TWM658191U - Carbon fiber ceramic brake disc - Google Patents

Abstract

A carbon fiber ceramic brake disc has a connection part, a plurality of ribs connected to the periphery of the connection part, and a brake ring connected to the periphery of the ribs; the brake disc has two end faces, and the brake ring has a brake surface formed on each end face. The main improvement is that the cross section of the brake disc along the end face includes: an inner layer and two outer layers; the inner layer includes at least two layers of 24K carbon fiber cloth glued to each other; the outer layer is respectively bonded to the outer surface of the inner layer, and includes at least one layer of 3K carbon fiber prepreg cloth, and a layer of composite colloid coated on the 3K carbon fiber prepreg cloth containing epoxy resin, nano ceramic powder and aluminum oxide. This can achieve many effects such as improved structural strength, lightweight and high heat dissipation.

Description

Carbon fiber ceramic brake disc

This work is about a bicycle component, in particular a carbon fiber ceramic brake disc for a bicycle.

As we all know, bicycle brakes are divided into two types: disc brakes and C-clamp brakes. Disc brakes have better braking performance than C-clamp brakes and will not cause frame burning, so they are gradually being widely used.

However, disc brakes still have some disadvantages. The biggest problem is that they easily generate high temperatures after long-term high-speed braking, and the temperature rises faster as the braking force increases. In extreme control environments, high temperatures may cause the disc brake system to fail or reduce braking force. Therefore, changing the brake disc structure, adding heat sinks or using composite materials can appropriately improve the heat dissipation effect in order to achieve a cooling effect.

However, simply changing the disc structure design can only improve the heat dissipation effect to a limited extent. The design of adding a heat sink not only fails to significantly improve the heat dissipation effect, but also increases the overall weight, which does not meet the lightweight requirements, and increases the complexity of the components and product costs. Composite materials, such as carbon fiber composite materials, have been used in the market as the main material of brake discs, but they are still prone to bursting or breaking during actual use, affecting driving safety.

This invention provides a carbon fiber ceramic brake disc, which has a connection part, a plurality of ribs connected to the periphery of the connection part, and a brake ring connected to the periphery of the ribs; the brake disc has two end faces, and the brake ring forms a brake surface on each end face. The main improvement is that the cross section of the brake disc along the end face includes: an inner layer and two outer layers; the inner layer includes at least two layers of 24K carbon fiber cloth glued to each other; the outer layer is respectively bonded to the outer surface of the inner layer, and includes at least one layer of 3K carbon fiber prepreg cloth, and a layer of composite colloid coated on the 3K carbon fiber prepreg cloth containing epoxy resin, nano ceramic powder and aluminum oxide.

The brake disc provided by this invention can ensure that the brake disc has sufficient structural strength by at least two layers of 24K carbon fiber cloth glued to each other on the inner layer, thereby preventing explosion or breakage from the inside.

The outer layer of the brake disc utilizes a structural design in which a composite colloid is coated on at least one layer of 3K carbon fiber prepreg. Not only can it be firmly bonded to the inner layer to improve structural strength and achieve lightweight, but it can also greatly improve heat dissipation and wear resistance through the characteristics of nano-ceramic powder and alumina, thereby maintaining good braking force, reducing pad wear, and improving riding safety.

As shown in Figures 1 to 3, the present invention provides a preferred embodiment of a carbon fiber ceramic brake disc, wherein the brake disc 10 has a centrally located connection portion 101, a plurality of ribs 102 extending and connected to the periphery of the connection portion 101, and a brake ring portion 103 connected to the periphery of the ribs 102; the brake disc 10 has two end faces 104, and the brake ring portion 103 has a brake surface 105 formed on each end face 104.

As is well known, the connection portion 101 can be installed on the hub of a bicycle. A brake caliper is usually installed on the front fork of the bicycle, which can be controlled to clamp the brake surface 105 of the brake ring 103, thereby achieving a braking effect.

The main improvements of this creation are:

The cross section of the brake disc 10 along the end surface 104 includes: an inner layer 11 and two outer layers 12; wherein:

The inner layer 11 includes at least two layers of 24K carbon fiber cloth 111 bonded to each other and formed with two outer surfaces 112 .

The outer layer 12 is respectively bonded to the outer surface 112 of the inner layer 11, and includes at least one layer of 3K carbon fiber prepreg 121, and a layer of composite colloid 122 coated on the 3K carbon fiber prepreg 121; the composite colloid 122 is mainly composed of epoxy resin, and is added with a diluent, a hardener, a dispersant, 30-35% of nano ceramic powder and aluminum oxide.

Preferably, the thickness of any layer of 24K carbon fiber cloth 111 of the inner layer 11 is 0.55-0.75 mm, and particularly preferably 0.65 mm.

Preferably, the thickness of any layer of the 3K carbon fiber prepreg 121 of the outer layer 12 is 0.25-0.45 mm, and particularly preferably 0.35 mm.

