Brake Disc Porous Body Ceramic Infiltration
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Solution Overview
Problem
Current brake discs, particularly carbon-carbon discs, face issues with oxidation and wear due to high temperatures during braking, leading to decreased friction properties and increased oxidation of the friction surface, while existing coatings compromise braking efficiency and durability.
Innovation Solution
A method involving a porous body infused with a liquid precursor containing ceramic particles and acid phosphate, which forms a ceramic material throughout the body, reducing oxidation and wear, and maintaining frictional performance comparable to or exceeding that of standard carbon-carbon discs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ceramic coating is applied to the surface of a carbon-carbon brake disc to reduce oxidation, then oxidation resistance is improved, but braking efficiency deteriorates due to decreased friction properties of the coated surface
Solution Approach 1:
The patent applies different treatments to different regions of the brake disc. The friction surface is left as carbon-carbon to maintain high friction properties, while the non-friction surfaces are coated with ceramic material to provide oxidation resistance. This local differentiation resolves the contradiction by providing oxidation protection only where it is needed, without compromising braking efficiency.
Solution Approach 2:
The brake disc is segmented into functional zones: friction surfaces that require high friction properties and non-friction surfaces that require oxidation resistance. The ceramic coating is applied selectively to non-friction surfaces, creating a segmented protection strategy that maintains overall system performance while addressing specific regional needs.
2Reliability
If a ceramic coating is applied to protect non-friction surfaces from oxidation, then oxidation resistance is improved, but the coating is removed during use leading to increased oxidation of the friction surface
Solution Approach 1:
The friction surface is maintained as carbon-carbon without ceramic coating, providing inherent oxidation resistance at the friction interface. The ceramic coating is applied only to non-friction surfaces where it provides stable protection without interfering with braking performance, eliminating the problem of coating removal affecting friction surface oxidation.
3Temperature
If traditional CVD/CVI process is used to form carbon-carbon composite, then high temperature capability is achieved, but production time and energy consumption increase considerably
Solution Approach 1:
The patent uses a hybrid composite structure combining carbon-carbon composite for the bulk material with a ceramic matrix coating for surface protection. This composite approach allows the use of lower-cost, faster-to-produce carbon-carbon substrate while adding a thin ceramic layer that provides the necessary high-temperature oxidation resistance, significantly reducing production time compared to full CVD/CVI processing.
Solution Approach 2:
The carbon-carbon preform is prepared in advance using relatively fast成型 processes, and then the ceramic matrix is infiltrated in a subsequent step. This preliminary preparation allows the use of faster manufacturing methods for the bulk structure, reserving the more time-consuming ceramic infiltration for only the necessary protective layer.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method significantly reduces oxidation and wear of brake discs, maintaining or improving frictional properties and reducing energy and production time compared to traditional methods, with a brake disc showing over 60% reduction in wear and comparable friction performance.
Implementation Method 1
introducing into pores of the porous body one or more precursor materials for forming or depositing a ceramic material
Implementation Method 2
forming or depositing the ceramic material from the precursor material within the pores of the body
Implementation Method 3
chemically bonded phosphate ceramic formed from the acid phosphate and metal oxides
Implementation Method 4
reducing oxidation and wear of brake discs
Implementation Method 5
The disc is squeezed during braking between pads of friction material mounted in the caliper
Data Source
Figure 1
AI summary
A method for forming a material for a brake disc, the method comprising the steps of : (i) providing at least one porous body; (ii) introducing into pores of the porous body one or more precursor materials for forming or depositing a ceramic material; and (iii) forming the brake disc material by forming or depositing the ceramic material from the precursor material within the pores of the body, wherein the precursor material is a liquid containing a suspension of ceramic particles and/or acid phosphate.