KR101242078B1 - One-body type carbon-ceramic brake disk and method for fabricating the same - Google Patents

Abstract

The present invention relates to an integrated carbon-ceramic brake disc and a method of manufacturing the same. The integrated carbon-ceramic brake disc of the present invention includes a hub portion, a first disk portion extending on an outer circumferential surface of the hub portion, and a predetermined distance from the first disk portion. A main body including a second disk portion extending on an outer circumferential surface of the hub portion; And a plurality of supporting guide members coupled between the first disk portion and the second disk portion to support the first and second disk portions and guide the flow of air. The members are carbonized and molten silicon infiltrated. In the present invention, not only the disk portion and the hub portion are integrally formed, but also the ceramics, and thus have excellent heat resistance, thereby minimizing thermal deformation. In addition, the manufacturing method of the integral carbon-ceramic brake disc of the present invention injects the molten mixture into an injection mold and then hardens the mixture to produce a molded product. do.

Description

ONE-BODY TYPE CARBON-CERAMIC BRAKE DISK AND METHOD FOR FABRICATING THE SAME}

The present invention relates to an integral carbon-ceramic brake disc and a method of manufacturing the same.

As shown in FIG. 1, a brake system of a vehicle includes a hub (also called a hat part) 10 connected to the axle, a brake disc 20 coupled to the hub 10, Brake pads (also referred to as linings) 30 positioned adjacent to the friction surface 21 of the brake disc 20 to selectively press the friction surface 21 of the brake disk 20. The brake disc 20 and the hub 10 are coupled by a coupling means 40.

The brake system is a friction force generated by the friction between the brake pad 30 and the friction surface 21 of the brake disk 20 as the brake pads 30 press the friction surface 21 of the brake disk 20. By slowing or stopping the rotation of the brake disc 20, the speed of the vehicle equipped with the brake system is slowed down or stopped.

Recently, the brake disc 20 and the brake pad 30 are made of a carbon fiber reinforced ceramic composite in order to increase wear resistance, heat resistance, and light weight of the brake disc and the pad. Carbon fiber reinforced ceramic composites are materials in which the matrix is ceramic and reinforced with carbon fibers. Hereinafter, the brake disc 20 made of a carbon fiber reinforced ceramic composite will be referred to as a carbon-ceramic brake disc.

The hub 10 is generally made of stainless steel having excellent corrosion resistance and good workability. The coupling means are generally used bolts and nuts, the bolts and nuts are also made of stainless steel.

The assembly in which the hub and the brake disc are joined by the coupling means is called a hub-disk assembly.

In the brake system, when the brake pad 30 is pressed against the friction surface 21 of the brake disk 20 to generate a braking force on the brake disk 20, the brake disk 20 and the brake pad 30 may be hot. Friction heat is generated. When the high temperature heat generated by the brake disc 20 is not radiated to the outside smoothly, the high temperature heat generated by the brake disc 20 is transferred to the hub 10 to the hub 10 and the brake disc 20. The distortion, ie deformation, occurs in the brake disc 20 or the hub 10 due to the difference in the coefficient of thermal expansion.

As one of methods for dissipating heat generated from the brake disc to the outside, as shown in FIG. 2, the brake disc includes a plurality of cooling channels 21 passing through the inner and outer circumferential surfaces of the brake disc. The cooling channels 21 vary in shape. When the brake disc 20 rotates, air flows through the center hole H formed in the center of the brake disc 20 and flows through the cooling channels 21 to flow to the outer circumferential surface of the brake disc 20. As air flows through the cooling channels 21, the heat of friction generated in the brake disc 20 is radiated to the outside.

On the other hand, the prior art for manufacturing the hub-disk assembly is mostly manufacturing the hub 10 and the carbon-ceramic brake disc 20, respectively, the hub 10 and the carbon-ceramic brake disc 20 coupling means ( 40) to each other.

In addition, in the conventional method of manufacturing the carbon-ceramic brake disc, as shown in FIG. 3, the first layer L1 is formed by filling a mixture containing carbon fibers and a phenol resin in the mold 100. . The mold 100 has a cylindrical shape in which one side is blocked.

