A method for forming a material for a brake disc, the method comprising the steps of: (i) providing at least one porous body; (ii) introducing into pores of the porous body one or more precursor materials for forming or depositing a ceramic material; and (iii) forming the brake disc material by form
A method for forming a material for a brake disc, the method comprising the steps of: (i) providing at least one porous body; (ii) introducing into pores of the porous body one or more precursor materials for forming or depositing a ceramic material; and (iii) forming the brake disc material by forming or depositing the ceramic material from the precursor material within the pores of the body, wherein the precursor material is a liquid containing a suspension of ceramic particles and/or acid phosphate.
대표청구항▼
1. A method for forming a material for a brake disc, the method comprising the steps of: (i) providing at least one porous body;(ii) introducing into pores of the porous body one or more precursor materials for forming or depositing a ceramic material , wherein the precursor material is introduced t
1. A method for forming a material for a brake disc, the method comprising the steps of: (i) providing at least one porous body;(ii) introducing into pores of the porous body one or more precursor materials for forming or depositing a ceramic material , wherein the precursor material is introduced throughout the porous body from first to second surfaces on opposite sides of the porous body ; and(iii) forming a brake disc material comprising said porous body and the ceramic material by a process comprising depositing the ceramic material from the precursor material within the pores of the porous body or forming the ceramic material from the precursor material within the pores of the porous body,wherein the precursor material is a liquid containing a suspension of ceramic particles and/or acid phosphate;wherein step (iii) of forming the brake disc material comprises an operation selected from the group consisting of:a) depositing the ceramic material from the precursor material within the pores of the porous body, wherein the precursor material is the liquid containing the suspension of the ceramic particles, and the ceramic particles are particles of the ceramic material, followed by heating the porous body to form the brake material comprising the porous body and the deposited ceramic material;b) depositing the ceramic material from the precursor material within the pores of the porous body, wherein the precursor material is the liquid containing the suspension of the ceramic particles, and the ceramic particles are particles of the ceramic material, followed by vitrifying the ceramic particles to form the brake material comprising the porous body and the deposited ceramic material;c) forming the ceramic material from the precursor material within the pores of the porous body, wherein the precursor material is the liquid containing the suspension of the acid phosphate, followed by curing or vitrifying the acid phosphate in the absence of any other reactant;d) forming the ceramic material from the precursor material within the pores of the porous body, wherein the precursor material is the liquid containing the suspension of the ceramic particles and the acid phosphate, followed by curing or vitrifying the ceramic particles and the acid phosphate in the absence of any other reactant; ande) forming a chemically bonded phosphate ceramic by reacting the acid phosphate with a metal oxide wherein the precursor material is the liquid containing the suspension of the acid phosphate and further containing the metal oxide. 2. A method as claimed in claim 1, wherein the porous body comprises one or more materials selected from carbon, silicon and alumina. 3. A method as claimed in claim 1, wherein, in step (i), the porous body comprises a collection of fibres, which comprise carbon. 4. A method as claimed in claim 1, wherein the ceramic particles comprise a material selected from one or more of alumina, zirconia, magnesia, yttria, silicon carbide, silica, boron carbide, boron nitride, titanium boride, iron oxides and chromium oxides. 5. A method as claimed in claim 1, wherein the precursor material comprises a Sol of ceramic particles. 6. A method as claimed in claim 1, wherein the precursor material is introduced into the pores of the porous body by one or more techniques selected from vacuum infiltration, immersion of the porous body at least partially into the precursor material, painting the porous body with the precursor material and spraying the porous body with the precursor material. 7. A method as claimed in claim 1, wherein the ceramic particles of the precursor material are deposited into the pores by one or more means selected from electrically charging the porous body, freezing the porous body, introduction of an acidic or alkaline material and introducing into the pores a material containing particles having an opposite charge from the particles in the suspension. 8. A method as claimed in claim 1, wherein in step (ii) and/or step (iii) the porous body and the precursor material are exposed to an ultrasonic treatment. 9. A method as claimed in claim 1, wherein the acid phosphate comprises one or more of potassium acid phosphate, calcium acid phosphate, ammonium acid phosphate and aluminum acid phosphate. 10. A method as claimed in claim 1, wherein the acid phosphate comprises mono aluminum phosphate. 11. A method as claimed in claim 1, wherein step (iii) or subsequent treatment forms a brake disc from the brake disc material. 12. A method as claimed in claim 11, wherein the mean surface roughness of the brake disc so formed is 30 microns Rz or less. 13. A method as claimed in claim 1, the method comprising in step (i) providing two or more porous bodies and placing the porous bodies together to form a combined porous body; andcarrying out steps (ii) and (iii) on the combined porous body to form the material for a brake disc. 14. A method as claimed in claim 13 wherein, in step (iii), the combined porous body forms a multi-brake-disc stack. 