Carbon-Carbon Brake Disc Ceramic Slot Surface via Reactive Sintering
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Solution Overview
Problem
Carbon-carbon composite brake discs require expensive metal inserts for torque transmission, which add weight and risk damage during installation or removal, and existing solutions do not effectively address the need for a durable, insert-free surface.
Innovation Solution
A method is developed to toughen the carbon-carbon composite material by applying a paste of metal and carbon powders in a nitrogen atmosphere, inducing a combustion reaction to create a hard, abrasion-resistant ceramic surface within the brake disc slots, eliminating the need for metal inserts and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If metal inserts are attached to carbon-carbon brake discs for torque transmission, then torque transmission capability is improved, but weight increases and damage risk during installation/removal occurs
Solution Approach 1:
The invention extracts and eliminates the metal inserts from the brake disc system. Instead of using separate metal inserts attached to the carbon-carbon composite brake disc, the patent creates drive slots directly in the brake disc that receive torque transmission elements, thereby removing the inserts and reducing weight while maintaining torque transmission capability
Solution Approach 2:
The invention merges the torque transmission function directly into the brake disc structure by creating drive slots within the carbon-carbon composite material itself. This integration eliminates the need for separate metal insert components, combining the functions of torque transmission and structural support into a single unified component
2Force
If metal inserts are attached to carbon-carbon brake discs, then torque transmission is enabled, but manufacturing cost and labor increase
Solution Approach 1:
The invention removes the metal inserts and the associated manufacturing steps of drilling rivet holes and attaching inserts. The drive slots are created directly in the brake disc during the manufacturing process, eliminating the need for separate insert installation operations and reducing both labor and manufacturing cost
Solution Approach 2:
The drive slots are formed during the brake disc manufacturing process itself, before final assembly. This preliminary creation of torque transmission features integrates the torque transmission capability into the base manufacturing process, avoiding subsequent separate operations for insert installation
3Force
If metal inserts are used in carbon-carbon brake discs, then torque transmission is achieved, but damage occurs to the brake disc during insert installation or removal
Solution Approach 1:
By eliminating the metal inserts entirely, the invention removes the source of potential damage associated with insert installation and removal. The drive slots are designed to receive torque transmission elements without requiring separate insert components that could damage the carbon-carbon composite during handling
Solution Approach 2:
The invention changes the material parameter approach by using carbon-carbon composite material for the drive slot surfaces instead of metal inserts. This material substitution provides a compatible interface that reduces stress concentrations and damage risk while maintaining the necessary torque transmission capability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting brake discs have a tough, hard, abrasion-resistant ceramic surface that withstands pressure without crushing, reducing material costs and avoiding damage during installation, while maintaining torque transmission efficiency.
Implementation Method 1
The disc is then placed into a furnace in a nitrogen atmosphere and heated to the ignition temperature. When the furnace reaches the ignition temperature, a combustion reaction begins that creates a molten liquid ceramic material on the slot face.
Data Source
AI summary
A brake disc rotor or stator is manufactured with slots in the interior face of the disc. A paste comprised of a fine powder of a carbide-forming metal along with fine carbon powder, suspended in an organic binder, is applied to the force-bearing areas in the rotor slot faces or the stator slot faces. The disc is then placed into a furnace in a nitrogen atmosphere and heated to the ignition temperature. When the furnace reaches the ignition temperature, a combustion reaction begins that creates a molten liquid ceramic material on the slot face. Upon cooling, the resulting brake disc has a tough, hard, abrasion-resistant ceramic surface on the portion of the brake disc slot that bears pressure.