Systems, devices, and methods for manufacturing carbon ceramic brake discs
AssigneeSiC Technologies, Inc.
InventorClifford B. Leonard
Life of this patent
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Abstract
Systems, devices, and methods are provided for manufacturing a carbon ceramic brake disc. Generally, a plurality of uncured or partially-cured bulk molding compound preforms or molding compound layers and ventilation cores are placed in a mold cavity and warm-pressed at a first temperature. The ventilation cores are removed from the resulting cured green body. The cured green body is then removed from the mold, and treated through a polymer infiltration and pyrolysis or reactive melt infiltration process. Certain steps can be repeated until a desired target density or weight is attained.
Claims16
A method of manufacturing a carbon ceramic brake disc, the method comprising:
- placing a plurality of molding compound layers and a plurality of ventilation cores in a cavity of a mold, wherein the plurality of molding compound layers includes one or more friction layers comprising a first molding compound formulation and one or more structural layers comprising a second molding compound formulation that is different from the first molding compound formulation, and wherein the first molding compound formulation is a dry molding compound, and the second molding compound formulation is a bulk molding compound;
- press-molding the plurality of molding compound layers in the mold at a first predetermined temperature and a first predetermined pressure to form a cured green body;
- removing the plurality of ventilation cores from the cured green body;
- pyrolyzing the cured green body in a first inert atmosphere at a second predetermined temperature to form a pyrolyzed body;
- and
- placing the pyrolyzed body in a vacuum furnace with a silicon powder and heating the pyrolyzed body in a second inert atmosphere to a third predetermined temperature to form a silicon-infiltrated body.
Dependencies are inferred from the claim text.