Segmented Composite Preform Fiber Layout for Uniform Brake Friction
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Solution Overview
Problem
Existing composite materials for brake friction applications, such as carbon-carbon composites, face challenges in achieving consistent performance and durability due to variations in fiber orientation and consolidation techniques.
Innovation Solution
A composite preform is designed with multiple layers of fibrous materials, where each layer includes segments of reinforcing fibers oriented at specific angles relative to the radial direction, and the layers are consolidated using techniques like needle punching to enhance interlayer reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional consolidation techniques are used for carbon-carbon composite preforms, then manufacturing simplicity is maintained, but fiber orientation consistency and structural uniformity deteriorate
Solution Approach 1:
The preform is divided into multiple discrete layers, each with controlled fiber orientations. This segmentation allows independent optimization of each layer's fiber arrangement before consolidation, improving overall fiber orientation consistency without requiring complex monolithic consolidation techniques
Solution Approach 2:
Different layers are assigned different fiber orientations and consolidation parameters tailored to local requirements. This enables precise control of fiber orientation in each region, achieving manufacturing precision through localized quality control rather than uniform complex processing
2Stability of the object's composition
If fiber layers are consolidated with varying orientations, then structural uniformity improves, but manufacturing complexity increases
Solution Approach 1:
Fiber layers are pre-oriented and arranged in specific patterns before consolidation. This preliminary action establishes the desired structural uniformity in advance, allowing simpler consolidation processes to achieve the target configuration without requiring complex real-time manipulation during manufacturing
3Reliability
If multiple fibrous layers with different fiber orientations are used, then friction material performance consistency improves, but production complexity increases
Solution Approach 1:
Systematic variation of fiber orientation parameters across layers creates predictable performance characteristics. By controlling the angular parameters of fiber arrangements, the invention achieves consistent friction material performance through parameter optimization rather than complex multi-step production processes
Data Source
AI summary
A preform for a composite may include a plurality of fibrous layers consolidated together and forming the preform extending along a longitudinal axis. The plurality of fibrous layers includes at least one first fibrous layer and at least one second fibrous layer. The at least one first fibrous layer includes a plurality of first segments, and the least one second fibrous layer includes a plurality of second segments. At least one first segment of the plurality of first segments includes a plurality of reinforcing fibers extending at an angle −α relative to a radial direction extending from the longitudinal axis. At least one second segment of the plurality of second segments includes a plurality of reinforcing fibers extending at an angle +α relative to the radial direction. α is greater than 0° and less than 90°.