first groove 31 and a second groove 32, with the width of the first groove 31 being greater than the width of the second groove 32. Specifically, the inner wall of the groove 30 can be stepped. In a specific embodiment, the first groove 31 can be etched first on the first surface 11, and then the second groove 32 can be etched on the bottom wall of the first groove 31, thereby obtaining a connected first groove 31 and a second groove 32. Furthermore, during the etching process, the etching process can be controlled so that the width of the first groove 31 is greater than the width of the second groove 32. Therefore, viewed along the axial direction of the brake disc, the inner wall of the groove 30 in the brake disc cross-section is stepped. By setting the groove 30 as a first groove 31 and a second groove 32, and the groove width of the first groove 31 being greater than the groove width of the second groove 32, it is beneficial to further increase the contact area between the groove 30 and the friction layer 20, improve the friction between the inner wall of the groove 30 and the friction layer 20, and make the connection between the friction layer 20 and the substrate 10 more stable.

[0173] In one embodiment, referring to Figure 11b), along the depth direction of the groove 30, the groove 30 includes a first groove 31 and a second groove 32 that are connected. The width of the first groove 31 is smaller than the width of the second groove 32. Specifically, based on the above embodiment, the inner wall of the groove 30 can be stepped, and in a specific embodiment, the bottom wall of the second groove 32 is the bottom wall of the entire groove 30, and the first groove 31 is closer to the disk surface of the substrate 10. By setting the groove 30 as the first groove 31 and the second groove 32, and the width of the first groove 31 being smaller than the width of the second groove 32, the second groove 32 and the first groove 31 form a hook-shaped structure relative to the friction layer 20. This not only helps to further increase the contact area between the groove 30 and the friction layer 20, but also helps to form an interlocking structure between the substrate 10 and the friction layer 20. The two interlock with each other, thereby making the connection between the friction layer 20 and the substrate 10 more stable.

[0174] In one embodiment, referring to FIG10, the thickness S of the friction layer 20 is 0.01 mm to 6 mm. The thickness of the friction layer 20 is the distance from the side of the friction layer 20 facing away from the first surface 11 to the first surface 11. Optionally, the thickness S of the friction layer 20 can be 0.01 mm, 0.05 mm, 0.1 mm, 0.5 mm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, or 6 mm. The thickness of the portion of the friction layer 20 extending into the groove 30 is not included in these thicknesses.

[0175] Based on the third aspect mentioned above, the brake disc provided by the present invention is specifically a carbon-ceramic brake disc. Referring to Figures 16 and 17, the brake pad includes a base 10, a protrusion 40A, and a friction layer 20. The base 10 includes a first surface 11, the protrusion 40A is disposed on the first surface 11, and the friction layer 20 covers the protrusion 40A and is connected to the first surface 11.

[0176] Specifically, the brake disc has a cylindrical structure (i.e., a cylinder with a hollow center). Therefore, the brake disc includes a front and a back (the top and bottom surfaces of the cylinder), as well as an inner and an outer ring. The inner ring is the inner wall surface of the hollow portion of the brake pad cylinder, and the outer ring is the outer circumference of the brake disc. Both the front and back of the brake disc are annular. The brake disc includes a base 10 and a friction layer 20, with friction layers 20 provided on both the front and back. Therefore, the specific structure of the brake disc should include two friction layers 20. Thus, both the front and back of the brake disc have protrusions 40A, with the top surface of the protrusion 40A on the front and back of the brake disc being the top surface of the protrusion 40A on the back.

[0177] Optionally, the protrusion 40A on the front side is a first protrusion 40A, and the protrusion 40A on the back side is a second protrusion 40A. The first protrusion 40A is connected to the first surface 11 and protrudes from the first surface 11; the second protrusion 40A is connected to the second surface 12 and protrudes from the second surface 12. Since the friction layer 20 on the first surface 11 and the friction layer 20 on the second surface 12 can be configured in the same way, the friction layer 20 on the first surface 11 will be used as an example in the following invention.

[0178] The matrix 10 is made of a carbon / silicon carbide ceramic matrix composite material. This material combines the high strength and toughness of carbon fiber with the high wear resistance of silicon carbide ceramic materials, and has a low density, making it the preferred material for brake discs. The friction layer 20 can be made of a composite material, specifically a combination of silicon carbide and silicon. The silicon carbide and silicon composite friction layer 20 has excellent tribological properties. When applied to the surface of the matrix 10, it protects the exposed carbon fibers or carbon in the matrix 10 from oxidation, effectively meeting the braking performance requirements of carbon-ceramic brake discs.

[0179] However, simply placing the friction layer 20 on the substrate 10 can easily lead to problems such as coating chipping and peeling during braking, causing wear and oxidation of the disc. In cases of large-area severe peeling, the caliper brakes may experience uneven stress on the friction pads, damaging the braking system and causing safety accidents. Therefore, solving this problem has become crucial.

[0180] In this invention, protrusions 40A are fabricated on two opposing sides (first side 11 and second side 12) of a substrate 10. The material of the protrusions 40A is the same as that of the substrate 10, meaning that the protrusions 40A are a part of the substrate 10. In a specific embodiment, the protrusions 40A can be obtained by surface etching of a preform of the substrate 10. For example, etching can be performed on the front side of the preform to thin a predetermined position on the front side, thereby creating a groove 30 in a portion of the front side. The bottom surface of the groove 30 is the first side 11. The protrusions 40A are retained without being etched and protrude beyond the first side 11. It should be explained that the front side mentioned in the text refers to the top surface of the protrusions 40A, and the first side 11 refers to the bottom surface of the groove 30.

[0181] The present invention provides a protrusion 40A on the first surface 11, so that when the friction layer 20 is formed on the first surface 11, the slurry of the friction layer 20 can simultaneously cover the first surface 11 and the top and side surfaces of the protrusion 40A. After the slurry is cured, the protrusion 40A extends into the friction layer 20. That is, the connection interface between the friction layer 20 and the substrate 10 is not a plane, thereby increasing the contact area between the friction layer 20 and the substrate 10. Moreover, the side surface of the protrusion 40A has a frictional force intersecting the first surface 11 with the friction layer 20, which greatly improves the bonding force between the friction layer 20 and the substrate 10.

[0182] In one embodiment, referring to Figures 16 and 17, there are multiple protrusions 40A, and a gap exists between any two adjacent protrusions 40A. Specifically, the number of protrusions 40A is not limited and can be greater than one. The shape of the protrusions 40A can be quadrilateral, triangular, or other polygons, or it can be circular or elliptical. The gap between two adjacent protrusions 40A is the groove 30 obtained after etching the preform.

[0183] In one embodiment, referring to Figures 16 and 17, a plurality of protrusions 40A are arranged in multiple rows and columns. Specifically, the plurality of protrusions 40A are arranged in an array, that is, the spacing between any two adjacent protrusions 40A is the same.

[0184] In a specific embodiment, as shown in Figure 17, after multiple protrusions 40A are arranged in an array, multiple intersecting grooves 30 can be formed on one side of the brake disc. The vertical grooves 30 in the figure are first grooves, and the horizontal grooves 30 are second grooves. As can be seen from the figure, the first grooves extend along the first direction M, and multiple first grooves are arranged sequentially along the second direction N; multiple second grooves extend along the second direction, and multiple second grooves are arranged sequentially along the first direction M, with the first direction M and the second direction N being perpendicular. Therefore, on the large surface of the brake disc, the first and second grooves intersect and connect, forming an interwoven network structure.

[0185] By setting multiple protrusions 40A in multiple rows and columns, the protrusions 40A on the first surface 11 are arranged in a regular manner. On the one hand, the external forces on the regularly arranged protrusions 40A are roughly similar, which can reduce the uneven force on the protrusions 40A and thus ensure the structural stability of each protrusion 40A. On the other hand, it is easier to set up molds for making the protrusions 40A, thereby reducing the difficulty and making the processing easier.