In addition, the core C having the plurality of through holes 2 is inserted into the mold 100 so as to be placed on the first layer L1. The material of the core C is plastic.

The mixture containing the carbon fibers and the phenol resin is put in the through holes 2 of the core C, respectively. Filling the mixture in the mold 100 to form a second layer (L2) on the core (C).

The first layer L1, the core C, and the second layer L2 in the mold 100 are heated under pressure to form a cured molded body, and the molded body is removed from the mold 100. At this time, the first layer L1, the core C, and the second layer L2 are pressed using the press 300.

The molded body is placed in a furnace and heated to a high temperature to carbonize the molded body. The temperature at which the molded body is heated is 1000 to 2000 degrees, which is the temperature at which the molded body is carbonized. In the process of carbonizing the molded body, the core C located inside the molded body is melted and removed from the molded body. As the core C is melted away, the portion where the core C is located forms the cooling channels 24.

In some cases, a friction plate forming a friction layer is attached to outer surfaces of the first and second layers L1 and L2, respectively. The friction plate has a ring shape having a uniform thickness and is a carbonized carbide containing short fibers.

The molten silicon is infiltrated into the machined carbonized molded body. Since the temperature at which the silicon is melted is 1400 to 1700 degrees, the silicon is melted at this temperature to penetrate into the carbonized body.

As the molten silicon penetrates into the carbonized body, it reacts with the carbonized carbonized body to form silicon carbide (SiC), and the unreacted silicon (Si) solidifies and remains.

The result is a carbon-ceramic brake disc whose matrix is silicon carbide, ie ceramic and carbon fiber reinforced. The carbon-ceramic brake disc is post processed.

The carbon-ceramic brake disc thus produced is combined with the hub by the coupling means as described above.

However, in the conventional hub-disk assembly as described above, since the carbon-ceramic brake disc 20 and the hub 10 are made of different materials, the thermal expansion coefficients of the carbon-ceramic brake disc 20 and the hub 10 are different from each other. This causes distortion, ie deformation, in the carbon-ceramic brake disc 20 and the hub 10.

In addition, the conventional hub-disc assembly includes a carbon-ceramic brake disc, a hub 10, and a coupling means 40, so that many components are complicated. And since the hub and the coupling means are made of stainless steel, respectively, the weight of the hub and the coupling means is heavy.

In addition, when the carbon-ceramic brake disc is manufactured, carbon fiber and a phenol resin are mixed and inserted into the mold 100, and then the mixture is pressurized and heated to produce a cured molded body. Is not high, so the amount of post processing is large. The densified molded body has a high strength and is not easy to be processed, so if a large amount of post processing is required, it takes a lot of processing time to reduce productivity.

An object of the present invention is to provide an integrated carbon-ceramic brake disc and a method of manufacturing the same that minimize thermal deformation due to frictional heat generated during braking.

Another object of the present invention is to provide an integral carbon-ceramic brake disc and a method of manufacturing the same that not only simplify the components but also reduce the weight.

It is another object of the present invention to provide an integrated carbon-ceramic brake disc which minimizes the amount of post-processing and a manufacturing method thereof.

In order to achieve the object of the present invention as described above, a hub portion, a first disk portion extending on the outer peripheral surface of the hub portion, and a second disk portion extending on the outer peripheral surface of the hub portion at regular intervals with the first disk portion Main body; And a plurality of supporting guide members coupled between the first disk portion and the second disk portion to support the first and second disk portions and guide the flow of air. The members are provided with an integral carbon-ceramic brake disc, characterized by carbonization and molten silicon infiltration.

The hub portion may be formed in a cylindrical shape with one side blocked, and a through hole is provided in the cylindrical blocked surface.

The hub portion may be formed in a cylindrical shape with both openings.

The supporting combined guide member has a vane shape, and is preferably inserted between the first disk portion and the second disk portion.

The dual purpose guide member may have a pin shape having a predetermined length, and may be coupled to the first and second disk portions through the first and second disk portions.

Preferably, the hub portion has through holes provided in an area between the first disk portion and the second disk portion.

Preferably, the hub portion and the first and second disk portions include silicon carbide, carbon (carbon fiber), and silicon components.

