Patent ID: 8962083
Filing Date: 2015-02-24
Classification: C04B,C23C,F16D,Y02T,Y10T

Abstract:
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; and 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.