[0186] In one embodiment, referring to FIG18, the multiple protrusions 40A are distributed in a scattered pattern on the first surface 11, that is, the multiple protrusions 40A are randomly arranged. By setting the multiple protrusions 40A to be distributed in a scattered pattern, as many protrusions 40A as possible can be set on the first surface 11, that is, the number of protrusions 40A is increased, thereby improving the utilization rate of the first surface 11 and increasing the surface area of ​​the substrate 10.

[0187] In a specific embodiment, as shown in FIG16, the scattered distribution of protrusions 40A makes the multiple gaps (grooves 30) between the protrusions also randomly interlaced, and the gap shapes are not all the same, thereby increasing the complexity of the gaps and further improving the connection strength between the friction layer 20 and the substrate 10.

[0188] In one embodiment, referring to Figures 16 and 17, the projected area of ​​any protrusion 40A along the axial direction of the brake disc is 0.25 mm². 2 ~25mm 2 Optionally, the projected area of ​​the protrusion 40A is 0.25 mm². 2 0.5mm 2 0.75mm 2 1mm 2 2mm 2 3mm 2 5mm 2 7mm 2 10mm 2 15mm 2 20mm 2 25mm 2 .

[0189] Understandably, along the axial direction of the brake disc, the orthographic projection of the protrusion 40A is the same as its orthographic projection onto the first surface 11. When the area of ​​a single protrusion 40A is within the aforementioned range, the size of the protrusion 40A can be kept within a suitable range. On the first surface 11 of equal area, as many protrusions 40A as possible can be provided, thereby increasing the contact area between the substrate 10 and the friction layer 20 (the more protrusions 40A there are, the larger the total lateral surface area of ​​the protrusions 40A). Furthermore, with the same number of protrusions 40A, a suitable protrusion area can control the groove width of the groove 30 (gap), preventing the groove 30 (gap) from being too wide or too narrow.

[0190] When the projected area of ​​the protrusion 40A is smaller than the aforementioned range, the manufacturing difficulty of the protrusion 40A increases. Furthermore, if the protrusion 40A is too small, the connection strength between the protrusion 40A and the friction layer 20 weakens, and the strength of the protrusion 40A itself also deteriorates, making it prone to breakage due to stress concentration. When the projected area of ​​the protrusion 40A is larger than the aforementioned range, the number of protrusions 40A decreases, resulting in a smaller contact area between the substrate 10 and the friction layer 20.

[0191] In one embodiment, referring to Figures 16 and 17, the projected area of ​​the clearance along the axial direction of the brake disc is S. dz The area of ​​the first face 11 is S. z The matrix 10 satisfies the following relation: Optional, The values ​​can be 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, or 60%.

[0192] Understandably, the projected area of ​​the gap is the area remaining on the first surface 11 after removing the projected areas of all protrusions 40A. The area of ​​the first surface 11 is the area of ​​the large surface of the brake disc. In a specific embodiment, when the projected areas of all protrusions 40A are the same, it can be expressed by the following formula: S dz =S z -n*S t , of which S t This refers to the orthographic projection of a single protrusion 40A as described above, where n is the number of protrusions 40A on the first surface 11.

[0193] The ratio of the total area of ​​the grooves 30 (gap) to the area of ​​the first surface 11 is to limit the number of grooves 30 (gap). If there are too many grooves 30 (gap) and not enough protrusions 40A, the stress concentration caused at the corners of the grooves 30 can easily lead to the destruction of the protrusions 40A themselves. If there are too few grooves 30 (gap), it is not conducive to enhancing the bonding force between the friction layer 20 and the substrate 10.

[0194] In one embodiment, referring to Figures 16 and 17, the total area of ​​the plurality of sides of the protrusion 40A is S. hz (Not shown in the figure), the matrix 10 satisfies the following relationship: Optional, The values ​​can be 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, 0.8, 1, 1.1, 1.2, 1.3, 1.4, and 1.5.

[0195] It is understandable that the lateral surface area of ​​the protrusion 40A is the same as the lateral surface area of ​​the aforementioned groove 30 (including the first groove and the second groove), which is the sum of the lateral surface areas of all protrusions 40A; and the aforementioned total area S hz Excluding the top surface of protrusion 40A (i.e., the surface facing the same direction as the first surface 11). In a specific embodiment, where all protrusions 40A are hexahedral prisms, the lateral surface area of ​​protrusion 40A is equal to the sum of the areas of the four lateral surfaces of all protrusions 40A.

[0196] The ratio of the side surface area of ​​the protrusion 40A to the total projected area of ​​the groove 30 (gap) is used to define the relationship between the depth of the groove 30 (i.e., the height of the protrusion 40A) and the length and width (first direction M and second direction N) of the groove 30. For a groove 30 of a certain area, if the depth is too large, it will affect the filling of the groove 30 by the slurry applied to the friction layer 20; if it is too shallow, it will affect the contact area between the friction layer 20 and the substrate 10. In the extreme case, there is no depth, which does not help to improve the bonding force. At the same time, the ratio of the side surface area to the area of ​​the groove 30 is used so that the shape of the protrusion 40A (or groove 30) is not limited. Other irregular shapes of the protrusion 40A (or groove 30) can also satisfy this relationship.

[0197] In one embodiment, referring to Figures 16 and 17, the height H of the protrusion 40A along the axial direction of the brake disc is... a The height is 0.05mm to 1.5mm. Optionally, the height H of the protrusion 40A is... a The thickness can be 0.05mm, 0.15mm, 0.35mm, 0.55mm, 0.85mm, 1mm, 1.1mm, 1.2mm, 1.3mm, 1.4mm, or 1.5mm.

[0198] Understandable, the height H of the protrusion 40A aThis refers to the depth of the groove 30 (gap) mentioned above. Ensuring the height of the protrusion 40A is within the aforementioned range is to guarantee that the area of ​​the side surface of the protrusion 40A is within a suitable range, thereby ensuring the contact area between the substrate 10 and the friction layer 20. When the height of the protrusion 40A is less than the aforementioned range, the area increase effect brought about by the protrusion 40A is poor, and the bonding force between the step and the friction layer 20 is insufficient. When the height of the protrusion 40A is greater than the aforementioned range, it results in a thinner substrate 10 (excluding the area of ​​the protrusion 40A), requiring excessive etching, which weakens the overall strength of the brake disc.

[0199] In one embodiment, referring to Figure 19, a first rounded corner 41A is provided between the top surface and the side surface of the protrusion 40A, and a second rounded corner 42A is provided between the side surface of the protrusion 40A and the first surface 11. Specifically, the top surface of the protrusion 40A and the bottom surface of the groove 30 (gap) are both rounded, as shown in Figure 19. The purpose of providing rounded corners is, on the one hand, to reduce stress concentration caused by overly sharp edges; on the other hand, it is also to reduce the gap between the friction layer 20 and the substrate 10, thereby improving the overall strength of the brake disc.

[0200] Because the slurry of the friction layer 20 contains a large number of particles, if the bottom surfaces of the grooves 30 (gaps) are all right angles, the particles will have difficulty filling the dead corners, thus forming gaps. Since a large number of grooves 30 (gaps) need to be made in this invention, a large number of gaps will appear between the friction layer 20 and the substrate 10. These gaps become defects in the brake pads and reduce the overall structural strength of the brake pads. Therefore, the connection is set as a rounded corner, making it easier for the slurry particles to fill the gaps.

[0201] In one embodiment, referring to Figure 19, the radius R of the first fillet 41A b The radius is 0.1mm to 2mm, and / or the radius of the second fillet 42A is R. t The radius is 0.1mm to 2mm. Optionally, the radius R of the first fillet 41A is... b The radius R of the fillet can be 0.1mm, 0.2mm, 0.4mm, 0.6mm, 0.8mm, 1mm, 1.2mm, 1.4mm, 1.6mm, 1.8mm, or 2mm. t The radius can be 0.1mm, 0.2mm, 0.4mm, 0.6mm, 0.8mm, 1mm, 1.2mm, 1.4mm, 1.6mm, 1.8mm, or 2mm. Optionally, the radii of the first fillet 41A and the second fillet 42A can be the same.

