Brake Disk Composite With Ceramic Inserts for Heat and Wear

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Solution Overview

Problem

Developing a reusable ceramic matrix composite (CMC) core for aircraft brake systems that combines high heat capacity with structural strength is challenging, particularly when incorporating boron or boron carbide materials into carbon fiber structures, due to limitations in size and expense, as well as susceptibility to fracture.

Innovation Solution

A brake disk design featuring carbon fiber-ceramic matrix composite materials with ceramic inserts, such as boron carbide, and chopped fibers, where recesses in the friction disks are filled with ceramic powder and carbon using chemical vapor infiltration, enhancing heat dissipation and wear resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If boron or boron carbide materials are incorporated into carbon fiber structures to increase heat capacity, then heat absorption capability is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveheat absorption capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent applies local quality by placing ceramic inserts with high heat capacity materials (boron or boron carbide) specifically in recesses located at the center and/or outer regions of the friction disks, rather than uniformly distributing them throughout. This localized approach concentrates heat absorption capability where thermal management is most critical while avoiding the manufacturing complexity and cost associated with incorporating these materials throughout the entire carbon fiber structure.

Inventive Principle:

Principle #3Local quality

2Use of energy by moving object

If solid disks of boron carbide are used to maximize heat capacity, then heat absorption is improved, but susceptibility to fracture increases

Engineering Contradiction:

Improveheat capacityVSAvoidsusceptibility to fracture

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The patent segments the high heat capacity material into discrete ceramic inserts rather than using solid disks of boron carbide. These inserts are placed in recesses within the carbon fiber friction disks, distributing the thermal mass throughout the structure. This segmentation reduces the susceptibility to fracture by avoiding large continuous sections of brittle ceramic material while maintaining adequate heat capacity through the cumulative effect of multiple smaller inserts.

Inventive Principle:

Principle #1Segmentation

3Temperature

If ceramic inserts are added to carbon fiber friction disks to enhance heat dissipation, then thermal performance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveheat dissipation performanceVSAvoidstructural complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent implements local quality by concentrating ceramic inserts in specific recesses located at the center and outer regions of the friction disks, where thermal management is most critical for heat dissipation. This localized placement enhances thermal performance without requiring complex structural modifications throughout the entire friction disk assembly.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent applies the nesting principle by placing ceramic inserts within recesses that are formed as cavities in the carbon fiber friction disk structure. The ceramic inserts are nested within the existing friction disk geometry, allowing thermal enhancement without adding external complexity or increasing the overall footprint of the brake system.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 solution provides improved heat dissipation and wear resistance for aircraft brake systems, enabling greater heat absorption and structural integrity while minimizing material limitations and costs.

Implementation Method 1

Boron or boron carbide materials possess relatively high heat capacities and thermal stability

Methodology Applied

Scientific EffectHeat capacity: Thermal Energy Storage

Implementation Method 2

depositing carbon around the ceramic powder in the plurality of first recesses using chemical vapor infiltration

Methodology Applied

Scientific EffectChemical vapor infiltration: Chemical Vapour Deposition

Implementation Method 3

convert the kinetic energy of the aircraft into heat through frictional forces experienced between the friction disks

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11448274B2Composites and methods of forming composites having ceramic inserts

Publication Date: 2022.09.20 GOODRICH CORP

AI summary

A brake disk may comprise a friction disk formed of at least one of a carbon fiber-ceramic matrix composite material or a carbon fiber-carbon matrix composite material. A first surface of the friction disk defines a first recess. A first ceramic insert comprising ceramic powder may be located in the first recess.