Carbon Brake Preform Layering for Low Wear and Material Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing carbon fiber carbon matrix composite (C/C) components for aircraft brake systems are time-consuming and expensive, with significant material wastage and weight loss during preform fabrication, leading to inefficient production of brake stacks.
Innovation Solution
A method involving the formation of fibrous preforms by layering graphite powder and phenolic resin compound mixtures between textile layers, followed by densification using chemical vapor deposition (CVD), which reduces material loss and production time, and includes the use of web material fabrics and varying graphite particle sizes to control fiber volume and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional preform fabrication methods are used with multiple layers of oxidized polyacrylonitrile fiber fabric stacked and needled, then the preform can be formed, but 50% or more of the material is cut away and wasted
Solution Approach 1:
The preform is segmented into multiple layers with different functions: textile layers provide structural framework while graphite powder layers provide densification material. This segmentation allows each layer to be optimized independently, reducing overall material waste while maintaining manufacturing feasibility
Solution Approach 2:
The invention changes the material parameters by using graphite powder instead of traditional organic binders, and by controlling the particle size distribution of graphite (25-400 mesh ranges). This parameter change reduces material wastage while maintaining ease of manufacture through standardized processing
2Loss of substance
If the preform is carbonized in traditional manufacturing, then the preform structure is stabilized, but 50% of the preform weight is lost
Solution Approach 1:
The invention uses graphite powder as a disposable densification material that is consumed during the carbonization process. The graphite layers serve their purpose during carbonization and are transformed into the final carbon matrix, eliminating the need for separate densification materials and reducing overall weight loss
Solution Approach 2:
The preform uses a composite structure of textile layers and graphite powder layers. The textile provides structural stability while the graphite provides densification. During carbonization, both materials transform into a stable carbon composite structure, maintaining stability while minimizing weight loss
3Manufacturing precision
If further preform material is removed for CVD densification, then the final product achieves desired density, but the preform ends up being only 20-25% of the original mass
Solution Approach 1:
The graphite powder layers are incorporated into the preform structure before carbonization, performing the densification function in advance. This preliminary action eliminates the need for subsequent material removal, achieving desired density while retaining most of the original preform mass
Solution Approach 2:
The graphite powder layers serve as a template or copy of the desired final carbon matrix structure. During carbonization, the graphite transforms into the final dense carbon structure, copying the intended density distribution without requiring material removal
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
This approach results in a cost-effective, low-wear carbon preform with improved frictional performance and reduced material wastage, enhancing the efficiency of brake stack production for aircraft applications.
Implementation Method 1
the phenolic resin in the first graphite powder and phenolic resin compound mixture layer and the second graphite powder and phenolic resin compound mixture layer is carbonized during the densification
Implementation Method 2
densifying the fibrous preform
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
A method of fabricating a composite component is provided. The method includes forming a fibrous preform by: forming a first graphite powder and phenolic resin compound mixture layer over a first textile layer, the first graphite powder and phenolic resin compound mixture layer having a first group of graphite particles; disposing a second textile layer over the first graphite powder and phenolic resin compound mixture layer; forming a second graphite powder and phenolic resin compound mixture layer over the second textile layer, the second graphite powder and phenolic resin compound mixture layer having a second group of graphite particles; and disposing a third textile layer over the second graphite powder and phenolic resin compound mixture layer; and densifying the fibrous preform.