Friction discs having a structured ceramic friction layer and method of manufacturing the friction discs

1. A method for producing a cylindrical annular friction disc having a microstructure being planned and formed deliberately in a friction layer, which comprises the steps of:

preparing a preform for a support body of porous carbon;

preparing a preform for a friction layer body of porous carbon;

adhesively bonding at least one friction layer preform on the preform for the support body by means of an adhesive layer containing as an organic binder a thermosetting resin, and at least one additive selected from the group consisting of elemental carbon, carbides, nitrides and silicides of metals and semi-metals of groups 13, 14, and 15 according to the current IUPAC nomenclature of periodic table of elements, high temperature-resistant fibers selected from carbon fibers, fibers of binary and ternary compounds of elements Si, C, N, B, O, and P, and whiskers of refractory metals;

pyrolysing a resulting composite material in an absence of oxidizing agents, thereby obtaining carbon from the organic binder resulting in a carbonized composite;

infiltrating the carbonized composite with one of a liquid silicon or a liquid alloy containing a mass fraction of at least 50% silicon, thereby forming carbides of silicon and possibly of the other alloy components resulting in a siliconized composite;

cooling the siliconized composite according to a selectable temperature profile, wherein an intermediate layer is formed from the adhesive layer by the steps of carbonization and infiltration with subsequent reaction to form carbides; and

forming the adhesive layer as an uneven adhesive layer for assisting in defining a microstructure of the friction layer, the forming step for forming the uneven adhesive layer includes performing one of the steps of:

providing a carbon filament bundle mesh weave fabric with a plain weave impregnated or coated with an adhesive, the adhesive can be convertible into carbon by heating in an absence of oxidizing substances to temperatures of about 800° C. or more;

performing an uneven application of the adhesive by one of screen printing or a computer-controlled applicator; or

solidifying the adhesive on an anti-adhesively treated smooth surface to form a film, from which a grid-shaped overlay is punched out, which later returns to an adhesive state under further heating before reaching a state of a cross-linked and non-melting thermoset.

2. The method according to claim 1 , wherein the adhesive is a thermosetting resin or pitch, or a mixture thereof, and the adhesive also contains other additives of heat-resistant inorganic materials.

3. The method according to claim 2 , which further comprises providing heat-resistant inorganic materials as the additives, selected from the group consisting of powders of silicon carbide, boron carbide, titanium boride, boron nitride, and mixtures thereof.

4. The method according to claim 1 , wherein further comprises modifying the adhesive by performing one of

sprinkling in heat-resistant fibers selected from the group consisting of fibers of carbon, fibers of silicon carbide, fibers of silicon nitride, whiskers of ceramic materials, and whiskers of metallic materials; or

mixing in heat-resistant fibers selected from the group consisting of fibers of carbon, fibers of silicon carbide, fibers of silicon nitride, whiskers of ceramic materials, and whiskers of metallic materials with the adhesive in such manner that when the adhesive solidifies the heat-resistant fibers cause a formation of anisotropic structures.

5. The method according to claim 1 , wherein an average dimension of individual areal zones in a structure formed in the intermediate layer that are transformed by carbonization into carbon-containing layers with different coefficients of thermal expansion ranges from 2 mm to 8 mm.

6. The method according to claim 5 , wherein a thickness of the areal zones in the intermediate layer is between 0.2 mm and 2 mm in a carbonized state.

7. The method according to claim 1 , which further comprises:

reinforcing the preform for the support body of porous carbon with high-temperature-resistant fibers;

forming the preform for the friction layer body of porous carbon with silicon carbide as a filler; and

forming the adhesive layer with at least one of a pitch or a thermoplastic plastic.

8. The method according to claim 1 , wherein which further comprises performing the uneven application of the adhesive to a form of a grid that intersects at right angles or in a form of a spider's web with concentric circles or spirals and radii that intersect the circles or the spirals.