Brake Disc Laser Surface Pretreatment for Adhesion
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Solution Overview
Problem
Existing brake disk production methods face challenges in achieving effective adhesion between the basic body and the wearing coat, often requiring costly and complex pretreatment processes like preheating or blasting, which can introduce fine particle inclusions and reduce reproducibility.
Innovation Solution
The use of laser radiation to modify the surface topography of the contact surface of the brake disk, allowing for controlled modification of parameters such as structure, cleanliness, chemical composition, and roughness, thereby enhancing the adhesion of the wearing coat without the drawbacks of traditional methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional pretreatment methods (preheating or blasting) are used to improve adhesion, then adhesion between basic body and wearing coat is enhanced, but production complexity and cost increase
Solution Approach 1:
The patent replaces mechanical pretreatment methods (blasting, preheating) with laser radiation to modify the surface topography of the basic body. The laser creates a structured surface that enhances adhesion without requiring complex mechanical equipment or multiple process steps, thereby reducing production complexity while maintaining strong adhesion between the basic body and wearing coat.
Solution Approach 2:
The patent changes the physical state and parameters of the basic body surface through laser radiation, creating specific surface topography parameters (roughness, structure) that enhance adhesion. By controlling laser parameters (energy, intensity, duration), the surface properties are optimized for adhesion without requiring complex pretreatment processes.
2Strength
If blasting with fine particles is used to roughen the surface for better adhesion, then adhesion is improved, but fine particle inclusions are introduced that adversely affect adhesion
Solution Approach 1:
The patent replaces the mechanical blasting process with laser radiation to create surface roughness. This substitution eliminates the introduction of fine particle inclusions that would otherwise contaminate the surface and adversely affect adhesion, while still achieving the desired surface topography for enhanced wearing coat adhesion.
Solution Approach 2:
The patent converts the potential harm of surface contamination into a benefit by using laser radiation to create a controlled surface topography that enhances adhesion without introducing contaminants. The laser process transforms the surface in a way that eliminates the harmful effect of particle inclusions while maintaining the beneficial effect of improved adhesion.
3Strength
If adhesion promoter layers are applied to improve wearing coat adhesion, then adhesion is enhanced, but production cost and process complexity increase
Solution Approach 1:
The patent replaces the chemical approach of applying adhesion promoter layers with a physical approach using laser radiation to modify the basic body surface. This substitution eliminates the cost and complexity associated with applying and curing adhesion promoters, while achieving equivalent or superior adhesion through surface topography modification.
Solution Approach 2:
The patent extracts the adhesion enhancement function from the adhesion promoter layer and transfers it to the basic body surface itself through laser-induced topography modification. This eliminates the need for separate adhesion promoter materials and application processes, reducing production cost and simplifying manufacturing.
4Strength
If conventional surface pretreatment methods are used, then adhesion is improved, but reproducibility of surface modification is reduced
Solution Approach 1:
The patent uses laser radiation with controllable parameters (energy, intensity, duration, scanning speed) to create reproducible surface topography on the basic body. By precisely controlling these parameters, the same surface characteristics can be consistently achieved across different production batches, ensuring reproducible adhesion properties that conventional methods cannot provide.
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
This approach improves the adhesion between the basic body and the wearing coat, leading to increased reliability of the braking effect, reduces production costs and complexity, and allows for reproducible surface modifications, ensuring a strong bond between the disk and the lining.
Implementation Method 1
the at least one contact surface of the basic body has a surface topography modified by laser radiation
Implementation Method 2
the contact surface is heated and/or melted and/or vaporized
Implementation Method 3
the contact surface is heated and/or melted and/or vaporized and/or cleaned by way of correspondingly settable parameters of the laser radiation
Data Source
AI summary
A brake disc includes a basic body with at least one contact surface that has a wearing coat applied thereon. The at least one contact surface of the basic body is pretreated to realize the bond between the wearing coat and the basic body. The at least one pretreated contact surface of the basic body has a surface topography that is modified by laser irradiation and has at least one predetermined parameter. A method produces the brake disc.