Carbon Fiber Brake Disc Structure for Crack-Resistant Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Carbon-based disc brake discs exhibit regions of low resistance to applied load, leading to cracks or fractures in extreme braking applications due to their asymmetric structural architecture, making them unsuitable for high-performance use.
Innovation Solution
A shaped material with an asymmetric structure comprising layers of carbon fibers oriented in radial and transverse directions, with a higher number of transverse segments, and incorporating silicon carbide zones formed by reacting carbon with infiltrated silicon, which is processed through stacking, needling, heat treatment, and optional infiltration to reduce porosity and enhance mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional C/C disc brake discs are manufactured using conventional stratified carbon fiber layers, then the manufacturing process is relatively simple and cost-effective, but the discs exhibit regions of low resistance to applied load leading to cracks or fractures in extreme braking applications
Solution Approach 1:
The patent applies asymmetry by intentionally creating non-uniform fiber distribution and varying layer orientations in the carbon fiber reinforcement. Specifically, the fabric layers are arranged with different weave patterns and orientations in different regions of the disc, creating an asymmetric internal structure that directs mechanical strength to critical load-bearing areas while maintaining overall structural integrity. This asymmetric design eliminates the uniform weakness present in traditional stratified structures.
Solution Approach 2:
The patent implements local quality by modifying specific regions of the disc structure to have enhanced properties where needed. The carbon fiber reinforcement is concentrated and oriented specifically in regions subjected to high stress during braking, while other regions maintain a lighter structure. This localized optimization ensures that critical areas have high resistance to cracks and fractures without requiring the entire disc to be uniformly complex.
2Strength
If the carbon fiber layers are stacked in a conventional stratified manner, then the manufacturing process is straightforward, but the mechanical properties are anisotropic with weak regions that are critical to structural integrity
Solution Approach 1:
The patent applies segmentation by dividing the carbon fiber reinforcement into multiple distinct fabric layers with different orientations and weave patterns. Each layer is positioned and oriented to address specific stress vectors, creating a segmented reinforcement strategy. This segmentation allows the disc to achieve isotropic mechanical properties by distributing strength uniformly in multiple directions rather than relying on a single stratified arrangement.
Solution Approach 2:
The patent utilizes composite materials by combining carbon fiber fabrics with a carbon matrix in a multi-layered configuration. The composite structure integrates different fiber orientations and weave patterns within the same disc, creating a heterogeneous composite that achieves isotropic mechanical properties. This composite approach allows the material to exhibit uniform strength in all directions while maintaining ease of manufacture through established composite fabrication techniques.
3Reliability
If additional equipment or complex processing steps are introduced to improve structural uniformity, then crack resistance improves, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent applies self-service by designing a manufacturing process where the carbon fiber fabric layers themselves create the desired structural uniformity through their inherent weave patterns and orientations. The fabric structure and layer arrangement are configured to automatically distribute stress and prevent crack propagation without requiring additional external equipment or complex processing steps. The material structure serves its own reinforcement function, eliminating the need for supplementary strengthening processes.
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 drastically reduces the occurrence of cracks and fractures, providing high flexural strength and isotropic mechanical properties, making the material suitable for high-performance applications without requiring additional equipment or complex processing.
Implementation Method 1
incorporating silicon carbide zones formed by reacting carbon with infiltrated silicon
Implementation Method 2
processed through stacking, needling, heat treatment, and optional infiltration to reduce porosity and enhance mechanical properties
Data Source
AI summary
Shaped material (1), in particular a disc for a disc brake includes layers (2, 4, 6) of carbon fibers stacked in a construction direction (X). Each layer (2, 4, 6) has segments (8, 10) placed side by side and joined together to form the layer, the segments of a layer (2, 4, 6) include radial segments (8) and transverse segments (10). In each layer (2, 4, 6) of carbon fibers, the number of transverse segments (10) is greater than the number of radial segments (8). A method manufactures a shaped material.