The hub portion of the main body preferably comprises long fibers or continuous fibers.

In addition, to achieve the object of the present invention, melting the mixture; Injecting the molten mixture into a mold having a molding space having a shape of the hub portion and the first and second disk portions; Solidifying the mixture injected into the mold; Separating the molding hardened in the mold from the mold; Coupling the support and guide members to the molding; Carbonizing a molded article to which the supporting guide members are coupled; And impregnating molten silicon into the carbonized molding.

It is preferable that the said mixture contains a phenol resin and carbon fiber.

It is preferable to insert long fibers or continuous fibers into the hub portion of the molding space before injecting the molten mixture into the molding space of the mold.

According to the present invention, the hub portion 61 coupled to the axle, the first and second disk portions provided with the friction surface, and the supporting guide members are integrally formed and made of a ceramic material. The disk portion and the supporting guide member have a large heat resistance, so that the thermal deformation is reduced.

In addition, the present invention since the hub portion and the first and second disk portion are integrally formed, there is no need for a separate coupling means, so that the component parts are simplified, and the hub portion is made of ceramic and is not made of metal. The weight is reduced because the use of means is eliminated.

In addition, in the present invention, since the molten mixture is injected into an injection mold and then the mixture is hardened to produce a molded product, the dimensional accuracy is high after carbonization and densification (melt silicon infiltration), thereby reducing the amount of post-processing. This increases the productivity of the product.

1 is a side view showing a general brake system,
FIG. 2 is a perspective view illustrating a carbon-ceramic brake disc having cooling channels constituting the brake system; FIG.
3 is a cross-sectional view sequentially showing each conventional method of manufacturing the carbon-ceramic brake disc;
4 and 5 are a perspective view and a cross-sectional view showing one embodiment of an integrated carbon-ceramic brake disc according to the present invention;
Figure 6 is a perspective view showing one embodiment of a combined support guide member constituting an embodiment of the integrated carbon-ceramic brake disc according to the present invention,
Figure 7 is a perspective view showing another embodiment of the combined support guide member constituting an embodiment of the integrated carbon-ceramic brake disc according to the present invention and the arrangement thereof,
8 is a flow chart showing a manufacturing method of an integrated carbon-ceramic brake disc according to the present invention;
9 is a front view schematically showing an injection molding machine used in the method of manufacturing the integrated carbon-ceramic brake disc according to the present invention;
10 is a cross-sectional view showing an embodiment of an injection mold used in the manufacturing method of the integral carbon-ceramic brake disc according to the present invention;
11 is a cross-sectional view showing a first molded product molded by the injection mold;
12 is an enlarged partial cross-sectional view of a portion of the first molding;
13 is a cross-sectional view showing a mold for hot press molding;
14 is a cross-sectional view showing a supporting combined guide member bonded to the first molded article and the first molded article;
15 is a sectional view of a second molding,
16 is a sectional view showing another embodiment of a mold.

Hereinafter, an embodiment of an integrated carbon-ceramic brake disc and a method of manufacturing the same according to the present invention will be described with reference to the accompanying drawings.

First, Figure 4 is a perspective view showing one embodiment of an integrated carbon-ceramic brake disc according to the present invention. 5 is a cross-sectional view of one embodiment of the integral carbon-ceramic brake disc.

4 and 5, an embodiment of the integrated carbon-ceramic brake disc according to the present invention includes a hub portion 61, a first disc portion 62 extending on an outer circumferential surface of the hub portion 61, A main body (K) including a second disk portion (63) extending on an outer circumferential surface of the hub portion (61) at a predetermined distance from the first disk portion (62); And a plurality of supporting guide members 64 coupled between the first disk portion 62 and the second disk portion 63. The assembly of the main body K and the supporting guide member 64 is made of carbonization and molten silicon infiltration.

Preferably, the main body K and the plurality of support and guide members 64 are made of the same material. The hub portion 61 and the first and second disk portions 62 and 63 preferably include silicon carbide, carbon (carbon fiber), and silicon components.

