Angled Fiber Composite Preforms for Balanced Brake Friction
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Solution Overview
Problem
Existing composite materials for brake friction applications, such as carbon-carbon composites, face challenges in achieving consistent performance and uniformity due to variations in fiber orientation and consolidation techniques.
Innovation Solution
A composite preform is designed with a plurality of fibrous layers, including at least one first fibrous layer and one second fibrous layer, where the reinforcing fibers in each layer are oriented at specific angles relative to the radial direction, and the layers are consolidated using techniques like needle punching to enhance intermeshing and reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional consolidation techniques are used, then manufacturing simplicity is maintained, but fiber orientation uniformity and preform structure consistency deteriorate
Solution Approach 1:
The preform is divided into multiple fibrous layers, each containing segments with specific fiber orientations. This segmentation allows different layers to have controlled fiber angle variations, improving overall fiber orientation uniformity while maintaining manageable manufacturing complexity through modular layer construction
Solution Approach 2:
Different fibrous layers are designed with specific local fiber orientation characteristics. Each layer can have tailored fiber angles and segment configurations optimized for its position in the preform, achieving uniform fiber distribution throughout the structure without requiring complex consolidation equipment
2Ease of manufacture
If fibers are oriented at extreme angles (0° or 90°), then manufacturing alignment is simplified, but friction force distribution and heat dissipation performance deteriorate
Solution Approach 1:
The fiber orientation angle parameter is changed from extreme values (0° or 90°) to intermediate angles (±α where 0° < α < 90°). This parameter modification enables better friction force distribution and heat dissipation while still maintaining practical manufacturability through standard laying techniques
Solution Approach 2:
Instead of aligning fibers with the radial direction (traditional approach), the invention inverts the orientation strategy by using angled orientations relative to the radial direction. This inverted approach creates alternating positive and negative angle layers that improve performance while remaining manufacturable
3Productivity
If single-layer preform structure is used, then manufacturing process is simplified, but structural balance and performance consistency deteriorate
Solution Approach 1:
The preform is segmented into multiple fibrous layers with alternating fiber orientations. This multi-layer segmentation achieves structural balance and performance consistency through the combined effect of different oriented layers, while the modular nature allows for efficient sequential manufacturing
Solution Approach 2:
The preform uses a composite structure of multiple fibrous layers with different fiber orientations. This composite approach combines the advantages of each layer orientation to achieve balanced structural properties and consistent performance, while the layered composite structure can be manufactured through repeated application of standardized processes
Data Source
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AI summary
A preform for a composite may include a plurality of fibrous layers consolidated together and forming the preform extending along a longitudinal axis. The plurality of fibrous layers includes at least one first fibrous layer and at least one second fibrous layer. The at least one first fibrous layer includes a plurality of first segments, and the least one second fibrous layer includes a plurality of second segments. At least one first segment of the plurality of first segments includes a plurality of reinforcing fibers extending at an angle -α relative to a radial direction extending from the longitudinal axis. At least one second segment of the plurality of second segments includes a plurality of reinforcing fibers extending at an angle +α relative to the radial direction, α is greater than 0° and less than 90°.