초록 ▼

An integrated brake pad and back plate having a brake pad section formed from a first fiber reinforced ceramic matrix composite (FRCMC) material and a back plate section formed from a second FRCMC material. The brake pad and back plate are integrated because the sections are molded together to form

An integrated brake pad and back plate having a brake pad section formed from a first fiber reinforced ceramic matrix composite (FRCMC) material and a back plate section formed from a second FRCMC material. The brake pad and back plate are integrated because the sections are molded together to form an integral, unitary structure. The first FRCMC material used in the brake pad section includes a pre-ceramic resin in its ceramic state, fibers and possibly a filler material. The types and amount of these constituents are generally chosen so as to impart characteristics desirable in brake pads, such as high temperature and erosion resistance, and a high coefficient of friction. The second FRCMC material used in the back plate section includes a pre-ceramic resin in its ceramic state and fibers. In this case, the types and amounts of the constituents making up the second FRCMC material are generally chosen to impart the strength to the back plate section necessary to withstand compressive and bending forces placed upon it during braking.

대표청구항 ▼

[ Wherefore, what is claimed is:] [1.] A method of forming an integrated fiber reinforced ceramic matrix composite (FRCMC) brake pad and back plate structure comprising the steps of:(a) placing at least one sheet of woven, continuous fibers which has been saturated in a pre-ceramic resin into a bott

[ Wherefore, what is claimed is:] [1.] A method of forming an integrated fiber reinforced ceramic matrix composite (FRCMC) brake pad and back plate structure comprising the steps of:(a) placing at least one sheet of woven, continuous fibers which has been saturated in a pre-ceramic resin into a bottom portion of a female die of a mold;(b) placing a quantity of FRCMC bulk molding compound into an upper portion of the female die of the mold on top of the at least one woven fiber sheet, said FRCMC bulk molding compound comprising a pre-ceramic resin and loose fibers;(c) pressing a male die of the mold onto the female die so as to mold said brake pad and back plate structure in a cavity formed between the female and male dies, said bottom portion of the female die forming a first part of the cavity having a shape corresponding to a desired shape of a back plate section of the structure and the upper portion of the female die forming a second part of the cavity having a shape corresponding to a desired shape of a brake pad section of the structure;(d) heating the mold at a temperature and for a time associated with the pre-ceramic resin that polymerizes the resin to form a fiber-reinforced polymer composite part;(e) removing the polymerized composite part from the mold;(f) heating the polymerized composite part at a temperature and for a time associated with the polymerized resin which pyrolyses it;(g) immersing the FRCMC structure containing pores formed during step (f) into a bath of a pre-ceramic resin to fill the pores;(h) heating the FRCMC structure at a temperature and for a time associate with the resin filling said pores so as to transform it to a ceramic material; and(i) repeating steps (g) and (h) until the pore density within the FRCMC structure is less than a prescribed percentage by volume.