Composite Brake Disc Preform with Nanoparticle Interlayers for Wear

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Solution Overview

Problem

Carbon-carbon composite materials used in aerospace applications, such as aircraft brake pads and discs, face challenges in wear rate and thermal conductivity, leading to reduced usable life and increased peak temperatures during braking operations.

Innovation Solution

A method involving the combination of a carbon fiber fabric and a highly oriented milled carbon fiber interlayer, wound around a core to form a composite fiber preform, which is then densified, improving mechanical stability and thermal conductivity by orienting fibers axially to reduce wear and enhance heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If conventional carbon-carbon composite materials are used in brake applications, then the brake components can provide friction braking, but the wear rate increases and usable life decreases

Engineering Contradiction:

Improveusable lifeVSAvoidwear rate

Core Design Contradiction:

Duration of action of moving objectVSLoss of substance

Solution Approach 1:

The patent applies local quality by creating distinct layers with different fiber orientations within the composite structure. The interlayer contains highly oriented carbon fibers perpendicular to the friction surface, while other layers have different orientations. This localized optimization of fiber arrangement in specific regions addresses wear at the friction interface without compromising the overall structural integrity of the brake component.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining carbon fibers with different orientations and properties into a multi-layered structure. The integration of interlayers with highly oriented perpendicular fibers into the carbon-carbon composite matrix creates a composite structure that simultaneously provides friction braking capability and enhanced wear resistance, directly addressing the contradiction between functionality and durability.

Inventive Principle:

Principle #40Composite materials

2Temperature

If conventional carbon-carbon composite materials are used, then brake components can operate at high temperatures, but peak temperatures increase during braking operations

Engineering Contradiction:

Improveheat dissipationVSAvoidpeak temperature

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If porous preforms are used for manufacturing carbon-carbon composites, then the components can be formed with complex geometries, but the density and mechanical stability are reduced

Engineering Contradiction:

Improvemechanical stabilityVSAvoiddensity

Core Design Contradiction:

Stability of the object's compositionVSQuantity of substance

Solution Approach 1:

The patent applies segmentation by dividing the carbon-carbon composite into multiple discrete layers with different fiber orientations and densities. The porous preform is segmented into alternating layers of conventional carbon fiber layers and interlayers with highly oriented perpendicular fibers. This segmentation allows each layer to contribute differently to the overall mechanical stability, with the interlayers providing enhanced interlaminar strength while maintaining the porous structure needed for infiltration processing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies preliminary action by incorporating the interlayer with highly oriented perpendicular fibers into the preform structure before the densification process. This preliminary arrangement of fibers in the desired orientation allows the subsequent infiltration and densification processes to lock in the enhanced mechanical stability without requiring post-processing realignment or additional manufacturing steps.

Inventive Principle:

Principle #10Preliminary action

4Loss of substance

If carbon fibers are oriented to reduce wear, then wear rates decrease, but the complexity of manufacturing the preform increases

Engineering Contradiction:

Improvewear rateVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP4137313A1Method for manufacturing composite fiber preform for disc brakes

Publication Date: 2023.02.22 HONEYWELL INTERNATIONAL INC

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AI summary

An example method includes forming an interlayer on a carbon fiber fabric to form a composite fiber fabric. The interlayer comprises a binder. The method further includes winding the composite fiber fabric around a core to form a composite fiber preform comprising a plurality of layers defining an annulus extending along a central axis. The method further includes densifying the composite fiber preform, wherein the binder comprises at least one of a resin, a thermoset resin, or a phenolic resin, wherein depositing the interlayer comprises: depositing the binder in a dry powder form onto the carbon fiber fabric; compressing the binder to the carbon fiber fabric prior to winding the composite fiber fabric; and curing, after winding, the binder, wherein the interlayer comprises a plurality of nanoparticles in the binder, the method further comprising blending the plurality of nanoparticles with the binder prior to depositing the interlayer, wherein the plurality of nanoparticles comprise at least one of a carbon nanotube, a carbon nanofiber, or a graphene nanoplatelet.