Composite Friction Elements via Pultrusion Resin Dispensing
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Solution Overview
Problem
Existing friction materials for brakes and clutches, particularly those replacing asbestos, face challenges in achieving uniform performance, durability, and cost-effectiveness due to non-uniform distribution and orientation of fibers in the manufacturing process, leading to variations in performance characteristics and maintenance issues.
Innovation Solution
A continuous process for manufacturing composite friction units involves using array gates, a resin plenum with dispensing tube assemblies, and a forming die to uniformly dispense resin onto reinforcing fiber fabrics, which are then pulled through a forming die to create a composite panel with controlled fiber orientation and distribution, enhancing uniformity and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional molding process with randomly oriented fibers is used, then manufacturing simplicity is maintained, but manufacturing precision and performance uniformity deteriorate
Solution Approach 1:
The manufacturing process is segmented into distinct functional zones: a resin plenum chamber for resin storage and distribution, multiple dispensing tubes with bores for controlled resin delivery, and a forming die for shaping. This segmentation allows each component to perform its specific function optimally, ensuring uniform fiber-resin distribution while maintaining process manageability
Solution Approach 2:
Resin is pre-positioned in the plenum chamber before the molding cycle begins. The dispensing tubes are pre-configured with multiple bores positioned to deliver resin to specific locations. This preliminary preparation ensures that when molding occurs, resin is already in position to uniformly distribute throughout the fiber reinforcement, eliminating the need for complex real-time adjustment mechanisms
2Reliability
If asbestos is used as reinforcing material, then friction performance is improved, but harmful factors increase due to carcinogenic properties
Solution Approach 1:
The invention changes the material parameter from asbestos to alternative reinforcing materials such as glass fibers, ceramic fibers, or organic fibers. These alternative materials maintain the necessary friction, wear, and heat resistance properties while eliminating the carcinogenic hazards associated with asbestos. The resin matrix parameters are also adjusted to ensure proper bonding and performance with the new fiber materials
3Manufacturing precision
If resin is uniformly dispensed onto fiber fabrics, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The resin plenum chamber serves multiple functions: it stores resin, distributes resin through multiple dispensing tubes, and maintains pressure control. The dispensing tubes with multiple bores simultaneously deliver resin to various locations in the mold cavity. This multi-functionality reduces the need for separate complex systems for resin storage, distribution, and delivery, achieving uniform resin distribution while keeping the overall device manageable
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 method ensures consistent and predictable performance of friction units with improved mechanical properties, reduced variability, and increased cost-effectiveness by ensuring uniform fiber distribution and orientation, addressing the limitations of previous manufacturing methods.
Implementation Method 1
a resin plenum with dispensing tube assemblies, and a forming die. The array gates comprise a plurality of cutouts, each of the plurality of cutouts sized to receive one reinforcing fiber fabric of a plurality of reinforcing fiber fabrics therethrough. The resin plenum comprises a plenum chamber within a body and a plurality of dispensing tube assemblies in fluid communication with the plenum chamber, each of the plurality of dispensing tube assemblies comprising a plurality of dispensing bores positioned to dispense resin pumped into the plenum chamber onto one reinforcing fiber fabric
Implementation Method 2
The forming die is positioned to receive the plurality of reinforcing fiber fabrics after the resin plenum has dispensed resin onto each one of the plurality of reinforcing fiber fabrics, the forming die configured to form a composite panel from the plurality of reinforcing fiber fabrics as the plurality of reinforcing fiber fabrics pass through the forming die
Data Source
AI summary
A system for continuous process manufacturing of composite friction units uses one or more array gates with a plurality of cutouts each sized to receive one of a plurality of reinforcing fiber fabric therethrough. The system also uses a resin plenum with plenum chamber and a plurality of dispensing tube assemblies. Each of the plurality of dispensing tube assemblies corresponds to a different cutout and includes dispensing bores positioned to dispense resin onto one of the reinforcing fiber fabrics. The system also uses a forming die that receives the reinforcing fiber fabrics with the resin to form a composite panel as they pass through the forming die.