It should be noted that the "K" in the above 24K or 3K refers to the number of thousands of filaments in a bundle of carbon fibers. For example, 24K means 24,000 filaments in a bundle of carbon fibers, while 3K means 3,000 filaments in a bundle of carbon fibers. From the above definition, it is clear that the larger the K number, the thicker the corresponding carbon fiber bundle, but it does not mean that the strength is different. Usually, when thicker carbon fiber cloth needs to be woven, a carbon fiber bundle with a larger K number is used. Therefore, the inner layer of this creation uses 24K carbon fiber cloth, and usually only two layers are needed to meet the thickness requirements.

The inner layer 11 of the invention is composed of at least two layers of 24K carbon fiber cloth by gluing, which can ensure that the brake disc 10 has sufficient structural strength to prevent explosion or breakage from the inside.

The outer layer 12 of the invention is coated with a composite colloid 122 on at least one layer of 3K carbon fiber prepreg 121. The composite colloid 122 can not only be tightly and firmly bonded with the inner layer 11 under high temperature pressure and baking, further improving the overall structural strength and achieving lightweight, but also can greatly improve the heat dissipation and wear resistance through the characteristics of the internal nano-ceramic powder and alumina, thereby avoiding overheating due to continuous friction between the brake disc 10 and the brake pad or brake leather, so as to maintain good braking force, reduce brake pad wear, and improve riding safety.

The manufacturing method of the creative brake disc 10 is summarized as follows:

a. First, at least two layers of 24K carbon fiber cloth are bonded together by gluing to form the inner layer 11 structure.

b. Pour the pre-mixed composite colloid 122 into a mesh plate to coat the 3K carbon fiber prepreg 121.

c. The 3K carbon fiber prepreg 121 coated with the composite colloid 122 is stacked on the upper and lower outer surfaces 112 of the inner layer 11 structure to form a desired thickness, and then placed in a molding mold and baked and shaped at a high temperature of 180-240°C under pressure.

d. The carbon ceramic sheet product after baking and shaping is processed by a computer numerical control machine (CNC) to obtain the brake disc 10.

It should be particularly noted that the brake ring portion 103 is usually arranged with a plurality of heat dissipation holes 106 in a circular pattern. Since the structural strength of the present invention has been greatly enhanced, the present invention can increase the number or area ratio of the heat dissipation holes 106 to improve the heat dissipation effect without worrying about insufficient structural strength.

In addition, a hollow hole 107 is formed between any two of the ribs 102. The structural strength can be improved by appropriately reducing the area of the hollow hole 107.

In summary, this invention has excellent practicality among similar products. At the same time, after searching relevant domestic and foreign technical data or patent documents, no similar structure has been found before. Therefore, this invention has the requirements for a new patent, and an application is filed in accordance with the law. However, the above is only a partial feasible embodiment of this invention. Any equivalent structural changes made by applying the description of this invention and the scope of the patent application should be included in the patent scope of this invention.

10: Brake disc 101: Connection part 102: Rib 103: Brake ring 104: End face 105: Brake surface 106: Heat dissipation hole 107: Hollow hole 11: Inner layer 111: 24K carbon fiber cloth 112: Outer surface 12: Outer layer 121: 3K carbon fiber prepreg cloth 122: Composite colloid

[Figure 1] is a three-dimensional appearance diagram of the brake disc of this creation. [Figure 2] is a side view of one end of the brake disc of this creation. [Figure 3] is a cross-sectional view of this creation along the section line 1-1 of Figure 2. [Figure 4] is a partial enlarged view of Figure 3 of this creation.

11: Inner layer

111:24K carbon fiber cloth

112: External surface

12: Outer layer

121:3K carbon fiber prepreg

122: Composite colloid

Claims (5)

A carbon fiber ceramic brake disc has a central connection portion, a plurality of ribs extending and connected to the periphery of the connection portion, and a brake ring connected to the periphery of the ribs; the brake disc has two end faces, and the brake ring has a brake surface formed on each end face; its characteristics are: the cross section of the brake disc along the end face includes: an inner layer and two outer layers; wherein: the inner layer includes at least two layers of 24K carbon fiber cloth bonded to each other, and is formed with two outer surfaces; The outer layers are respectively bonded to the outer surfaces of the inner layers, and include at least one layer of 3K carbon fiber prepreg and a layer of composite colloid coated on the 3K carbon fiber prepreg; the composite colloid is based on epoxy resin and is added with diluent, hardener, dispersant, nano-ceramic powder and alumina. A carbon fiber ceramic brake disc as described in claim 1, wherein the thickness of any layer of 24K carbon fiber cloth in the inner layer is 0.55~0.75 mm. A carbon fiber ceramic brake disc as described in claim 2, wherein the thickness of any layer of 24K carbon fiber cloth in the inner layer is 0.65 mm. A carbon fiber ceramic brake disc as described in claim 1, wherein the thickness of any layer of 3K carbon fiber prepreg cloth on the outer layer is 0.25~0.45 mm. A carbon fiber ceramic brake disc as described in claim 4, wherein the thickness of any layer of 3K carbon fiber prepreg cloth on the outer layer is 0.35 mm.

Images