[0202] The radii of the first fillet 41A and the second fillet 42A are kept within the aforementioned range to ensure that the fillets function effectively and that the protrusions have sufficient area. When the radii of the first fillet 41A and the second fillet 42A are smaller than the aforementioned range, the fillets are too small, resulting in the fillet area not being completely filled by the friction layer, leaving a small gap between the friction layer and the substrate. When the radii of the first fillet 41A and the second fillet 42A are larger than the aforementioned range, the fillets are too large, affecting the area of ​​the protrusions, reducing the area, and failing to meet the aforementioned range.

[0203] In one embodiment, the present invention also provides a method for manufacturing a brake disc according to a third aspect, as shown in FIG20, comprising the following steps:

[0204] Step S10: A protrusion is machined on the preform so that the protrusion protrudes from the first surface of the preform.

[0205] Step S20: Prepare a slurry from the precursor material of the friction layer and apply the slurry to the first surface.

[0206] Step S30: The brake disc is obtained by curing and sintering the slurry on the preform.

[0207] In this process, the precursor material of the friction layer is transformed into the friction layer, and the preform is transformed into the substrate.

[0208] Optionally, in step S10, a protrusion is machined on the preform, specifically including: opening grooves on the front and back sides of the preform according to the required groove (gap) shape, reserving the places where the grooves are formed as protrusions, the bottom surface of the groove being the first surface, and the protrusion protruding from the first surface.

[0209] Optionally, in step S20, the precursor material of the friction layer is made into a slurry, and the slurry is applied to the first surface. Specifically, this includes mixing silicon carbide particles, phenolic resin powder and alcohol, wherein the silicon carbide particle size is 50μm to 200μm, the content of silicon carbide particles is 30% to 50%, the content of phenolic resin powder is 10% to 50%, and the content of alcohol is 30% to 40%, to obtain a slurry, applying the slurry to the first and second surfaces, and placing it in a 60°C oven to completely dry the alcohol.

[0210] Optionally, referring to Figure 21, in step S30, the slurry is applied to the first surface to obtain a brake disc, including:

[0211] Step S31: The preform with coating is cured and then placed in a carbonization furnace for carbonization to obtain a carbonized blank.

[0212] Step S32: After processing the carbonized green body, liquid phase silicon infiltration is performed to obtain a carbon ceramic green body.

[0213] Step S33: The surface and sides of the carbon ceramic blank are machined to obtain the brake disc.

[0214] Optionally, in step S31, the preform with coating is cured, specifically including: placing the preform with coating at 150°C for curing, and the curing time is 2h to 3h.

[0215] Optionally, in step S31, the preform is placed in a carbonization furnace for carbonization, specifically including: the solidified preform is placed in a carbonization furnace for carbonization at a temperature of 1000℃ for 2 to 4 hours.

[0216] Based on the fourth aspect mentioned above, the brake disc provided by the present invention, please refer to Figures 23-25, the present invention provides a brake disc including a base 10 and a friction layer 20. The base 10 includes a first surface, and a plurality of grooves 30 are formed on the first surface. The plurality of grooves 30 are arranged in a regular manner. The friction layer 20 is connected to the first surface, and at least the friction layer 20 is housed in the grooves 30.

[0217] The relative movement between the friction layer 20 in the brake disc and the brake disc generates friction, thus producing a braking effect. During this process, the friction layer 20 converts the vehicle's kinetic energy into heat energy. Due to the different materials of the substrate 10 and the friction layer 20, they have different coefficients of thermal expansion. When the brake disc is in operation, it generates high temperatures and is subjected to enormous mechanical forces, leading to delamination between the substrate 10 and the friction layer 20. Furthermore, the intrinsic adhesion between the substrate 10 and the friction layer 20 is weak, failing to form a sufficient locking mechanism. This results in coating peeling, blistering, and interlayer cracking.

[0218] Multiple grooves 30 are formed on the first surface, arranged in a regular pattern, with at least one friction layer 20 housed within each groove 30. The multiple grooves 30 increase the contact area between the friction layer 20 and the substrate 10, providing a larger mechanical locking area. The presence of the grooves 30 provides a physical interlocking mechanism between the friction layer 20 and the substrate 10, making the friction layer 20 more firmly fixed to the substrate 10. This physical interlocking enhances the bonding force and reduces the likelihood of the friction layer 20 detaching from the substrate 10 under high temperature and intense friction conditions. The regular arrangement of the multiple grooves 30 forms an orderly mechanical interlock, resulting in regular and effective stress dispersion and load transfer, thereby providing a uniform mechanical locking and contact area and preventing peeling and cracking between the substrate 10 and the friction layer 20.

[0219] This invention provides a brake disc, comprising a substrate 10 and a friction layer 20. The substrate 10 includes a first surface with a plurality of grooves 30 arranged in a regular pattern. The friction layer 20 is connected to the first surface and is at least contained within the grooves 30. This arrangement increases the contact area between the friction layer 20 and the substrate 10, creating a physical interlock between them. This provides uniform mechanical locking and contact area, thereby enhancing the bonding force and reducing the likelihood of the friction layer 20 detaching from the substrate 10 under high temperature and intense friction conditions.

[0220] In one embodiment, referring to FIG24, a plurality of grooves 30 extend along a first direction D1, and a plurality of grooves 30 are arranged sequentially at intervals along a second direction D2, wherein the first direction D1 and the second direction D2 intersect.

[0221] Multiple grooves 30 extend along the first direction D1, and multiple grooves 30 are arranged sequentially at intervals along the second direction D2, so that multiple grooves 30 form a linear arrangement; thereby increasing the contact area between the friction layer 20 and the substrate 10, the friction layer 20 and the substrate 10 form a physical interlock, providing uniform mechanical locking and contact area, thereby enhancing the bonding force and reducing the detachment of the friction layer 20 from the substrate 10 under high temperature and severe friction conditions.

[0222] In one embodiment, referring to Figure 26, the plurality of grooves 30 are all annular and are arranged in concentric circles.

[0223] The multiple concentric annular grooves 30 ensure uniform friction distribution on the brake disc, improving its overall structural stability under high-speed rotation and braking force. Increasing the contact area between the friction layer 20 and the substrate 10 creates a physical interlock between them, providing uniform mechanical locking and contact area, thereby enhancing adhesion and reducing the likelihood of the friction layer 20 detaching from the substrate 10 under high temperature and intense friction conditions.

[0224] In one embodiment, the maximum depth H of the groove satisfies: 0.5mm≤H≤2mm. Optionally, the maximum depth H of the groove can be, but is not limited to, 0.5mm, 1mm, 1.5mm, or 2mm.

[0225] Within this range, the groove depth H ensures effective bonding between the friction layer and the substrate, improving adhesion and reducing the risk of detachment under high temperature and intense friction conditions. It also increases the surface area of ​​the friction layer, thereby improving the braking efficiency of the brake disc. The groove also increases the surface area of ​​the brake disc, aiding in heat dissipation and reducing heat accumulation. If the groove depth H is less than 0.5mm, the shallow groove cannot provide sufficient adhesion, and the friction layer cannot be firmly fixed to the substrate, leading to detachment under high temperature and intense friction conditions, reducing the braking efficiency of the brake disc. A shallow groove also reduces the heat dissipation area of ​​the friction layer, preventing effective heat dissipation and increasing heat accumulation. If the groove depth H is greater than 2mm, the excessive depth weakens the structural strength of the substrate, causing cracks or deformation under braking force, affecting its overall performance and lifespan, impacting the friction performance of the friction layer, and reducing braking effectiveness. Furthermore, an excessively deep groove exceeds the actual required range, resulting in over-performance.

