Bicycle brake pad and method for manufacturing bicycle brake pad

Patent metadata

Field	Value
Publication number	US-10215247-B2
Application number	US-201615006121-A
Country	US
Kind code	B2
Filing date	Jan 26, 2016
Priority date	Jan 30, 2015
Publication date	Feb 26, 2019
Grant date	Feb 26, 2019

Abstract

A bicycle brake pad includes a friction member and a first support member. The friction member includes a first intermetallic compound. The friction member and the first support member are, at least partially, chemically coupled to each other.

First claim

The invention claimed is:

1. A bicycle brake pad, comprising:
a friction member including a first intermetallic compound which is a Cu—Ti intermetallic compound including at least Cu and Ti; and
a first support member including Al, wherein the friction member and the first support member are, at least partially, chemically coupled to each other via a boundary structure including a second intermetallic compound which is a Cu—Al intermetallic compound composed of Cu derived from the friction member and Al derived from the first support member.

2. The brake pad according to claim 1 , wherein the first intermetallic compound is produced by performing combustion synthesis on metal materials including at least Cu and Ti.

3. The brake pad according to claim 2 , wherein the first intermetallic compound is produced by performing the combustion synthesis on the metal materials with an additive material added thereto.

4. The brake pad according to claim 3 , wherein the additive material includes carbon.

5. The brake pad according to claim 4 , wherein
the Cu—Ti intermetallic compound is at least one of TiCu, Ti 2 Cu, Ti 3 Cu 4 , Ti 2 Cu 3 , and TiCu 4 .

6. The brake pad according to claim 5 , wherein the friction member further includes at least one of TiC and Cu 3 Ti 3 O.

7. The brake pad according to claim 2 , further comprising a second support member that supports the friction member and the first support member, wherein the first support member and the second support member are mechanically coupled to each other.

8. The brake pad according to claim 7 , wherein:
the first support member includes a projection;
the second support member includes a recess; and
the first support member and the second support member are mechanically coupled to each other by the projection of the first support member that enters the recess of the second support member when combustion synthesis of the first intermetallic compound produces heat that softens or melts the projection.

9. The brake pad according to claim 8 , wherein the recess of the second support member is increased in diameter toward an opposite side of the friction member.

10. The brake pad according to claim 9 , wherein the recess of the second support member is a stepped through bore.

11. The brake pad according to claim 7 , wherein the second support member has the form of a plate.

12. The brake pad according to claim 2 , wherein the friction member further includes a metal phase including at least one of the metal materials.

13. The brake pad according to claim 12 , wherein the metal phase includes Cu.

14. The brake pad according to claim 2 , wherein
the friction member and the first support member are, at least partially, inorganically and chemically coupled to each other by the second intermetallic compound.

15. The brake pad according to claim 14 , wherein the second intermetallic compound is formed by heat produced during combustion synthesis of the first intermetallic compound.

16. The brake pad according to claim 14 , wherein
the second intermetallic compound includes Al 2 Cu.

17. The brake pad according to claim 1 , wherein the first intermetallic compound is produced by performing combustion synthesis on metal materials including at least Cu and Ti.

18. The brake pad according to claim 17 , wherein the first intermetallic compound is produced by performing the combustion synthesis on the metal materials with an additive material added thereto.

19. The brake pad according to claim 18 , wherein the additive material includes carbon.

20. The brake pad according to claim 19 , wherein
the Cu—Ti intermetallic compound is at least one of TiCu, Ti 2 Cu, Ti 3 Cu 4 , Ti 2 Cu 3 , and TiCu 4 .

21. The brake pad according to claim 20 , wherein the friction member further includes at least one of TiC and Cu 3 Ti 3 O.

22. The brake pad according to claim 17 , further comprising a second support member that supports the friction member and the first support member, wherein the first support member and the second support member are mechanically coupled to each other.

23. The brake pad according to claim 22 , wherein:
the first support member includes a projection;
the second support member includes a recess; and
the first support member and the second support member are mechanically coupled to each other by the projection of the first support member that enters the recess of the second support member when combustion synthesis of the first intermetallic compound produces heat that softens or melts the projection.

24. The brake pad according to claim 23 , wherein the recess of the second support member is increased in diameter toward an opposite side of the friction member.

25. The brake pad according to claim 24 , wherein the recess of the second support member is a stepped through bore.

26. The brake pad according to claim 22 , wherein the second support member has the form of a plate.

27. The brake pad according to claim 17 , wherein
the friction member and the first support member are, at least partially, inorganically and chemically coupled to each other by the second intermetallic compound.

28. The brake pad according to claim 27 , wherein the second intermetallic compound is formed by heat produced during combustion synthesis of the first intermetallic compound.

29. The brake pad according to claim 27 , wherein
the second intermetallic compound includes Al 2 Cu.

30. The brake pad according to claim 17 , wherein the friction member further includes a metal phase including at least one of the metal materials.

31. The brake pad according to claim 30 , wherein the metal phase includes Cu.

32. The bicycle brake pad according to claim 1 , wherein
the friction member includes a metal phase and the first intermetallic compound is dispersed in the metal phase, and
the second intermetallic compound of the boundary structure is composed only of Cu derived from at least one of the metal phase and the first intermetallic compound of the friction member, and Al derived from the first support member.

33. The bicycle brake pad according to claim 32 , wherein the second intermetallic compound of the boundary structure is composed of Cu derived from the metal phase of the friction member, and Al derived from the first support member at a certain ratio.

34. The bicycle brake pad according to claim 32 , wherein the boundary structure includes a diffusion bonding structure in which amounts of a selected one of first chemical species derived from the first intermetallic compound of the friction member and a selected one of second chemical species derived from the first support member vary depending on depth from a reference surface level between the friction member and the first support.

35. The brake pad according to claim 1 , wherein the friction member and the first support member are, at least partially, inorganically and chemically coupled to each other by diffusion bonding.

36. The brake pad according to claim 35 , wherein the first support member has the form of a plate.

37. A bicycle brake pad, comprising:
a friction member including a first intermetallic compound which is a Cu—Ti intermetallic compound including at least Cu and Ti

Assignees

• Shimano Kk

Inventors

• Iwai Toru
• Souwa Makoto

Classifications

• F16D2069/0466

  chemical, e.g. using adhesives, vulcanising · CPC title

• B62L1/00

  Brakes {(back-pedalling brakes B62L5/00)}; Arrangements thereof · CPC title

• B22F5/006

  of flat products, e.g. sheets (B22F3/1103 takes precedence; by using pressure rollers only see B22F3/18) · CPC title

• F16D2200/003

  Light metals, e.g. aluminium · CPC title

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title