Similar to the cup shape, the hub portion 61 is formed in a cylindrical shape with one side blocked, and the first through hole 61a is provided in the cylindrical blocked surface. A plurality of fastening holes (not shown) connected to an axle (not shown) may be provided on the cylindrical blocked surface. The hub portion 61 is preferably provided with second through holes 61b in an area between the first disk portion 62 and the second disk portion 63.

The first disk portion 62 is preferably formed in a ring shape having a uniform thickness and width. The first disk portion 62 extends to protrude from an open outer peripheral surface of one end of the hub portion 61. The second disk portion 63 is preferably formed in a ring shape having a uniform thickness and width. The first disk portion 62 preferably has the same size and shape as the second disk portion 63. The first disk portion 62 and the second disk portion 63 are disposed parallel to each other. The surfaces of the first and second disk portions 62 and 63 that face each other are the inner surfaces, and the surfaces that do not face each other are the outer surfaces, and the outer surfaces of the first and second disk portions 62 and 63 respectively. This friction surface becomes.

Hub portion 61 of the main body (K) preferably includes long fibers or continuous fibers to increase the strength. The long fiber and the continuous fiber are preferably carbon fibers. The continuous fiber is preferably in the form of a woven or prepreg.

The plurality of supporting guide members 64 not only support the first and second disk portions 62 and 63, but also guide the flow of air between the first and second disk portions 62 and 63.

Preferably, the plurality of supporting guide members 64 are formed in the same size and shape. As shown in FIG. 6, the supporting combined guide member 64 has a vane shape. The vane-shaped support and guide member 64 is inserted between the first disk portion 62 and the second disk portion 63. In this case, coupling grooves are formed on inner surfaces of the first and second disk portions 62 and 63, respectively, and both portions of the vane-shaped support and guide member 64 are formed in the first and second disk portions 62. It is preferable to be inserted into each of the coupling groove of the (63). The vane-shaped support and guide members 64 are arranged at regular intervals in the circumferential direction of the first and second disk portions 62 and 63.

In another embodiment of the dual purpose guide member 64, as shown in Figure 7, the dual purpose guide member 64 may be formed in a pin shape having a predetermined length. The pin-shaped support and guide member 64 is coupled to the first and second disk portions 62 and 63 through the first disk portion 62 and the second disk portion 63.

The pin-shaped support and guide members 64 are arranged in a row in the radial direction (radiation direction) of the first and second disk portions 62 and 63, and the rows thereof are preferably arranged at regular intervals in the circumferential direction. Do.

A brake band (not shown) is positioned next to each friction surface of the first and second disk parts 62 and 63, and the hub part 61 is coupled to an axle (not shown) of the vehicle.

8 is a flowchart illustrating a method of manufacturing an integrated carbon-ceramic brake disc according to the present invention.

As shown in FIG. 8, one embodiment of a method of fabricating an integrated carbon-ceramic brake disc according to the present invention comprises the steps of: melting a mixture; Injecting the molten mixture into a mold having a molding space having a shape of a hub portion and first and second disk portions; Solidifying the mixture injected into the mold; Separating the molding hardened in the mold from the mold; Coupling the support and guide members to the molding; Carbonizing a molded article to which the supporting guide members (64) are combined; And impregnating molten silicon into the carbonized molding.

The mixture comprises phenolic resin, fibers. It is preferable that the said phenol resin is in powder form, and it is preferable that the said fiber is carbon fiber. It is preferable to melt the phenol resin upon melting the mixture.

Making a molding using the mold can be produced by hot press molding or injection molding (injection molding). In addition, the support combined guide member may also be produced by hot press molding or injection molding.

First, a method for producing a molded article by injection molding will be described.

9 is a side view illustrating an example of an injection molding machine. As shown in FIG. 9, the injection molding machine includes a mold assembly A including a mold 600, and a mixture melting apparatus B for melting a mixture in the mold 600 and injecting the mixture into the mold 600. Include.

The mixture melting apparatus (B) includes a process tube 710 having a set length, a screw 720 inserted into the process tube 710, a driving unit 730 rotating the screw 720, and , And an injection guide 740 connected to one side of the process tube 710 and a heating unit 750 installed in the process tube 710.

One end of the process tube 710 is provided with a funnel-shaped outlet portion 711 of which the inner diameter is reduced. The mold 600 is connected to the outlet 711.