[0226] In one embodiment, the maximum groove width L on the first surface satisfies: 0.1mm ≤ L ≤ 5mm. Optionally, the maximum groove width L on the first surface can be, but is not limited to, 0.1mm, 0.5mm, 1mm, 1.5mm, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, or 5mm.

[0227] Within a certain range, the groove width L on the first surface ensures effective bonding between the friction layer and the substrate, improving adhesion and reducing the risk of detachment under high temperature and severe friction conditions. A groove with a moderate width L1 increases the surface area of ​​the friction layer, aiding heat dissipation and reducing heat accumulation, thereby improving the braking efficiency of the brake disc. When the groove width L on the first surface is less than 0.1mm, the insufficient surface area for contact between the friction layer and the substrate leads to insufficient adhesion, affecting the fixing effect of the friction layer and causing it to detach under high temperature and severe friction conditions. When the groove width L on the first surface is greater than 5mm, the excessive width increases manufacturing and processing costs; it also affects the friction performance of the friction layer, weakens the structural strength of the substrate, causing cracks or deformation in the substrate under braking force, affecting its overall performance and lifespan, and ultimately reducing braking performance.

[0228] In one embodiment, the cross-sectional shape of the groove along the axial direction of the brake disc includes at least one of rectangular, semi-circular, triangular, and trapezoidal shapes.

[0229] The cross-sectional shape of the groove includes at least one of rectangle, semicircle, triangle, and trapezoid to provide different mechanical and frictional properties, thereby optimizing the contact area between the friction layer and the substrate of the brake disc, providing uniform mechanical locking and contact area, and reducing the shedding of the friction layer from the substrate under high temperature and severe friction conditions.

[0230] Optionally, as shown in Figure 24, the cross-sectional shape of the grooves along the axial direction of the brake disc is all rectangular.

[0231] Optionally, as shown in Figure 27, the cross-sectional shape of the grooves along the axial direction of the brake disc is all semi-circular.

[0232] Optionally, as shown in Figure 28, the cross-sectional shape of the grooves along the axial direction of the brake disc is all triangular.

[0233] Optionally, as shown in Figure 29, the cross-sectional shape of the grooves along the axial direction of the brake disc is all trapezoidal.

[0234] Optionally, referring to Figure 30, the cross-sectional shape of the groove along the axial direction of the brake disc includes rectangle, semicircle, triangle, and trapezoid.

[0235] In one embodiment, when the cross-sectional shape of the groove includes a rectangle, the groove depth H1 satisfies: 0.5mm ≤ H1 ≤ 2mm; and / or, the groove width L1 on the first surface satisfies: 0.1mm ≤ L1 ≤ 5mm. Optionally, the groove depth H1 can be, but is not limited to, 0.5mm, 0.4mm, 0.8mm, 1.2mm, 1.6mm, or 2mm. The groove width L1 on the first surface can be, but is not limited to, 0.1mm, 0.5mm, 1mm, 1.5mm, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, or 5mm.

[0236] Within this range, a groove depth H1 ensures effective bonding between the friction layer and the substrate, improving adhesion and reducing the risk of detachment under high temperature and intense friction conditions. It also increases the surface area of ​​the friction layer, thereby improving the braking efficiency of the brake disc. The groove also increases the surface area of ​​the brake disc, aiding in heat dissipation and reducing heat accumulation. If the groove depth H1 is less than 0.5mm, the shallow groove cannot provide sufficient adhesion, and the friction layer cannot be firmly fixed to the substrate, leading to detachment under high temperature and intense friction conditions, reducing the braking efficiency of the brake disc. A shallow groove also reduces the heat dissipation area of ​​the friction layer, preventing effective heat dissipation and increasing heat accumulation. If the groove depth H1 is greater than 2mm, the excessive depth weakens the structural strength of the substrate, causing cracks or deformation under braking force, affecting its overall performance and lifespan, impacting the friction performance of the friction layer, and reducing braking effectiveness. Furthermore, an excessively deep groove exceeds the actual required range, resulting in overperformance.

[0237] Within a certain range, the groove width L1 on the first surface ensures effective bonding between the friction layer and the substrate, improves adhesion, and reduces the risk of detachment under high temperature and severe friction conditions. A groove with a moderate width L1 increases the surface area of ​​the friction layer, aiding heat dissipation and reducing heat accumulation, thereby improving the braking efficiency of the brake disc. When the groove width L1 on the first surface is less than 0.1mm, the insufficient surface area for contact between the friction layer and the substrate leads to insufficient adhesion, affecting the fixing effect of the friction layer and causing it to detach under high temperature and severe friction conditions. When the groove width L1 on the first surface is greater than 5mm, the excessive width increases manufacturing and processing costs; it also affects the friction performance of the friction layer, weakens the structural strength of the substrate, and causes cracks or deformation in the substrate under braking force, affecting its overall performance and lifespan, ultimately reducing braking effectiveness.

[0238] In one embodiment, when the shape of the groove cross-section includes a semi-circle, the groove depth H2 satisfies: 0.5mm ≤ H2 ≤ 2mm; and / or, the groove width L2 on the first surface satisfies: 0.1mm ≤ L2 ≤ 5mm. Optionally, the groove depth H2 can be, but is not limited to, 0.5mm, 0.6mm, 0.8mm, 1mm, 1.2mm, 1.4mm, 1.6mm, 1.8mm, or 2mm. The groove width L2 on the first surface can be, but is not limited to, 0.1mm, 0.5mm, 1mm, 1.5mm, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, or 5mm.

[0239] The reason for setting the depth H2 of the semi-circular groove is the same as the reason for setting the depth H1 of the rectangular groove; the reason for setting the groove width L2 of the semi-circular groove on the first surface is the same as the reason for setting the groove width L1 of the rectangular groove on the first surface. Further details will not be provided here.

[0240] In one embodiment, when the shape of the groove cross-section includes a triangle, the groove depth H3 satisfies: 0.5mm ≤ H3 ≤ 2mm; and / or, the groove width L3 on the first surface satisfies: 0.1mm ≤ L3 ≤ 5mm. Optionally, the groove depth H3 can be, but is not limited to, 0.5mm, 0.6mm, 0.8mm, 1mm, 1.2mm, 1.4mm, 1.6mm, 1.8mm, or 2mm. The groove width L3 on the first surface can be, but is not limited to, 0.1mm, 0.5mm, 1mm, 1.5mm, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, or 5mm.

[0241] The reason for setting the depth H3 of the triangular groove is the same as the reason for setting the depth H1 of the rectangular groove; the reason for setting the groove width L3 of the triangular groove on the first surface is the same as the reason for setting the groove width L1 of the rectangular groove on the first surface. Further details will not be provided here.

[0242] In one embodiment, when the shape of the groove cross-section includes a trapezoid, the groove depth H4 satisfies: 0.5mm ≤ H4 ≤ 2mm; and / or, the groove width L4 on the first surface and the groove width L5 on the bottom wall of the groove satisfy: 0.1mm ≤ (L4 + L5) / 2 ≤ 5mm. Optionally, the groove depth H4 can be, but is not limited to, 0.5mm, 0.2mm, 0.4mm, 0.6mm, 0.8mm, 1mm, 1.2mm, 1.4mm, 1.6mm, 1.8mm, or 2mm. The average value of the groove width L4 on the first surface and the groove width L5 on the bottom wall of the groove can be, but is not limited to, 0.1mm, 0.5mm, 1mm, 1.5mm, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, or 5mm.

[0243] The reason for setting the depth H4 of the trapezoidal groove is the same as the reason for setting the depth H1 of the rectangular groove; the reason for setting the average value of the groove width L4 on the first surface and the groove width L5 on the bottom wall of the trapezoidal groove is the same as the reason for setting the groove width L1 on the first surface of the rectangular groove. Further details will not be provided here.

