Ceramic Brake Rotor Cooling Channel Precision via Segmented Infiltration
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Solution Overview
Problem
Conventional methods for manufacturing ceramic brake disk rotors with internal cooling channels are costly and time-consuming due to strict processing tolerances and material restrictions, which affect the precision and ease of forming these channels.
Innovation Solution
The method involves producing loading portions, frictional surfaces, and vanes separately using carbon fiber-reinforced carbon-carbon composite materials and then integrating them through a liquid silicon-melt infiltration process, allowing for precise and economical formation of cooling channels without shape restrictions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cooling channels are formed by combining upper and lower plates with half-shapes, then cooling channels can be created in the disk rotor, but strict processing tolerances are required at the surface having cooling channels to prevent gaps, increasing machine processing cost and time
Solution Approach 1:
The disk rotor is divided into upper and lower plates that are processed separately and then combined. Each plate contains half-shapes of cooling channels that form complete channels when assembled. This segmentation allows independent processing of each plate while achieving the final cooling channel structure through combination.
Solution Approach 2:
A liquid composition is applied as an intermediary substance during the combination process of upper and lower plates. The liquid composition fills gaps and bonds the plates together, forming the complete cooling channels without requiring extremely tight tolerances at the interface surfaces.
2Manufacturing precision
If cooling channels are formed by combining upper and lower plates with half-shapes, then cooling channels can be created in the disk rotor, but highly strict processing tolerances are required at the surface having cooling channels, increasing machine processing cost
Solution Approach 1:
The liquid composition serves as a mediator that facilitates bonding between upper and lower plates while filling minor surface irregularities. This intermediary substance reduces the need for expensive high-precision machining to achieve gap-free joints, thereby lowering manufacturing costs while maintaining cooling channel integrity.
Solution Approach 2:
The invention changes the physical state of the bonding medium from solid (requiring precise mechanical fits) to liquid (which can flow and fill gaps). This parameter change in the bonding approach allows for more relaxed surface tolerances and reduces machining costs.
3Manufacturing precision
If a material having internal cooling channel shape is inserted during press molding and then incinerated, then accurate shape and dimension can be satisfied, but the selection of material is very restrictive and low-density regions are easily created in vane shaped portions
Solution Approach 1:
Instead of inserting solid materials that are later incinerated, the invention uses liquid composition that is applied after the carbon-carbon composite structure is formed. This parameter change from solid-to-liquid material state provides greater flexibility in material selection and application timing, avoiding the restrictive requirements of traditional methods.
Solution Approach 2:
The upper and lower plates are first formed with half-shapes of cooling channels through press molding, then the liquid composition is applied to complete the channel formation. This preliminary formation of plate structures followed by liquid infiltration allows accurate shape control without the limitations of material insertion methods.
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 enhances the dimensional precision and performance of the ceramic brake disk rotor by enabling the creation of complex cooling channels, improving thermal management and extending the life of the rotor.
Implementation Method 1
performing a liquid silicon-melt infiltration process
Data Source
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AI summary
The present invention relates to a method of more precisely and easily realizing cooling channels constituting a ceramic brake disk rotor. In order to achieve an object of the invention, there is provided a method of manufacturing a ceramic brake disk rotor having internal cooling channels, comprising the steps of: (a) producing loading portions 110, 210, frictional surfaces 120, 220, and vanes 300 of the disk rotor respectively through separate processes using a carbon fiber reinforced carbon-carbon composite; (b) fabricating the loading portions 110, 210, frictional surfaces 120, 220, and vanes 300 re¬ spectively produced through separate processes into one structure and (c) performing a liquid silicon-melt infiltration process for the fabricated one structure. According to the present invention, a shape of the cooling channel can be economically and easily realized, and furthermore the dimensional precision of the cooling channel is enhanced, thereby having an effect of improving the performance of the disk rotor.