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Sintered brake lining and method for its manufacture
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Origin:US Patent
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Time:2007-11-5 17:36:48
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1. A sintered brake pads for cooperating tribologically with a brake member including fiber-reinforced ceramic, the brake pad comprising:
carbon particles;
metal particles bonded at least partially by reaction to the carbon of the carbon particles;
hard material particles suitable for use as abradants; and
pyrolyzed polymers as binding agents, the pyrolyzed polymers being derived using a substance selected from the group consisting of polysiloxanes, polycarbosilanes and pitch.
2. The brake pad as recited in claim 1 wherein the metal particles include particles selected from the group consisting of iron, steel, gray cast iron, silicon, ferrosilicon, bronze, brass, and copper.
3. The brake pad as recited in claim 1 wherein the hard material particles include metal carbides of the metal particles.
4. The brake pad as recited in claim 1 wherein the hard material particles include particles selected from the group consisting of silicon carbide, titanium carbide, boron carbide, aluminum oxide and glass.
5. The brake pad as recited in claim 1 further comprising particles of at least one solid lubricant.
6. The brake pad as recited in claim 5 wherein the at least one solid lubricant includes a lubricant selected from the group consisting of molybdenum sulphide and graphite.
7. The brake pad as recited in claim 1 further comprising particles of at least one solid lubricant, and wherein:
the carbon particles include a primary or pyrolytically produced form of carbon and comprise 20 to 70% by weight of the brake pad;
the metal particles comprise 10 to 60% by weight of the brake pad;
the hard material particles comprise up to 20% by weight of the brake pad; and
the solid lubricant particles comprise up to 20% by weight of the brake pad.
8. A method for manufacturing a brake pad which cooperates tribologically with a brake member including fiber-reinforced ceramic, the method comprising:
pressing into a mold a mixture including pyrolyzable polymers as binding agents, carbon particles, metal particles, and hard material particles suitable for use as abradants, the polymers containing a substance selected from the group consisting of polysiloxane, polycarbosilane and pitch; and
sintering the mixture under vacuum or a protective gas until the metal particles are at least partially bonded by reaction to carbon of the carbon particles.
9. The method as recited in claim 8 wherein the carbon particles include a powdery form and include particles selected from the group consisting of coke and graphite.
10. The method as recited in claim 8 wherein the metal particles include particles selected from the group consisting of iron, steel, gray cast iron, silicon, ferrosilicon, bronze, brass, and copper in powder form.
11. The method as recited in claim 8 wherein the hard material particles include particles selected from the group consisting of silicon carbide, titanium carbide, boron carbide, aluminum oxide and glass.
12. The method as recited in claim 8 wherein the mixture further includes at least one solid lubricant in a powdery form.
13. The method as recited in claim 12 wherein the at least one solid lubricant includes a lubricant selected from the group consisting of molybdenum sulphide and graphite.
14. The method as recited in claim 8 wherein the mixture further includes at least one solid lubricant, the mixture comprising:
from 20 to 70% by weight of the carbon particles in a primary or pyrolytically produced form;
10 to 60% by weight of the metal particles;
up to 20% by weight of the hard material particles; and
up to 20% by weight of the at least one solid lubricant.
15. The method as recited in claim 8 wherein the pressing step is performed as a cold-pressing at a pressing pressure of about 500 to 2000 bar.
16. The method as recited in claim 8 wherein the pressing step is performed at a pressing pressure of about 50 bar.
17. The method as recited in claim 8 wherein the sintering step is performed at a temperature of about 800 to 1200กใ C.
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