[0244] In one embodiment, a cross section is obtained along the axial direction of the brake disc, the length direction of the cross section is parallel to the radial direction of the brake disc, and the length D of the cross section and the total area S of the multiple groove cross sections satisfy: 0.2mm≤S / D≤1.5mm.

[0245] Optionally, the ratio of the total area S of the multiple groove cross sections to the length D of the brake disc cross section can be, but is not limited to, 0.2mm, 0.4mm, 0.6mm, 0.8mm, 1mm, 1.2mm, 1.4mm, or 1.5mm.

[0246] The ratio of the total area S of multiple groove cross-sections to the length D of the brake disc cross-section, within this range, ensures that the groove depth relative to the total groove width on the first surface is within a suitable range. This provides sufficient bonding strength between the friction layer and the substrate, while avoiding surface fragility caused by over-processing. When the ratio of the total area S of multiple groove cross-sections to the length D of the brake disc cross-section is less than 0.2 mm, the area occupied by the pattern within the cross-section is small, resulting in weak bonding between the friction layer and the substrate. This affects the fixing effect of the friction layer, leading to friction layer detachment under high temperature and severe friction conditions, affecting the performance and lifespan of the brake disc. When the ratio of the total area S of multiple groove cross-sections to the length D of the brake disc cross-section is greater than 1.5 mm, the groove depth relative to the groove width on the first surface is large, the area occupied by the pattern within the cross-section is large, and the area occupied by the substrate is small. This indicates over-processing of the grooves, leading to reduced strength of the substrate surface, thus affecting the bonding strength between the friction layer and the substrate. This results in delamination between the friction layer and the substrate during braking, affecting the performance and lifespan of the brake disc.

[0247] Specifically, in this embodiment, the cross section refers to the cross section obtained along the axial direction of the brake disc. The total area S of the multiple groove cross sections is the total area of ​​all grooves on this cross section.

[0248] Please refer to Figure 31. By cutting the brake disc along its axial direction, we can obtain a cross-section of the brake disc. When the cross-section is a complete surface, the length of the cross-section is D.

[0249] Referring to Figure 32, by cutting the brake disc along its axial direction, a cross-section of the brake disc can be obtained. When the cross-section consists of two relatively independent surfaces, the widths of the two surfaces are d1 and d2, respectively. Therefore, the length of the brake disc cross-section is D = d1 + d2. In a specific embodiment, when the cross-section coincides with the axis of the brake disc, the length D of the brake disc cross-section can also be obtained from the difference between the outer diameter and the inner diameter of the brake disc.

[0250] In one embodiment, the total area S of the multiple groove cross-sections satisfies the following formula: S = N1*H1*L1 + N2*0.5*π*H2*H2 + 0.5*N3*H3*L3 + 0.5*N4*(L4+L5)*H4; where N1 is the number of grooves with rectangular cross-sections, N2 is the number of grooves with semi-circular cross-sections, N3 is the number of grooves with triangular cross-sections, and N4 is the number of grooves with trapezoidal cross-sections. H1 is the depth of the rectangular groove, L1 is the width of the rectangular groove on the first surface; H2 is the depth of the semi-circular groove; H3 is the depth of the triangular groove, L3 is the width of the triangular groove on the first surface; H4 is the depth of the trapezoidal groove, L4 is the width of the trapezoidal groove on the first surface, and L5 is the width of the bottom wall of the trapezoidal groove.

[0251] In a specific embodiment, when the cross-sectional shape of the multiple grooves is rectangular, the total area of ​​the cross-sections of the multiple grooves is S = N1 * H1 * L1. When the cross-sectional shape of the multiple grooves is semi-circular, the total area of ​​the cross-sections of the multiple grooves is S = N2 * 0.5 * π * H2 * H2. When the cross-sectional shape of the multiple grooves is triangular, the total area of ​​the cross-sections of the multiple grooves is S = 0.5 * N3 * H3 * L3. When the cross-sectional shape of the multiple grooves is trapezoidal, the total area of ​​the cross-sections of the multiple grooves is S = 0.5 * N4 * (L4 + L5) * H4.

[0252] This embodiment provides a method for calculating the total area S of multiple groove cross-sections when the multiple grooves simultaneously include N1 rectangular grooves, N2 semi-circular grooves, N3 triangular grooves, and N4 trapezoidal grooves. N1*H1*L1 is the total area of ​​the N1 rectangular grooves, N2*0.5*π*H2*H2 is the total area of ​​the N2 semi-circular grooves, N3*0.5*H3*L3 is the total area of ​​the N3 triangular grooves, and N4*0.5*(L4+L5)*H4 is the total area of ​​the N4 trapezoidal grooves. The total area S of the multiple groove cross-sections is obtained by combining the total areas of the N1 rectangular grooves, N2 semi-circular grooves, N3 triangular grooves, and N4 trapezoidal grooves.

[0253] In one embodiment, the substrate is annular cylindrical; the annular cylindrical substrate structure is stable and can withstand large mechanical stresses under high-speed rotation and braking force; it uniformly distributes stress, reduces stress concentration, thereby improving the durability and reliability of the substrate; it provides a large surface area, which helps to improve heat dissipation performance, reduce heat accumulation, and maintain the performance stability of the substrate at high temperatures.

[0254] In one embodiment, the height of the substrate is 20mm-60mm; optionally, the height of the substrate may be, but is not limited to, 20mm, 30mm, 40mm, 50mm, or 60mm.

[0255] Within this range, the height of the substrate ensures sufficient structural stability under braking forces, reducing the risk of deformation and damage; it also provides more surface area, aiding in heat dissipation, reducing heat accumulation, and maintaining the substrate's performance stability at high temperatures. When the substrate height is less than 20mm, the insufficient height leads to inadequate structural stability under braking forces, increasing the risk of deformation and damage; when the substrate height is greater than 60mm, it exceeds the practical requirements, resulting in overkill performance, increased manufacturing and processing costs, and higher material costs.

[0256] In one embodiment, the distance between the outer surface of the substrate and the axis of the substrate is 300mm-600mm; optionally, the distance between the outer surface of the substrate and the axis of the substrate can be, but is not limited to, 300mm, 400mm, 500mm, or 600mm.

[0257] Within this range, the distance between the outer surface of the substrate and the substrate axis ensures sufficient contact area between the friction layer and the brake disc, thereby improving the braking efficiency of the brake disc; increasing the heat dissipation area helps dissipate heat, reduces heat accumulation, and maintains the performance stability of the substrate at high temperatures. Insufficient contact area between the friction layer and the brake disc affects braking efficiency and performance; reduced heat dissipation area affects the structural stability of the substrate. When the distance between the outer surface of the substrate and the substrate axis is less than 300mm, or greater than 600mm, it exceeds the actual required range, leading to overperformance and increased material and manufacturing costs.

[0258] In one embodiment, the distance between the inner surface of the matrix and the matrix axis is 40mm-300mm. Optionally, the distance between the inner surface of the matrix and the matrix axis can be, but is not limited to, 40mm, 60mm, 80mm, 100mm, 200mm, or 300mm.

[0259] The reason for setting the distance between the inner surface of the matrix and the matrix axis is the same as the reason for setting the distance between the outer surface of the matrix and the matrix axis, and will not be repeated here.

[0260] In one embodiment, the density of the matrix is ​​1.2 g / cm³. 3 -1.6g / cm 3 Optionally, the density of the matrix may be, but is not limited to, 1.2 g / cm³. 3 1.3g / cm 3 1.4g / cm 3 1.5g / cm 3 1.6g / cm 3 .

[0261] Within this density range, the substrate can be guaranteed to have uniform strength after silicon infiltration, reducing material strength fluctuations and improving the stability and reliability of the brake disc; it also improves the wear resistance and thermal stability of the substrate, extending the service life of the brake disc. When the substrate density is less than 1.2 g / cm³... 3 When the substrate density is too low after silicon infiltration, the mechanical properties of the brake disc decrease, increasing the risk of breakage. When the substrate density is greater than 1.6 g / cm³, the substrate strength becomes insufficient, leading to a decline in mechanical properties and increasing the risk of breakage. 3 When silicon infiltration fails, the sample cannot achieve the desired performance.