The heating unit 750 is preferably composed of three heaters, that is, the first heater 751, the second heater 752, the third heater (753).

The process of melting the mixture using the mixture melting apparatus (B) is as follows.

In the state in which the heating unit 750 operates and the driving unit 730 rotates the screw 720, a mixture containing phenol resin and carbon fiber is placed in the injection guide 740. The mixture is introduced into the process tube 710 through the injection guide 740 and simultaneously transferred to the outlet 711 along the screw 720 by the rotation of the screw 720. By the rotation of the screw 720, the mixture is more evenly mixed and continuously moving toward the outlet 711. The mixture is injected into the mold 600 through the outlet part 711 while being melted by the heat of the heaters while passing through the 1,2 and 3 heater regions. The molten mixture is in a molten state of the phenol resin.

The molten mixture injected into the mold 600 is cooled. The mold 600 is separated to separate the molding formed by cooling the melt mixture from the mold 600. The molding is a main body K consisting of the hub portion 61 and the first and second disk portions 62 and 63 described above.

In a first embodiment of the mold 600, as shown in FIG. 10, a cavity mold 610 having an internal space, and a cavity mold assembled with the cavity mold 610. A core mold 620 that forms a molding space with the interior space of 610 is included.

The cavity mold 610 is composed of two half cavity molds 610A and 610B. The half cavity mold has a shape in which the cavity mold 610 is cut in half. Therefore, the two half cavity molds 610A and 610B are formed in the same shape.

The core mold 620 includes a base plate 621 and a cylindrical shaft 622 protruding to the base plate 621 by a predetermined length. An injection passage 623 is formed in the cylindrical shaft 622.

The core mold 620 is fixed. Each lower surface of the two half cavity molds 610A and 610B is slidably contacted with the base plate 621 of the core mold 620. The two half cavity molds 610A and 610B are in contact with each other. Is a linear reciprocating motion around the cylindrical shaft 622. In a state where the two half cavity molds 610A and 610B are joined to each other, the cylindrical shaft 622 is located in an inner space of the two half cavity molds 610A and 610B. A molding space is formed by the outer surface of the cylindrical shaft 622 and the inner surfaces of the inner spaces of the two half cavity molds 610A and 610B. The molding space includes a hub portion space S1 forming the hub portion 61 and first and second disk portion spaces S2 and S3 forming the first and second disk portions 62 and 63.

An injection passage 623 formed in the cylindrical shaft 622 communicates with the molding space, and the injection passage 623 is connected to an outlet portion 711 of the mixture melting apparatus B.

The molten mixture which is pushed out through the outlet 711 of the mixture melting apparatus B while the two half cavity molds 610A and 610B are joined together with the core mold 620 is an injection passage 623. Filling the molding space while flowing into the molding space through.

As shown in FIG. 11, the molded article formed through the mold 600 of the first embodiment includes first and second disks each extending from a cup-shaped hub portion 61 and an outer circumferential surface of the hub portion 61. Part 62 and 63 are made.

Meanwhile, as illustrated in FIG. 12, a plurality of through holes 61b may be formed in an area of the hub portion 61 positioned between the first and second disk portions 62 and 63. The through holes 61b may be formed by processing a molding by using a separate machine, and may also form through holes in a process of forming the molding by installing a hole forming apparatus inside the core mold.

An embodiment of the hole forming apparatus includes pins sliding through the cylindrical shaft of the core mold and a driving unit for linearly reciprocating the pins.

In the state where the two half cavity molds 610 and the core mold 620 are combined, the pins 630 are pushed into the hub portion space S1 of the molding space. Then, the molten mixture is injected into the molding space and the mixture is hardened. The pins 630 are removed from the molding space and the two half cavity molds 610A and 610B are separated from each other to separate the molding from the mold. The molding includes a hub 61 and first and second disks 62 and 63, and a plurality of through holes 61b are provided in the hub 61.

On the other hand, when the molded article consisting of the hub portion and the first and second disk portion is produced by hot press molding as follows.

