Carbon-Fiber Brake Disc Architecture for Crack-Resistant Thin Plates
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Solution Overview
Problem
Existing carbon-carbon (C/C) disc brake materials suffer from low resistance and flexural strength, leading to cracks and fractures in high-performance applications, and require a minimum thickness that is not optimal for extreme braking conditions.
Innovation Solution
A shaped material comprising a plurality of layers of carbon fibers with an alternation of radial and transverse segments, where each radial segment is adjacent to transverse segments on both sides, and vice versa, forming a '1-1' architecture, which is subjected to thermal or thermochemical densification and optionally infiltrated with silicon or silicon carbide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional carbon fiber layers with radial and transverse segments are used in C/C disc brakes, then the disc can function as friction material at high temperatures, but the disc exhibits low resistance and low flexural strength leading to cracks and fractures
Solution Approach 1:
The carbon fiber layers are divided into multiple segments (radial segments and transverse segments) that are stacked in a specific alternating sequence. This segmentation allows each layer to contribute differently to the overall structural properties, with radial segments providing drag resistance and transverse segments providing flexural strength, resolving the contradiction between temperature resistance and mechanical strength
Solution Approach 2:
The invention uses a composite structure combining carbon fibers with organic binder, where the carbon fibers provide high temperature resistance while the binder matrix provides structural continuity and strength. The alternating radial and transverse segment arrangement creates a composite architecture that simultaneously achieves both thermal stability and enhanced mechanical properties
2Reliability
If the disc architecture is designed to increase flexural strength, then crack resistance improves, but the minimum thickness of the disc plates cannot be reduced sufficiently for high-performance applications
Solution Approach 1:
The invention transitions from considering only the radial and transverse directions to incorporating the stacking sequence dimension. By alternating radial and transverse segments across multiple layers in a specific pattern, the structure gains enhanced mechanical properties in all three dimensions, allowing thinner plates to achieve the required strength and reliability
3Strength
If the number of transverse segments is increased to improve flexural strength, then structural resistance increases, but the manufacturing complexity and device complexity increase
Solution Approach 1:
Different regions of the disc (radial segments vs. transverse segments) are assigned different functional qualities based on local stress requirements. Radial segments are positioned where drag resistance is critical, while transverse segments are positioned where flexural strength is needed. This local differentiation achieves optimal structural resistance without requiring uniform complexity throughout the entire structure
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 '1-1' architecture significantly increases the flexural strength and drag resistance of the disc brake material, reducing the likelihood of cracks and fractures while allowing for a thinner minimum thickness, thus enhancing performance and longevity in high-end applications.
Implementation Method 1
The carbon matrix is obtained during densification processes of the fibrous structure, which may be performed in various manners, for example by means of Chemical Vapor Deposition (CVD), Chemical Vapor Infiltration (CVI), Liquid Polymer Infiltration (LPI), Polymer Infiltration and Pyrolysis (PIP), or impregnation with resin and/or pitch.
Implementation Method 2
The shaped material is subjected to a thermal or thermochemical densification treatment and optionally infiltrated with silicon or silicon carbide.
Data Source
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AI summary
The present invention relates to a shaped material (1, 11), for example, a disc for disc brakes, and a method for the manufacturing thereof. More in particular, the invention relates to a shaped material comprising a plurality of layers (2, 3, 4, 5) of carbon fibers stacked along an overlap axis (Z), each layer (2, 3, 4, 5) being formed by a plurality of radial segments (6) and transverse segments (7), wherein each radial segment (6) is adjacent and joined, on both sides, to a transverse segment (7) and each transverse segment (7) is adjacent and joined, on both sides, to a radial segment (6), forming in each layer (2, 3, 4, 5) an alternation of radial segments (6) and transverse segments (7).