[0262] In one embodiment, the average surface roughness of the substrate is 1μm-6μm; optionally, the average surface roughness of the substrate may be, but is not limited to, 1μm, 2μm, 3μm, 4μm, 5μm, or 6μm.

[0263] The average surface roughness of the substrate is within this range to ensure a certain degree of flatness before machining the grooves. When the average surface roughness of the substrate is less than 1 μm, the flatness is too small, leading to increased machining difficulty and cost. When the average surface roughness of the substrate is greater than 6 μm, there are more microscopic protrusions and depressions on the surface, making surface quality control difficult and making it hard to ensure that each substrate has uniform roughness. The friction layer cannot be uniformly adhered to the substrate, thus affecting the assembly of the friction layer.

[0264] In one embodiment, the maximum height of the substrate profile is 5μm-20μm. Optionally, the maximum height of the substrate profile can be, but is not limited to, 5μm, 10μm, 15μm, or 20μm.

[0265] The maximum height of the substrate profile is the vertical distance between the highest and lowest points of an object or surface profile, used to describe the surface roughness of the object. The reason for setting the maximum height of the substrate profile is the same as the reason for setting the average surface roughness of the substrate, and will not be repeated here.

[0266] In one embodiment, the distance between the side of the friction layer away from the substrate and the first surface of the substrate is 0.5mm-4mm. Optionally, the distance between the side of the friction layer away from the substrate and the first surface of the substrate can be, but is not limited to, 0.5mm, 1mm, 1.5mm, 2mm, 2.5mm, 3mm, 3.5mm, or 4mm.

[0267] Within this range, the distance between the side of the friction layer furthest from the substrate and the first surface of the substrate ensures that the friction layer provides sufficient friction during braking while maintaining good thermal stability, guaranteeing the performance stability of the friction layer at high temperatures; reducing noise and vibration during braking, improving driving comfort; and reducing wear, extending service life. When the distance between the side of the friction layer furthest from the substrate and the first surface of the substrate is less than 0.5mm, the friction layer cannot provide sufficient friction, affecting braking performance; the friction layer is too thin to withstand high temperatures, leading to decreased thermal stability and affecting the stability of braking performance; and wear is too rapid, affecting the service life of the brake disc. When the distance between the side of the friction layer furthest from the substrate and the first surface of the substrate is greater than 4mm, it exceeds the actual required range, resulting in excessive performance, increased costs; and increased overall weight of the brake disc, affecting vehicle performance.

[0268] In one embodiment, the friction layer comprises phenolic resin, silicon carbide, and additives.

[0269] Phenolic resin acts as a binder, firmly bonding silicon carbide and additives together to form a unified whole. It also possesses good thermal stability and mechanical strength, contributing to improved heat resistance and structural stability of the brake disc. Silicon carbide, with its high hardness and wear resistance, significantly enhances the wear resistance and thermal stability of the brake disc. Additives include various friction modifiers, friction reducers, thermal conductive agents, and lubricants, which improve the performance of the friction layer, increase the coefficient of friction, reduce wear, and improve thermal conductivity.

[0270] In one embodiment, the phenolic resin accounts for 30%-40% of the friction layer by volume percentage; optionally, the phenolic resin accounts for 30%, 32%, 34%, 36%, 38%, or 40% of the friction layer by volume percentage.

[0271] Within this volume percentage range, phenolic resin can effectively bond silicon carbide and additives together firmly. When the volume percentage of phenolic resin in the friction layer is less than 30%, insufficient bonding performance results in ineffective bonding of silicon carbide and other fillers, affecting the overall performance and structural stability of the friction layer. When the volume percentage of phenolic resin in the friction layer is greater than 40%, the coating is prone to blistering in subsequent processes (such as carbonization), affecting coating formation.

[0272] In one embodiment, silicon carbide accounts for 40%-50% of the friction layer by volume percentage; optionally, the volume percentage of silicon carbide in the friction layer may be, but is not limited to, 40%, 42%, 44%, 46%, 48%, or 50%.

[0273] Within this volume percentage range, silicon carbide optimizes the friction performance of the brake disc, providing a stable coefficient of friction and good braking effect, significantly improving the wear resistance of the brake disc, and extending its service life. It also exhibits good thermal stability, contributing to improved performance stability of the brake disc at high temperatures. When the volume percentage of silicon carbide in the friction layer is less than 40%, the friction performance is unstable, affecting braking effect and leading to insufficient wear resistance of the brake disc, thus shortening its service life. It also affects the thermal stability of the brake disc at high temperatures, leading to thermal fade. When the volume percentage of silicon carbide in the friction layer is greater than 50%, it increases the difficulty of mixing and molding, affecting production efficiency and product quality. This results in increased costs and impacts the product's economic viability.

[0274] In one embodiment, the additive accounts for 10%-15% of the friction layer by volume percentage. The volume percentage of the additive in the friction layer can be, but is not limited to, 10%, 11%, 12%, 13%, 14%, or 15%.

[0275] Within this volume percentage range, additives can improve the brake disc's coefficient of friction, reduce wear, and improve heat transfer performance. When the additive's volume percentage in the friction layer is less than 10%, the brake disc's coefficient of friction fails to meet requirements, resulting in poor wear performance and poor thermal stability. When the additive's volume percentage in the friction layer is greater than 15%, the brake disc's coefficient of friction fails to meet requirements, resulting in poor wear performance and poor thermal stability.

[0276] In one embodiment, the particle size R of silicon carbide satisfies: 0.01 mm ≤ R ≤ 0.5 mm. Optionally, the particle size R of silicon carbide can be, but is not limited to, 0.01 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, or 0.5 mm.

[0277] Within this particle size range (R), silicon carbide particles can be uniformly distributed in the friction layer, forming an effective friction layer structure. This uniform distribution reduces wear and improves wear resistance. It also improves the thermal conductivity of the friction layer, aiding in heat dissipation and reducing heat accumulation. When the particle size (R) is less than 0.01 mm, the excessively small particles may not provide sufficient wear resistance, leading to rapid wear of the friction layer during use and affecting its overall performance. When the particle size (R) is greater than 0.5 mm, the excessively large particles negatively impact the friction performance of the friction layer, resulting in decreased braking effectiveness.

[0278] In one embodiment, the present invention provides a method for manufacturing a brake disc, as shown in Figure 33, including:

[0279] Step S1: Create multiple grooves on the first surface of the substrate.

[0280] Step S2: Set the friction layer on the first surface of the substrate.

[0281] The grooves are arranged in a regular pattern, and at least the friction layer is contained within the grooves.

[0282] Multiple regularly arranged grooves are created, and the friction layer is housed within these grooves. This increases the contact area between the friction layer and the substrate, providing a larger mechanical locking area. The grooves provide a physical interlocking mechanism between the friction layer and the substrate, making the friction layer more firmly fixed to the substrate.

[0283] Fifthly, the present invention provides a vehicle comprising a brake disc as described in any of the above embodiments, or a brake disc manufactured by the method described in the above embodiments; the brake disc generates friction to brake the vehicle.

[0284] The friction layer of the brake disc is carefully designed, including appropriate bonding materials, filler particles, and additives, to provide stable friction performance and wear resistance. The groove design of the brake disc allows the friction layer to be more firmly fixed to the substrate. Vehicle brake discs can reduce the detachment of the friction layer from the substrate under high temperature and intense friction conditions.

[0285] The technical solution of the first aspect of the present invention will be described in detail below through specific embodiments 1-4 and comparison 1.

[0286] Example 1

[0287] This embodiment provides a brake disc. The cross-section of the brake disc is shown in Figure 2. The boss is triangular in shape, and the smooth line connecting its cross-section is y1 = 0.5sin(2x). The groove width is 1.57mm, and the friction layer thickness is 2mm.

