Multi-layered Carbon Ceramic Brake Disk Design
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Solution Overview
Problem
Existing carbon ceramic brake disks face challenges in balancing torsional strength, stiffness, friction coupling, and heat dissipation, with materials like carbon-fibre reinforced carbon degrading at high temperatures and requiring complex geometries to meet all requirements effectively.
Innovation Solution
A multi-layered carbon ceramic brake disk design featuring separate layers of a carrier body, ventilation layer with ducts, and friction layer, made from thermoplastic or thermoset polymeric materials, which are carbonised and infiltrated with carbide-forming elements to form a silicon carbide matrix, allowing for optimized force transmission, traction, and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If carbon-fibre reinforced carbon material is used to reduce unsprung masses, then weight is reduced, but the material undergoes oxidative degradation at temperatures above 400°C
Solution Approach 1:
The brake disk uses a composite structure combining carbon-fibre reinforced carbon friction layers with a silicon carbide carrier body. The carbon layers provide low density for weight reduction, while the silicon carbide carrier body provides high-temperature stability and structural integrity, resolving the contradiction between weight reduction and high-temperature reliability
Solution Approach 2:
The brake disk is divided into functionally distinct segments: friction layers made of carbon-fibre reinforced carbon for weight savings and friction function, and a carrier body made of silicon carbide for high-temperature structural stability. This segmentation allows each material to be optimized for its specific function without compromise
2Temperature
If ventilation ducts are introduced into the brake disk geometry, then heat dissipation is improved, but structural complexity increases
Solution Approach 1:
The ventilation system is segmented into the carrier body with integrated cooling channels and separate friction layers. This allows the cooling function to be built into the structural component without adding separate cooling apparatus, managing complexity through functional integration
Solution Approach 2:
The cooling function is merged with the carrier body structure itself. The silicon carbide carrier body incorporates internal cooling channels that serve both as structural support and as the heat dissipation system, eliminating the need for separate cooling components
3Reliability
If separate friction layers and carrier bodies are used to optimize specific functions, then functional performance is improved, but manufacturing complexity increases
Solution Approach 1:
The brake disk is manufactured as separate components (friction layers and carrier body) that are later joined together. This segmentation allows each component to be manufactured using optimized processes for its specific material and function, then assembled into the final product
Solution Approach 2:
A bonding layer or joining process acts as an intermediary between the friction layers and carrier body, enabling the assembly of separately manufactured components into a functional whole. This intermediary connection allows manufacturing complexity to be managed through modular construction
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 a brake disk that meets all performance criteria, including high temperature stability, low unsprung masses, and efficient heat dissipation, while being manufacturable from standardised components and adaptable for various vehicle applications.
Implementation Method 1
subjecting the stack to pyrolysis in a non-oxidising atmosphere under heat, to form a carbonised body
Implementation Method 2
infiltration with a liquid carbide-forming material, which material preferably comprises silicon, to form a ceramic body having a matrix comprising a carbide, preferably silicon carbide
Implementation Method 3
infiltration with a liquid carbide-forming material... to form a ceramic body having a matrix comprising a carbide
Data Source
Figure 1a~1e
Figure 2
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AI summary
The invention relates to a multi-layered carbon ceramic brake disk having at least one carrier body, and at least one ventilation layer that comprises ventilation ducts, and optionally, at least one friction layer, made by joining green bodies of at least one individual carrier body, and of at least one individual ventilation layer, and optionally, of at least one individual friction layer, which green bodies comprise thermoplastic or thermoset polymeric materials, in their solid or cured states, and by subsequent carbonisation and ceramicisation by infiltration with carbide-forming elements.