As an example of a mold to be used for hot press molding, as shown in FIG. 13, a first mold M1 having a space in which a hub portion and a second disk portion are formed, and a space in which a first disk portion is formed, are provided. And a second frame M2 provided therein, a ring-shaped intermediate plate M4 positioned between the first frame M1 and the second frame M2 to partition the space of the first and second disk portions, and the first frame. And a press shaft M3 inserted reciprocally in the two molds M1 and M2 and the ring-shaped intermediate plate M4. The first and second molds M1 and M2 and the ring-shaped intermediate plate M4 are called mold assemblies.

The molten mixture is injected into the mold assembly of the mold while the press shaft M3 is removed from the mold assembly. The press shaft M3 is inserted into the mold assembly with the molten mixture injected into the mold assembly at a set temperature. After cooling the molten mixture, the press shaft M3 is removed, the second mold M2 and the ring-shaped intermediate plate M4 are separated, and the molding is separated from the first mold M1.

On the other hand, before injecting the molten mixture into the mold assembly of the mold insert the long fiber or continuous fiber in the space corresponding to the hub portion of the inner space of the mold assembly and then inject the molten mixture into the inner space of the mold assembly have. The long fiber and the continuous fiber are preferably carbon fibers. The continuous fiber is preferably in the form of a woven or prepreg. In this case, long fibers or continuous fibers are inserted into the hub part in the final molding.

As shown in FIG. 14, the support and guide members 64 are coupled to the molded article provided with the hub portion and the first and second disk portions.

The dual purpose guide member 64 may have a vane shape and a pin shape, as described above.

When the supporting combined guide member 64 has a vane shape, it is inserted between the first disk portion 62 and the second disk portion 63 of the molding. In this case, coupling grooves are formed on inner surfaces of the first and second disk portions 62 and 63, respectively, and both portions of the vane-shaped support and guide member 64 are formed in the first and second disk portions 62. Are respectively inserted into the coupling groove of the (63). The vane-shaped support and guide members 64 are arranged at regular intervals in the circumferential direction of the first and second disk portions 62 and 63.

When the dual purpose guide member 64 has a pin shape, as described above, the dual guide member 64 having a pin shape penetrates through the first disk portion 62 and the second disk portion 63 of the molding. It is coupled to the first and second disk portions 62 and 63. The pin-shaped support and guide members 64 are arranged in a row in the radial direction (radiation direction) of the first and second disk portions 62 and 63, and the rows thereof are preferably arranged at regular intervals in the circumferential direction. Do.

The support combined guide member 64 is manufactured by using a mold for manufacturing a guide member (not shown). The molten mixture injected into the mold for manufacturing the guide member is preferably made of the same material as the molten mixture used for the molded product consisting of the hub portion 61 and the first and second disk portions 62 and 63.

Meanwhile, the molded article combined with the supporting guide members 64 is placed in a furnace and heated to a high temperature to carbonize the molded article. The temperature for heating the molding is 900 to 1200 degrees, the temperature at which the molding is carbonized.

Ring-shaped carbides having a thin thickness may be attached to both sides of the disk portion 62 of the carbonized molding. The ring shaped carbide forms a friction layer in the final product.

The molten silicon is infiltrated into the carbonized molding. The temperature at which the silicon is melted is 1400 to 1700 degrees, so silicon is melted and penetrated into the carbonized molding at this temperature. As the molten silicon penetrates into the carbonized molding, it reacts with the carbonized molding to become silicon carbide and the unreacted silicon remains and solidifies upon cooling.

After the molten silicon is infiltrated into the carbonized product, the carbonized product in which the silicon is infiltrated is cooled.

The molten silicon impregnated and reacted to the carbonized molded body is a silicon carbide, that is, an integral carbon-ceramic brake disc with ceramic and carbon fiber reinforced. The integral carbon-ceramic brake discs are microfabricated for precise dimensions. Since the molding is manufactured to precise dimensions in the mold, the final result is precisely dimensioned, thereby reducing post-processing.

On the other hand, in the second embodiment of the molding, as shown in Fig. 15, a cylindrical hub portion 61 'having a cylindrical shape with both openings and a first formed on the outer peripheral surface of one end of the cylindrical hub portion 61'. The disk part 62 and the 2nd disk part 63 extended in the outer peripheral surface of the other end of the said cylindrical hub part 61 '. The support and guide members 64 are coupled between the first and second disk portions 62 and 63 of the molding.

