Composite Disc Brake Pad Structure for High Stiffness

The patent changes the material parameter by introducing silicon carbide (SiC) particles into the C/C matrix, transforming the material composition rather than relying on asymptotic carbon deposition. This chemical composition change achieves continued density and stiffness improvement beyond what CVD alone can provide.

The patent creates a composite material by incorporating SiC particles into the C/C matrix. This composite structure combines the benefits of C/C (lightness, high-temperature resistance) with SiC (high stiffness, low porosity), resolving the contradiction between stiffness improvement and manufacturing cost.

Instead of using a uniform support plate throughout the pad, the patent locally introduces SiC particles into the C/C matrix. This localized reinforcement provides stiffness where needed while maintaining the overall lightness of the C/C material, avoiding the weight penalty of ceramic or metal support plates.

The patent uses a C/C-SiC composite material that combines the low density of carbon-based materials with the high stiffness of silicon carbide. This composite approach achieves the stiffness of ceramic/metal support plates without their weight, as SiC particles are integrated at the microstructural level rather than as a separate heavy component.

The patent uses SiC particles as a nucleation substrate for carbon deposition. The SiC particles are distributed throughout the matrix, providing internal surfaces for carbon to deposit on, thereby enabling volumetric densification rather than just surface deposition. This resolves the contradiction between density increase and stiffness gain.

SiC particles act as an intermediary between the C/C matrix and the densification process. They serve as nucleation sites that facilitate uniform carbon deposition throughout the material volume, enabling internal densification and stiffness improvement that CVD alone cannot achieve.