15. A method as claimed in claim 1, the method comprising providing two or more porous bodies and placing the porous bodies together to form a combined porous body, which may be a multi-brake disc stack, wherein at least one of the porous bodies contains within its pores a ceramic material. 16. The method of claim 1 wherein the forming the brake disc material comprises the (a) depositing the ceramic material from the precursor material within the pores of the porous body, wherein the precursor material is the liquid containing the suspension of the ceramic particles, and the ceramic particles are particles of the ceramic material, followed by heating the body. 17. The method of claim 16 wherein the brake disc material formed by the heating consists essentially of the porous body and the deposited ceramic materials from the precursor in the porous body. 18. The method of claim 1 wherein the forming the brake disc material comprises the (b) depositing the ceramic material from the precursor material within the pores of the porous body, wherein the precursor material is the liquid containing the suspension of the ceramic particles, and the ceramic particles are particles of the ceramic material, followed by vitrifying the ceramic particles. 19. The method of claim 18 wherein the brake disc material formed by the vitrifying consists essentially of the porous body and the deposited ceramic materials from the precursor in the porous body. 20. The method of claim 1 wherein the forming the brake disc material comprises the (c) forming the ceramic material from the precursor material within the pores of the porous body, wherein the precursor material is the liquid containing the suspension of the acid phosphate, followed by curing or vitrifying the acid phosphate in the absence of any other reactant. 21. The method of claim 20 wherein the brake disc material formed by the curing or vitrifying consists essentially of the porous body and phosphate ceramics formed in the absence of any other reactant in the porous body. 22. The method of claim 1 wherein the forming the brake disc material comprises the (d) forming the ceramic material from the precursor material within the pores of the porous body, wherein the precursor material is the liquid containing the suspension of the ceramic particles and the acid phosphate, followed by curing or vitrifying the ceramic particles and the acid phosphate in the absence of any other reactant. 23. The method of claim 22 wherein the brake disc material formed by the curing or vitrifying consists essentially of the porous body, the deposited ceramic materials from the precursor, and phosphate ceramics formed in the absence of any other reactant in the porous body. 24. The method of claim 1 wherein the forming the brake disc material comprises the (e) forming a chemically bonded phosphate ceramic by reacting the acid phosphate with a metal oxide wherein the precursor material is the liquid containing the suspension of the acid phosphate and further containing the metal oxide. 25. The method of claim 24 wherein the brake disc material formed by the reaction of the acid phosphate with the metal oxide and the curing or vitrifying consists essentially of the porous body and chemically bonded phosphate ceramics formed in the porous body. 26. A method as claimed in claim 24, wherein the metal oxide comprises one or more of aluminum oxide, calcium oxide, iron oxide, magnesium oxide and zinc oxide. 27. The method of claim 1 wherein the formed brake disc material is a disc wherein the concentration of ceramic material does not vary by more than 20% from the first surface to the second surface. 28. The method of claim 1 wherein the formed brake disc material is a disc wherein the concentration of ceramic material is not zero in any cubic centimeter of volume between the first and second surfaces. 29. A method for forming a material for a brake disc, the method comprising the steps of: (i) providing at least one porous body;(ii) introducing into the pores of the porous body one or more precursor materials for forming or depositing a ceramic material; and(iii) forming the brake disc material comprising the porous body and the ceramic material by a process comprising forming the ceramic material from the precursor material within the pores of the porous body,wherein the precursor material comprises a first precursor liquid containing a suspension of ceramic particles and a second precursor liquid containing acid phosphate and/or phosphoric acid,followed by curing or vitrifying the ceramic materials and the acid phosphate in the absence of any other reactant,wherein the precursor material is introduced substantially throughout the porous body from first to second surfaces on opposite sides of the porous body. 30. A method as claimed in claim 29, wherein the particles of the first precursor liquid are deposited in the pores of the porous body prior to introduction of the second precursor liquid.
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이 특허에 인용된 특허 (12)
Belitskus David L. (New Kensington PA) Boland Daniel J. (New Kensington PA) Evans W. Thomas (Indiana PA) Kampert William P. (Lower Burrell PA) Marra Robert A. (Penn Hills PA) Wieserman Larry F. (Apol, Aluminum phosphate bonded fiber reinforced composite material containing metal coated fibers.
Thebault Jacques (Bordeaux FRX) Laxague Michel (Bordeaux FRX) Rey Jacques (Merignac FRX) Delaval Rodolphe (St. Martin au Laert FRX) Palavit Gerard (Douai FRX), Method for applying an anti-oxidative coating on brake disks of a carbon-containing composite material.
Tawil Henri,FRX ; Bernard Xavier,FRX ; Cavalier jean-Claude,FRX, Process for protecting products made of composite material containing carbon against oxidation, and products obtained b.
Leluan Jean-Luc (Bordeaux FRX) Rey Jacques (Merignac FRX) Bertone Christian (Castelnau de Medoc FRX) Bernard Bruno (Eysines FRX), Process for uniformly integrating a solid charge within a porous substrate.
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