As shown in Fig. 16, the molded product can be produced by changing the mold shape of the first embodiment. The mold is composed of two half cavity molds 610C and 610D and a core mold 620 that form a cylindrical hub space having both sides opened and a first and second disk space.

After the molding of the second embodiment undergoes carbonization and molten silicon infiltration, the hub is coupled to the molding of the second embodiment by a coupling means.

Hereinafter, the operation and effects of the integrated carbon-ceramic brake disc and its manufacturing method according to the present invention will be described.

According to the present invention, the hub portion 61 coupled to the axle, the first and second disk portions 62 and 63 having friction surfaces, and the support and guide members 64 are integrally formed and made of ceramic material. As a result, the hub portion 61, the first and second disk portions 62 and 63, and the support and guide member 64 become large in heat resistance, thereby reducing heat deformation.

In addition, since the hub part 61 and the first and second disk parts 62 and 63 are integrally formed, the present invention eliminates the need for a separate coupling means, thereby simplifying components, and the hub part 61. The weight is lighter because it does not consist of metal but consists of ceramic and excludes the use of coupling means, which are metal parts.

In addition, the present invention, after injecting the molten mixture into the injection mold to harden the mixture to produce a molded article, high dimensional accuracy after carbonization and densification (melt silicon infiltration) to reduce the amount of post-processing. Conventionally, carbon fibers and phenol resins are mixed and inserted into a mold, and then the mixture is heated under pressure to produce a cured molded body, so that the dimensional accuracy is not high after carbonizing and densifying the molded body, thereby increasing the post-processing amount. Since the densified molding (or molded body) has a high strength, it is not easy to process, so if the post-processing amount is large, the processing time takes a lot, thereby decreasing productivity.

61; Hub portion 62; 1st disc part
63; Second disk portion 64; Support combined guide member

Claims (11)

And a hub portion, a second disk portion with the first disk portion, said first disk portion and a predetermined distance extending to the outer circumference of the hub portion extending on the outer circumference of the hub portion, which is located between the first and second disc portions group A through hole provided in an area of the hub portion, wherein the hub portion and the first and second disk portions are integrally formed with the main body;
It is coupled between the first disk portion and the second disk portion, and includes a plurality of support and guide members for supporting the flow of air as well as supporting the first and second disk portion,
The main body and the supporting guide member are integral carbon-ceramic brake discs characterized in that the carbon and molten silicon infiltration. The integrated carbon-ceramic brake disc of claim 1, wherein the hub portion is formed in a cylindrical shape with one side blocked, and a through hole is provided in the cylindrical blocked surface. 2. The integral carbon-ceramic brake disc of claim 1, wherein the hub portion is formed in a cylindrical shape with both openings. 2. The integrated carbon-ceramic brake disc of claim 1, wherein the dual guide member is vane-shaped and is inserted between the first disc portion and the second disc portion. The integrated carbon-ceramic brake according to claim 1, wherein the support and guide member has a pin shape having a predetermined length and is coupled to the first and second disk portions through the first and second disk portions. disk. delete 2. The integrated carbon-ceramic brake disc of claim 1, wherein the hub portion and the first and second disc portions comprise silicon carbide, carbon (carbon fiber), and silicon components. 2. The integral carbon-ceramic brake disc of claim 1 wherein the hub portion of the main body comprises long fibers or continuous fibers. Melting the mixture;
Injecting the molten mixture into a mold having a molding space having a shape of a hub portion and a first and second disk portions;
Solidifying the mixture injected into the mold;
Separating the molding hardened in the mold from the mold;
Coupling the support and guide members of claim 1 between the first and second disk portions of the molding;
Carbonizing a molded article to which the supporting guide members are coupled; And
A method of fabricating an integral carbon-ceramic brake disc comprising the step of permeating molten silicon into the carbonized molding. 10. The method of claim 9, wherein the mixture comprises a phenolic resin and carbon fibers. 10. The method of claim 9, wherein a long fiber or a continuous fiber is inserted into a hub of the molding space before the molten mixture is injected into the molding space of the mold.

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