[0288] Example 2

[0289] This embodiment provides a brake disc. The cross-section of the brake disc is shown in Figure 5. The boss is rectangular in shape, and the smooth line connecting its cross-section is y1 = 0.8sin(1.5x). The groove width is 1mm, and the friction layer thickness is 2mm.

[0290] Example 3

[0291] This embodiment provides a brake disc. The cross-section of the brake disc is shown in Figure 6. The boss shape is a multi-rectangular composite. The smooth line connecting its cross-section is y1+y2=0.8sin(2x)+1.2sin(2x). The width of the first groove is 2.1mm, the width of the second groove is 2.1mm, and the thickness of the friction layer is 2mm.

[0292] Example 4

[0293] This embodiment provides a brake disc. The cross-section of the brake disc is shown in Figure 7. The boss shape is a multi-rectangular composite. The smooth line connecting its cross-section is y1=sin(0.5x). The groove width is 6.28mm and the friction layer thickness is 2mm.

[0294] Comparative Example 1

[0295] This comparative example provides a brake disc, the cross-section of which is shown in Figure 8. The base surface of the brake disc is untreated, and the friction layer thickness is 2mm.

[0296] The brake discs provided in Examples 1-4 and Comparative Example 1 were tested as follows:

[0297] Coating adhesion test

[0298] Based on the AK-Master bench performance testing standard, the brake disc was heated to 700 degrees Celsius by friction, then rapidly cooled to room temperature by compressed air. This performance test was repeated until the friction layer on the surface of the carbon-ceramic brake disc showed signs of peeling, at which point the test was stopped. The number of cycles that could be repeated under the high-temperature rapid cooling condition was used to evaluate the bonding strength between the Si / SiC composite ceramic layer and the carbon-ceramic substrate on the surface of the carbon-ceramic brake disc.

[0299] The specific test results are shown in Table 1 below:

[0300] Table 1

[0301] By comparing Examples 1-4 with Comparative Example 1, it can be seen that the bonding force between the friction layer and the substrate in the examples is significantly better than that in the comparative example. The main reason is that the connection between the friction layer and the substrate increases the contact area through the microstructure, thereby improving the bonding force between the two.

[0302] The technical solution of the second aspect of the present invention will be described in detail below through specific embodiments 5-9 and comparison 2.

[0303] Example 5

[0304] This embodiment provides a brake disc, as shown in Figure 9. The brake disc includes a substrate and a friction layer, and the substrate has an arc-shaped groove. The outer diameter of the brake disc is 480 mm, the inner diameter is 184 mm, the thickness of the friction layer is 3 mm, the groove depth is 1 mm, the groove width is 1 mm, the included angle α of the groove is 30°, and the distance between two adjacent grooves is 6 mm.

[0305] Example 6

[0306] This embodiment provides a brake disc, as shown in Figure 12. The brake disc includes a substrate and a friction layer, and the substrate has an arc-shaped groove. The outer diameter of the brake disc is 480 mm, the inner diameter is 184 mm, the thickness of the friction layer is 3 mm, the groove depth is 1.1 mm, the groove width is 1.5 mm, the included angle α of the groove is 15°, and the distance between two adjacent grooves is 3 mm.

[0307] Example 7

[0308] This embodiment provides a brake disc, as shown in Figure 13. The brake disc includes a substrate and a friction layer, and the substrate has an arc-shaped groove. The outer diameter of the brake disc is 480 mm, the inner diameter is 184 mm, the thickness of the friction layer is 3 mm, the groove depth is 1.3 mm, the groove width is 1.6 mm, the included angle α of the groove is 60°, and the distance between two adjacent grooves is 17 mm.

[0309] Example 8

[0310] This embodiment provides a brake disc, as shown in Figure 14. The brake disc includes a substrate and a friction layer, and the substrate has an arc-shaped groove. The outer diameter of the brake disc is 480 mm, the inner diameter is 184 mm, the thickness of the friction layer is 3 mm, the groove depth is 1.2 mm, the groove width is 1.8 mm, the included angle α of the groove is 75°, and the distance between two adjacent grooves is 35 mm.

[0311] Example 9

[0312] This embodiment provides a brake disc, as shown in Figure 9. The brake disc includes a substrate and a friction layer, and the substrate has an arc-shaped groove. The outer diameter of the brake disc is 480 mm, the inner diameter of the brake disc is 184 mm, the thickness of the friction layer is 3 mm, the groove depth is 1 mm, the groove width is 1 mm, the included angle α of the groove is 30°, and the distance between two adjacent grooves is 3 mm.

[0313] Comparative Example 2

[0314] This comparative example provides a brake disc, as shown in Figure 15. The brake disc includes a substrate and a friction layer, and the substrate does not have grooves. The thickness of the friction layer is 3mm.

[0315] The coating adhesion of the brake discs provided in Examples 5-9 and Comparative Example 2 was tested using the following method:

[0316] Based on the AK-Master bench performance testing standard, the brake disc was heated to 700 degrees Celsius by friction, then rapidly cooled to room temperature using compressed air. This performance test was repeated until the friction layer on the carbon-ceramic brake disc surface showed signs of peeling, at which point the test was stopped. The number of cycles that could be repeated under the high-temperature rapid cooling condition was used to evaluate the bonding strength between the Si / SiC composite ceramic layer and the carbon-ceramic substrate on the surface of the carbon-ceramic brake disc. Specific test results are shown in Table 2 below.

[0317] Table 2

[0318] By comparing Examples 5-9 and Comparative Example 2, it can be seen that the bonding force between the friction layer and the substrate in the examples is significantly better than that in the comparative example. The main reason is that the connection between the friction layer and the substrate increases the contact area through the microstructure, thereby improving the bonding force between the two.

[0319] The technical solution of the third aspect provided by the present invention will be described in detail below through specific embodiments 10-16 and comparison 3.

[0320] The technical solution of the present invention will be described in detail below through specific embodiments, and the data of each embodiment are shown in Table 3:

[0321] Table 3

[0322] Mechanical forming tests were conducted on the brake discs provided in Examples 10-16 and Comparative Example 3. The test method was as follows: the brake discs were fabricated into the sample shape shown in Figure 22, with dimensions of 4cm x 1cm x 1cm. A universal testing machine was used to test the interlayer bonding between the friction layer and the substrate. The test results are shown in Table 4 below.

[0323] Table 4

[0324] Among them, the shear strength of the brake discs obtained in Examples 10-16 is greater than that in Comparative Example 3, indicating that the bonding force between the substrate and the friction layer in the brake disc of the embodiments provided by the present invention is better than that of existing brake discs.

[0325] The technical solution of the fourth aspect of the present invention will be described in detail below through specific embodiments 17-28 and comparative examples 4-5.

[0326] Example 17

[0327] This embodiment provides a brake disc, which includes a base and a friction layer. A plurality of regularly arranged grooves are formed on the first surface of the base, and the friction layer is connected to the first surface and is contained in the grooves.

[0328] The grooves are all annular and arranged concentrically. The cross-sectional shape of the grooves is rectangular, and the ratio of the total cross-sectional area S of the grooves to the length L of the brake disc cross-section is 1.3.

[0329] The matrix is ​​a ring-shaped cylinder with a height of 40 mm. The distance between the outer surface of the matrix and its axis is 400 mm, and the distance between the inner surface of the matrix and its axis is 150 mm. The density of the matrix is ​​1.4 g / cm³. 3 The average surface roughness of the substrate is 3μm, and the maximum height of the substrate profile is 10μm. The cylindrical rectangular cross-section is 2.6mm long and 2mm high, with grooves spaced 1.4mm apart, for a total of 62 grooves. S / L=(2*2.6*62) / (400-150)=1.3.

