Metal working – Method of mechanical manufacture – Shaping by direct application of fluent pressure
Reexamination Certificate
2002-06-17
2004-02-10
Bonck, Rodney H. (Department: 3681)
Metal working
Method of mechanical manufacture
Shaping by direct application of fluent pressure
C083S053000, C156S248000, C156S272800, C188S259000, C192S10700R, C219S121180, C228S160000
Reexamination Certificate
active
06687968
ABSTRACT:
BACKGROUND OF THE INVENTION
The invention relates to brake bands, friction linings and analogous friction generating devices or bodies which can be utilized in automatic transmissions and/or friction clutches of motor vehicles or for other purposes. The invention also relates to a method of making such friction generating bodies. Friction generating bodies of the above outlined character normally constitute laminates or sandwiches wherein a metallic first layer or substrate carries a second layer consisting at least in part of a friction generating material.
Brake bands wherein a metallic layer carries a layer of friction generating material are disclosed, for example, in the aforementioned commonly owned copending patent application Ser. No. 07/952,582, of Johann Jäckel et al. and in U.S. Pat. No. 4,602,706 granted Jul. 29, 1986 to John C. Blinks et al. for “Double wrap brake band”. The disclosures of Jäckel et al. and of the patent to Blinks et al. are incorporated herein by reference.
Friction generating bodies in the form of substantially disc-shaped circular friction clutch linings are disclosed, for example, in the German Auslegeschrift No. 1 210 686. The friction generating layer of the friction lining which is disclosed in this German publication is glued to the metallic layer or substrate. A drawback of the just described friction linings is that, when the friction clutch which embodies the friction lining of the German publication is heated, the thermally induced expansion of the metallic layer departs from the thermally induced expansion of the friction generating layer. The friction lining then acts not unlike a bimetallic element, i.e., the friction lining undergoes undue and highly undesirable deformation. Moreover, the bond between the two layers of such friction lining is subjected to highly pronounced separating stresses.
OBJECTS OF THE INVENTION
An object of the invention is to provide a relatively simple and inexpensive friction generating device or body wherein a metallic layer is affixed to and supports a friction generating layer.
Another object of the invention is to provide a novel and improved brake band for use in automatic transmissions of motor vehicles.
A further object of the invention is to provide a friction lining for use in clutch plates or clutch discs of friction clutches for motor vehicles.
An additional object of the invention is to provide a novel and improved method of making a friction generating device or body of the above outlined character.
Still another object of the invention is to construct and assemble the friction generating body in such a way that the metallic layer is movable to an optimum position relative to the friction generating layer and/or vice versa.
A further object of the invention is to provide a method of assembling a friction generating device or body of the above outlined character in such a way that any weakening of the one and/or the other layer takes place subsequent to affixing of the second layer to the first layer.
Another object of the invention is to provide a novel and improved method of making incisions into the one and/or the other layer of the friction generating body.
An additional object of the invention is to provide a novel and improved method of converting the above outlined friction generating body into a multiple wrap brake band.
Still another object of the invention is to provide a novel and improved method of converting the above outlined friction generating body into a friction lining for use in the clutch plates or clutch discs of friction clutches in motor vehicles.
A further object of the invention is to provide novel and improved means for making incisions in the above outlined friction generating body.
Another object of the invention is to provide novel and improved means for making incisions in the friction generating layer of the above outlined body.
An additional object of the invention is to provide a transmission which embodies one or more friction generating bodies of the above outlined character.
Still another object of the invention is to provide a clutch plate or clutch disc which embodies the above outlined friction generating body.
SUMMARY OF THE INVENTION
One feature of the present invention resides in the provision of a shaped friction generating body which can be used as a brake band (e.g., in automatic transmissions), as a friction lining in the clutch plate or clutch disc of a friction clutch for motor vehicles, or for other purposes. The improved friction generating body comprises a metallic first layer (e.g., a layer of steel) having a first side and a second side, and a second layer which is affixed (e.g., bonded) to one side of the first layer and consists at least in part of a friction generating material (e.g., a material which is used to make brake linings for incorporation into the clutch plates or clutch discs of friction clutches for motor vehicles). In accordance with a feature of the invention, at least one of the two layers has at least one incision or cut resulting from the application of at least one high-energy stream such as a laser beam, an electron beam or a liquid jet.
The layers can together constitute or form part of a friction lining for use in clutch plates or clutch discs. The at least one incision can be provided in and can extend at least substantially through the second layer. The at least one stream for the making of such incision can be a laser beam. The at least one incision can extend substantially radially or substantially chordally of the friction lining, and at least the radial incision can extend at least substantially all the way from the center to the periphery of the friction lining.
The two layers can jointly constitute a substantially cylindrical brake band for use in conjunction with a brake drum or clutch drums. One or more laser beams can be used to provide the cylindrical brake band with one or more incisions.
The second layer has a first side adjacent the one side of the first layer and a second side, and the at least one incision can extend from the second side toward the first side of the second layer (e.g., toward but short of the first side, all the way to the first side, beyond the first side and into the first layer, or all the way to the other side of the first layer).
The first layer can at least partially surround the second layer. For example, if the two layers are hollow cylinders, the hollow cylinder which constitutes the first layer can surround the entire hollow cylinder which constitutes the second layer.
The second layer can include at least one portion of reduced thickness (e.g., zero thickness) as a result of material removal, e.g., by subliming and/or by melting. Such subliming and/or melting can be carried out in an atmosphere of inert gas. Any remnant or remnants of material which has been removed from the second layer (e.g., by subliming and/or by melting) but tends to adhere to the one and/or the other layer can be separated from the layers as a result of entrainment with one or more streams of a gaseous fluid, e.g., air or nitrogen.
The at least one incision can be formed as a result of the application of one or more fluids.
The at least one incision can extend through the second layer and thence from the one side toward the other side of the first layer, e.g., toward but short of the other side or all the way to the other side of the first layer. Such incision can be formed as a result of cutting with a laser beam in the presence of oxygen.
The at least one incision can extend through one of the layers and into the other layer as a result of cutting with one or more high-pressure laser beams.
The at least one stream can be an uninterrupted laser beam or a pulsating laser beam.
Another feature of the invention resides in the provision of a friction lining for use in the clutch plates or clutch discs of friction clutches, particularly in motor vehicles. The friction lining comprises a metallic first layer having a first side and a second side, and a second layer which is affixed (e.g., soldered, brazed
Willerscheid Heiner
Wurm Karl
Bonck Rodney H.
Darby & Darby
LuK Lamellen und Kupplungsbau Beteiligungs KG
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