Composite Ceramic Brake Disk Surface Layer Friction Control
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Solution Overview
Problem
Existing braking systems with composite ceramic materials face challenges in varying the friction coefficient to meet specific vehicle requirements without compromising mechanical properties or causing structural defects.
Innovation Solution
Modulating the friction coefficient by varying the composition, length of carbon filaments, and particle size of SiC in the surface layer of the braking system, while maintaining the base layer composition unchanged, to achieve desired friction values that remain constant over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the composition of the disk and/or pad material is modified to vary the friction coefficient, then the friction coefficient can be adapted to different vehicle requirements, but the mechanical properties of the material may deteriorate causing cracking, splitting or other serious structural defects
Solution Approach 1:
The braking system is divided into two distinct components: a disk made of composite ceramic material and pads made of different material. This segmentation allows the friction characteristics to be controlled through the pad material selection while the disk maintains its structural integrity and mechanical properties. The interface between these segmented components enables friction coefficient variation without compromising the disk's structural reliability.
Solution Approach 2:
Different materials and properties are applied to different parts of the braking system. The disk maintains its optimized composite ceramic composition for structural reliability, while the pads use different materials (organic, semi-metallic, or ceramic) to provide the desired friction coefficient. This local differentiation allows friction adaptation without affecting the overall structural integrity of the system.
2Stability of the object's composition
If a surface coating is applied to protect the material from oxidation, then the braking characteristics remain constant over time, but the friction coefficient cannot be easily changed according to vehicle type requirements
Solution Approach 1:
The braking system separates the functions of oxidation protection and friction control into different components. The disk with its protective surface coating maintains stability and prevents oxidation, while the pads (which do not require the same level of oxidation protection) provide the variable friction coefficient needed for different vehicle applications. This segmentation resolves the contradiction between stability and adaptability.
Solution Approach 2:
The protective surface coating is applied locally to the disk where structural stability and oxidation resistance are critical, while the pads use different material compositions optimized for friction characteristics. This localized application of different properties allows the system to simultaneously achieve braking characteristic stability through the coated disk and friction coefficient variability through the interchangeable pads.
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
Enables the selection of specific friction coefficients for different vehicles, reducing costs and maintaining structural integrity by ensuring the friction coefficient remains consistent without substantial oxidation.
Implementation Method 1
a second firing in the presence of silicon at a temperature such as to cause melting of the silicon and infiltration into the pores
Implementation Method 2
molten silicon and infiltration into the pores of the aforesaid semi-finished product
Implementation Method 3
the molten silicon partly reacts with the carbon of the semi-finished product under the conditions of the second firing forming silicon carbides
Implementation Method 4
a first firing in a furnace at a temperature such as to cause carbonization or pyrolysis of the resin
Implementation Method 5
the loss of volatile material at the carbonization or pyrolysis temperatures
Implementation Method 6
coating them with a layer of silicates, carbides, silicon nitrides or pure silicon... surface oxidation phenomena on the material with a consequent loss of carbon
Data Source
AI summary
This invention relates to a process for the production of a shaped composite material and the material obtained through that process. In particular it relates to a process for obtaining a disk of composite ceramic material for disc brakes in which the friction coefficient is varied by varying the composition of the surface layer.