Method for producing ceramic brake disks, with an insert in the green body before the pyrolysis

• US 7,163,653 B2
• Filed: 09/20/2001
• Issued: 01/16/2007
• Est. Priority Date: 10/18/2000
• Status: Expired due to Fees

• Current Assignee: Menzolit-Fibron GmbH (Albemarle Corporation)
• Original Assignee: Menzolit-Fibron GmbH (Albemarle Corporation)
• Inventors: Ehnert, Gerd
• Primary Examiner(s): Johnson; Christina
• Assistant Examiner(s): Daniels; Matthew J.
• Application Number:
  US10/398,736
• Publication Number:
  US 20040035658A1
• Time in Patent Office: 1,944 Days
• Field of Search: 264/264, 264/271.1, 264/279.1, 264/154, 264/129, 264/629, 264/635, 264/641, 264/610, 264/612, 259/259
• US Class Current: 264/271.1
• CPC Class Codes: C04B 2235/48 Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
• CPC Class Codes: C04B 2235/5248 Carbon, e.g. graphite
• CPC Class Codes: C04B 2235/526 characterised by the length of the fibers
• CPC Class Codes: C04B 2235/616 Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 35/573 obtained by reaction sintering or recrystallisation
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: F16D 69/02 Composition of linings ; Methods of manufacturing
• CPC Class Codes: F16D 69/023 Composite materials containing carbon and carbon fibres or fibres made of carbonizable material

Abstract

The invention relates to a method for producing ceramic brake disks from a green body consisting of a sheet molding compound (SMC) having reinforcing fibers, and the ensuing pyrolysis and melt infiltration. The aim of the invention is to create a single-element green body comprising very complex inner cavities after pyrolysis. In order to achieve this, the method comprises the following steps: the green body (1) is produced from a sandwich consisting of SMC (2), a thermoplastic insert (4), and SMC (2) in one working step in a tool (5a, 5b), subjected to pressure and temperature; and the insert (4) fills the green body (1) over its entire surface and comprises openings (6) which are arranged in such a way that the upper and lower SMC layers (2) are interconnected, at least in parts.

Claims

1. A process for producing ceramic brake disks, comprising the following process steps:

producing a green compact from a sandwich comprising a lower layer of sheet moulding compound, a round thermoplastic insert having an inner diameter, an outer diameter, and decentered apertures, and an upper layer of sheet moulding compound in a working step in a tool subject to the application of pressure and heat, whereby the insert fills out the green compact substantially over its entire expanse and at the same time the green compact is fashioned by the apertures in such a way that the upper and lower sheet moulding compound layers are connected to one another at least in places at least through the apertures, and the upper and lower sheet moulding compound layers completely flow around and enclose the insert, wherein the upper and lower sheet moulding compound layers comprise a phenolic resin matrix and carbon reinforcing fibers having a length of at least 6 mm;

exposing the inner diameter and outer diameter of the insert by machining;

then

pyrolysing the green compact for the purpose of producing a porous moulded article; and

melt infiltrating the porous moulded article with a melt to produce a moulded article with reaction-bonded fibers.

2. Process according to claim 1, characterised in that prior to pyrolysis additional apertures to the insert are introduced in the green compact.

3. Process according to claim 1, characterised in that projecting cooling fins are arranged on the insert.

4. Process according to claim 1, characterised in that the insert is produced from a thermoplastic or from a polyamide.

5. Process according to claim 1, characterised in that the insert is produced from polypropylene or polycarbonate.

6. Process according to claim 1, characterised in that the melt is a silicon melt.