[0330] The distance between the side of the friction layer away from the substrate and the first surface of the substrate is 2 mm. The friction layer comprises phenolic resin, silicon carbide, and additives. By volume percentage, the phenolic resin accounts for 39%, the silicon carbide accounts for 49%, and the additives account for 12%. The particle size R of the silicon carbide is 0.2 mm.

[0331] The method for manufacturing the brake disc in this embodiment is as follows:

[0332] (1) Dissolve phenolic resin in ethanol, add silicon carbide and additives to obtain friction layer slurry.

[0333] (2) Multiple grooves arranged in a regular pattern are opened on the precast body to obtain precast body A.

[0334] (3) Apply friction layer slurry to the groove of preform A and cure at 150°C for 3 hours to obtain preform B.

[0335] (4) Carbonize the preform B at 1060℃ to obtain the preform C.

[0336] (5) The preform C is subjected to silicon infiltration treatment at a temperature of 1680℃ for 3 hours to obtain a brake disc.

[0337] Example 18

[0338] The difference between Example 18 and Example 17 is that in Example 18, multiple grooves extend along a first direction, and multiple grooves are arranged sequentially at intervals along a second direction, with the first and second directions being perpendicular. The ratio of the total cross-sectional area S of the multiple grooves to the length L of the brake disc cross-section is 1.3.

[0339] The method for manufacturing the brake disc in Example 18 is the same as that in Example 17.

[0340] Example 19

[0341] The difference between Example 19 and Example 17 is that the cross-sectional shape of the groove in Example 19 is trapezoidal.

[0342] The method for manufacturing the brake disc in Example 19 is the same as that in Example 17.

[0343] Example 20

[0344] The difference between Example 20 and Example 17 is that the cross-sectional shape of the groove in Example 20 is semi-circular.

[0345] The method for manufacturing the brake disc in Example 20 is the same as that in Example 17.

[0346] Example 21

[0347] The difference between Example 21 and Example 17 is that the cross-sectional shape of the groove in Example 21 is triangular.

[0348] The method for manufacturing the brake disc in Example 21 is the same as that in Example 17.

[0349] Example 22

[0350] The difference between Example 22 and Example 17 is that the cross-sectional shape of the groove in Example 22 includes rectangle, semicircle, triangle, trapezoid and triangle.

[0351] The method for manufacturing the brake disc in Example 22 is the same as that in Example 17.

[0352] Example 23

[0353] The difference between Example 23 and Example 17 is that the depth H1 of the groove in Example 23 is 0.5mm, and the groove width L1 on the first surface is 0.1mm.

[0354] The method for manufacturing the brake disc in Example 23 is the same as that in Example 17.

[0355] Example 24

[0356] The difference between Example 24 and Example 17 is that the depth H1 of the groove in Example 24 is 2mm, and the groove width L1 on the first surface is 5mm.

[0357] The method for manufacturing the brake disc in Example 24 is the same as that in Example 17.

[0358] Example 25

[0359] The difference between Example 25 and Example 17 is that the cross-sectional shape of the groove in Example 25 is trapezoidal, and the ratio of the total area S of the multiple groove cross-sections to the length L of the brake disc cross-section is 0.88mm.

[0360] The method for manufacturing the brake disc in Example 25 is the same as that in Example 17.

[0361] Example 26

[0362] The difference between Example 26 and Example 17 is that the total area S of the groove cross-section and the total groove width L of the multiple grooves on the first surface are S / L = 0.2 mm.

[0363] The method for manufacturing the brake disc in Example 26 is the same as that in Example 17.

[0364] Example 27

[0365] The difference between Example 27 and Example 17 is that the total area S of the groove cross section and the total groove width L of the multiple grooves on the first surface are S / L = 1.5 mm.

[0366] The method for manufacturing the brake disc in Example 27 is the same as that in Example 17.

[0367] Example 28

[0368] The difference between Example 28 and Example 17 is that the groove cross-section is semi-circular, and the total area S of the groove cross-section and the length L of the brake disc cross-section are S / L = 0.39 mm.

[0369] The method for manufacturing the brake disc in Example 28 is the same as that in Example 17.

[0370] Comparative Example 4

[0371] The difference between Comparative Example 4 and Example 17 is that the friction layer does not have grooves.

[0372] The manufacturing method of the brake disc in Comparative Example 4 is the same as that in Example 17.

[0373] Comparative Example 5

[0374] The difference between Comparative Example 5 and Example 17 is that the friction layer has a single groove.

[0375] The manufacturing method of the brake disc in Comparative Example 5 is the same as that in Example 17.

[0376] The brake discs provided in Examples 17-28 and Comparative Examples 4-5 were subjected to the following tests:

[0377] (1) Bending strength: Bending strength test shall be conducted in accordance with the national standard GB / T 6569.

[0378] (2) Compressive strength: The compressive strength is tested according to the ASTM D2344 / D2344M-13 standard.

[0379] (3) Interlaminar shear test: Interlaminar shear test was conducted in accordance with the national standard GB / T 34559-2017.

[0380] The experimental results are shown in Table 5.

[0381] Table 5

[0382] Comparing Examples 17-28 and Comparative Examples 4-5 in Table 5, the flexural strength, compressive strength, and interlaminar shear of Examples 17-28 are superior to those of Comparative Examples 4-5. Multiple regularly arranged grooves increase the contact area between the friction layer and the substrate, forming a physical interlock between them. This provides uniform mechanical locking and contact area, thereby enhancing the bonding force and reducing the detachment of the friction layer from the substrate under high temperature and intense friction conditions. This, in turn, improves the flexural strength, compressive strength, and interlaminar shear of the brake disc.

[0383] In the description of the embodiments of this application, it should be noted that the orientation or positional relationship of the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and other indicators are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0384] The above-disclosed embodiments are merely preferred embodiments of this application and should not be construed as limiting the scope of this application. Those skilled in the art will understand that all or part of the processes for implementing the above embodiments and equivalent variations made in accordance with the claims of this application are still within the scope of this application.

Claims

1. A brake disc, wherein, The brake disc comprises a base (10), a friction layer (20) and a plurality of bosses (40), the base (10) comprises a first surface (11), the bosses (40) are arranged on the first surface (11), the bosses (40) are arranged periodically, and the friction layer (20) covers the bosses (40) and is connected with the first surface (11).

2. The brake disc of claim 1, wherein, The gap between two adjacent bosses (40) is a first groove (30A).

3. The brake disc of claim 2, wherein, On the axial section of the brake disc, the smooth connection line from the highest point of the boss (40) to the lowest point of the adjacent first groove (30A) satisfies the relationship y1=Asin(ωx), wherein A is 0.05mm-5mm, ω is 0.3mm-20mm, and A and ω satisfy A≤π / ω.

4. The brake disc of claim 3, wherein, The top surface of the boss (40) is provided with a second groove (41).

5. The brake disc of claim 4, wherein, On the axial section of the brake disc, the smooth connection line from the highest point of the boss (40) to the lowest point of the adjacent first groove (30A) and the smooth connection line from the highest point of the boss (40) to the lowest point of the second groove (41) satisfy the relationship y1+y2=Asin(ωx)+Bsin(βx), wherein B is 0.05mm-5mm, β is 0.3mm-20mm.

6. The brake disc of claim 3, wherein, The groove width d of the first groove (30A) satisfies d≤π / ω.

7. The brake disc of claim 3 wherein, The roughness Ra of the first surface (11) provided with the boss (40) satisfies the relationship Ra=1 / 2A.

8. The brake disc of claim 1, wherein, The area of the orthogonal projection of any of the said bosses (40) on the first face (11) is 0.01 mm 2 ~ 100 mm 2 .

9. The brake disc of claim 1, wherein, The normal projection of the boss (40) along the radial direction of the brake disc is one or more of a circle, an ellipse and a polygon.

10. The brake disc of claim 1, wherein, The thickness H of the friction layer (20) satisfies 0 11. A vehicle, wherein, The brake disc comprises the brake disc according to any one of claims 1-10.

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