Brake Component Preform Using Pre-Ceramic Binder Pyrolysis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Fibre-reinforced composite materials made with traditional organic resin-based pre-pregs are unsuitable for high-temperature applications due to low thermal conductivity, limited carbonaceous residue after pyrolysis, and insufficient hardness, making them inadequate for components like disc brake components that require elevated temperature operation and resistance to abrasion.
Innovation Solution
A fibre-reinforced ceramic composite material is developed using a pre-preg impregnated with a polymeric binder composition predominantly composed of siloxane and silsesquioxane resins, which form inorganic amorphous and crystalline structures upon pyrolysis, enhancing thermal conductivity and hardness, and allowing for densification processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional organic resin-based pre-pregs are used, then ease of manufacture is improved, but thermal conductivity and operating temperature capability deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the polymeric binder from traditional organic resins (epoxy, phenolic, vinyl ester, cyanate ester) to pre-ceramic polymers (siloxane, silsesquioxane, polysilazane). This parameter change enables the material to form inorganic ceramic structures after pyrolysis, achieving high operating temperature capability (>400°C) and improved thermal conductivity while maintaining manufacturability through standard pre-preg formation processes.
Solution Approach 2:
The patent creates a composite material system where pre-ceramic polymer matrices are combined with fibrous reinforcements (carbon, glass, or ceramic fibres). After pyrolysis, the organic polymer converts to inorganic ceramic structures, forming a fibre-reinforced ceramic composite that achieves both high temperature capability and structural integrity, resolving the contradiction between ease of manufacture and temperature resistance.
2Strength
If traditional organic resin-based pre-pregs are used, then mechanical resistance is improved, but resistance to abrasion and hardness deteriorate
Solution Approach 1:
The patent changes the material phase from organic polymer to inorganic ceramic through pyrolysis of pre-ceramic polymers. This transformation fundamentally alters the surface properties, increasing hardness and abrasion resistance while maintaining bulk mechanical strength through fibre reinforcement, thus resolving the contradiction between mechanical resistance and abrasion resistance.
Solution Approach 2:
The patent converts the typically harmful effect of organic resin decomposition during pyrolysis (which produces limited carbonaceous residue and reduces mechanical properties) into a beneficial process. By using pre-ceramic polymers, the decomposition leads to formation of inorganic ceramic structures with superior hardness and abrasion resistance, turning the degradation process into a strengthening mechanism.
3Strength
If thermosetting polymeric compositions are used for pre-preg, then mechanical resistance is improved, but adaptability to high temperature applications deteriorates
Solution Approach 1:
The patent changes the chemical structure parameters of the polymeric binder from conventional thermosetting resins to pre-ceramic polymers with inorganic backbone structures (siloxane, silsesquioxane, polysilazane). This parameter change enables the material to withstand high temperatures and oxidising environments while maintaining mechanical integrity, achieving adaptability to high temperature applications without sacrificing strength.
Solution Approach 2:
The patent creates a hybrid composite system where pre-ceramic polymer matrices are combined with high-performance fibres (carbon, glass, or ceramic). The fibre reinforcement maintains mechanical strength while the pre-ceramic matrix provides high temperature stability and oxidisation resistance, achieving both strength and adaptability to high temperature applications.
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 composite material exhibits improved thermal conductivity, mechanical resistance, and increased operating temperature capabilities, making it suitable for high-temperature applications such as disc brake components and engine parts, with silicon carbide formation enabling higher resistance to abrasion.
Implementation Method 1
A fibre-reinforced ceramic composite material, obtained from a pre-preg after forming and pyrolysis
Implementation Method 2
which form inorganic amorphous and crystalline structures upon pyrolysis
Data Source
AI summary
A preform for making a component of a braking system having a fibre-reinforced ceramic composite material, obtained by forming and subsequent pyrolysis of a pre-preg is described. Also described is a component of a braking system made wholly or in part from the preform, and a method for making a preform in a fibre-reinforced ceramic composite material.