Shaped material and manufacturing method

Patent metadata

Field	Value
Publication number	US-11215250-B2
Application number	US-201615578609-A
Country	US
Kind code	B2
Filing date	Jun 8, 2016
Priority date	Jun 10, 2015
Publication date	Jan 4, 2022
Grant date	Jan 4, 2022

Abstract

Shaped material ( 1 ), in particular a disc for a disc brake includes layers ( 2, 4, 6 ) of carbon fibers stacked in a construction direction (X). Each layer ( 2, 4, 6 ) has segments ( 8, 10 ) placed side by side and joined together to form the layer, the segments of a layer ( 2, 4, 6 ) include radial segments ( 8 ) and transverse segments ( 10 ). In each layer ( 2, 4, 6 ) of carbon fibers, the number of transverse segments ( 10 ) is greater than the number of radial segments ( 8 ). A method manufactures a shaped material.

First claim

The invention claimed is:

1. Shaped material configured as a disc for a disc brake, comprising a plurality of layers of carbon fibres or precursors of said fibres stacked in a direction of construction, each layer comprising a plurality of segments placed side by side and joined together to form said layer, the segments of a layer comprising radial segments and transverse segments;
wherein the radial segments are segments in which the carbon fibres are predominantly oriented in a radial direction relative to the direction of construction or oriented substantially parallel to the radial direction, and the transverse segments are segments in which the carbon fibres are directed in an incident direction incident to said radial direction;
wherein the plurality of radial and transverse segments of each layer of carbon fibres or of precursors of said fibres stacked in the direction of construction are placed side by side and joined together to form said layer;
wherein, in each layer of carbon fibres or precursors of said fibres, the number of transverse segments is higher than the number of radial segments.

2. Shaped material according to claim 1 , wherein the number of transverse segments is higher by at least two units than the number of radial segments.

3. Shaped material according to claim 1 , wherein, inside one or more layers of carbon fibres, five radial segments are alternated with at least six transverse segments.

4. Shaped material according to claim 1 , wherein, relative to the direction of construction, the segments of one layer are angularly staggered with respect to the segments of an adjacent layer so that joining zones between the segments do not overlap through a thickness of said material.

5. Shaped material according to claim 1 , wherein the segments extend in a spiral around the direction of construction in a substantially continuous manner through the plurality of layers of carbon fibres.

6. Shaped material according to claim 1 , in which the number of layers of carbon fibres or the number of coils of said segments is in the range 18-40.

7. Shaped material according to claim 1 , in which the incident direction is substantially perpendicular to the radial direction.

8. Shaped material according to claim 1 , wherein at least part of the segments are in the form of a circular sector or circumference arc, of a circumferential width in the range 60-90°.

9. Shaped material according to claim 1 , wherein each segment comprises unidirectional carbon fibres, arranged in the radial direction or in the incident direction.

10. Shaped material according to claim 1 , wherein at least part of the carbon fibres, are derived from oxidised polyacrylonitrile fibres.

11. Shaped material according to claim 1 , in which the direction of construction is oriented parallel to a rotation axis of the shaped material or of the disc for a disc brake, during use.

12. Shaped material according to claim 1 , comprising areas of silicon carbide obtained by reaction of part of the carbon of said carbon fibres, and/or of a carbonaceous matrix of said shaped material, with at least part of a silicon infiltrated in said material, said regions of silicon carbide being arranged to bridge layers of adjacent carbon fibres.

13. Shaped material according to claim 1 , wherein the shaped material has a residual porosity of less than 5%.

14. A method for making a shaped material configured as a disc for a disc brake, comprising a plurality of layers of carbon fibres stacked in a direction of construction, each layer comprising a plurality of segments placed side by side and joined together to form said layer, the segments of a layer comprising radial segments and transverse segments;
wherein the radial segments are segments in which the carbon fibres are predominantly oriented in a radial direction relative to the direction of construction or oriented substantially parallel to the radial direction, and the transverse segments are segments in which the carbon fibres are directed in an incident direction incident to said radial direction;
wherein, in each layer of carbon fibres, the number of transverse segments is higher than the number of radial segments; the method, comprising the following steps:
i) in the direction of construction, stacking the plurality of layers of carbon fibres or of precursors of said fibres, each of said carbon fibres or of precursors of said fibres comprises the plurality of radial and transverse segments placed side by side and joined together to form said layer, the number of transverse segments of each layer being higher than the number of radial segments;
ii) subjecting the product of step i) to a heat treatment or to a thermochemical treatment, so as to densify said product and thereby obtain said shaped material;
iii) infiltrating the product of step ii) with an infiltrating agent comprising silicon or silicon carbide.

15. Method according to claim 14 , wherein the step of stacking comprises a step of arranging the segments in a spiral around the direction of construction, in a substantially continuous manner through the plurality of layers of carbon fibres.

16. Method according to claim 14 , wherein the infiltrating agent comprises silicon and wherein, during step iii), part of the carbon of the carbon fibres, and/or of a carbonaceous matrix of said shaped material, forms silicon carbide by reaction with part of the infiltrated silicon.

17. The shaped material according to claim 1 , wherein the plurality of layers of carbon fibres or precursors of said fibres stacked in the direction of construction comprises heat treated or thermochemically treated carbon fibres or precursors of said fibres.

18. The shaped material according to claim 1 , wherein the plurality of layers of carbon fibres or precursors of said fibres stacked in the direction of construction comprises carbon fibres or precursors of said fibres infiltrated with an infiltrating agent comprising silicon or silicon carbide.

19. A Method for making a shaped material configured as a disc for a disc brake, comprising a plurality of layers of carbon fibres stacked in a direction of construction, each layer comprising a plurality of segments placed side by side and joined together to form said layer, the segments of a layer comprising radial segments and transverse segments;
wherein the radial segments are segments in which the carbon fibres are predominantly oriented in a radial direction relative to the direction of construction or oriented substantially parallel to the radial direction, and the transverse segments are segments in which the carbon fibres are directed in an incident direction incident to said radial direction;
wherein, in each layer of carbon fibres, the number of transverse segments is higher than the number of radial segments; the method comprising the following steps:
i) stacking a plurality of layers of carbon fibres or of precursors of said fibres in the direction of construction, each of said carbon fibres or of precursors of said fibres comprises a plurality of radial and transverse segments placed side by side and joined together to form said layer, the number of transverse segments of each layer being higher than the number of radial segments;
ii) subjecting the product of step i) to a heat treatment or to a thermochemical treatment, so as to densify said product and thereby obtain said shaped material.

Assignees

• Freni Brembo Spa

Inventors

• Cividini Omar
• Miglioli Lorenzo

Classifications

• C04B35/573 Primary

  obtained by reaction sintering {or recrystallisation} · CPC title

• F16D65/121

  consisting of at least three circumferentially arranged segments · CPC title

• F16D65/126 Primary

  the material being of low mechanical strength, e.g. carbon, beryllium; Torque transmitting members therefor · CPC title

• C04B35/80

  Fibres, filaments, whiskers, platelets, or the like · CPC title

• F16D2200/0052

  Carbon · CPC title