Composite Fiber Preform Interlayers for Longer-Life Disc Brakes
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Solution Overview
Problem
Existing carbon-carbon composite brake discs in the aerospace industry face challenges with wear rate and thermal conductivity, which affect their usable life and efficiency in high-temperature applications.
Innovation Solution
A method involving the use of a highly oriented milled carbon fiber ply as an interlayer combined with a carbon fiber fabric, wound around a core to form a composite fiber preform, which is then densified, providing axial orientation of fibers to enhance mechanical stability and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional carbon fiber fabric layers are wound around a core to form a composite fiber preform, then the structural integrity and mechanical strength are improved, but the thermal conductivity and wear resistance remain insufficient for high-temperature aerospace applications
Solution Approach 1:
The patent employs a composite fiber preform structure combining carbon fiber fabric layers with interlayers containing highly oriented milled carbon fibers. This composite architecture integrates the tensile strength of fabric layers with the thermal conductivity of aligned fiber interlayers, creating a material system that simultaneously achieves mechanical strength and thermal performance required for aerospace brake discs.
Solution Approach 2:
The invention introduces a new dimensional aspect by incorporating interlayers with highly oriented milled carbon fibers between the conventional fabric layers. This additional dimensional element (the interlayer orientation) provides a pathway for enhanced thermal conductivity in the radial direction, complementing the mechanical strength provided by the fabric layers' in-plane orientation.
2Ease of manufacture
If conventional carbon fiber fabric layers are used without interlayers, then the manufacturing process is simpler, but the wear rate is too high and usable life is reduced
Solution Approach 1:
The patent segments the composite structure into distinct functional layers: carbon fiber fabric layers for mechanical strength and interlayers with highly oriented milled carbon fibers for wear resistance and thermal conductivity. This segmentation allows each layer to be optimized for its specific function while maintaining a relatively simple winding manufacturing process.
Solution Approach 2:
The invention applies local quality by placing interlayers with highly oriented milled carbon fibers at specific locations between the fabric layers. This localized enhancement of fiber orientation provides improved wear resistance and thermal conductivity precisely where needed, without complicating the overall manufacturing process or requiring changes to the fabric layers themselves.
3Temperature
If highly oriented milled carbon fiber interlayers are incorporated into the composite fiber preform, then thermal conductivity and wear resistance are improved, but the device complexity increases
Solution Approach 1:
The interlayers with highly oriented milled carbon fibers serve multiple functions simultaneously: they provide thermal conductivity pathways, enhance wear resistance, and contribute to the overall structural integrity. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity despite the enhanced thermal performance.
Solution Approach 2:
The invention modifies the fiber orientation parameter by using highly oriented milled carbon fibers in the interlayers, creating a preferred orientation that enhances thermal conductivity and wear resistance. This parameter change is achieved through a controlled winding process that maintains manufacturing simplicity while improving thermal performance.
4Productivity
If carbon fiber fabric layers are wound without interlayers, then the manufacturing process is faster, but heat dissipation is insufficient leading to reduced performance
Solution Approach 1:
The interlayers with highly oriented milled carbon fibers act as intermediary elements between the fabric layers, providing thermal pathways that facilitate heat dissipation. These interlayers mediate the thermal transfer across the composite structure without significantly impacting the winding manufacturing speed, as they can be integrated into the existing layer-by-layer fabrication process.
Data Source
AI summary
An example method includes forming an interlayer on a carbon fiber fabric to form a composite fiber fabric. The interlayer comprises a binder. The method further includes winding the composite fiber fabric around a core to form a composite fiber preform comprising a plurality of layers defining an annulus extending along a central axis. The method further includes densifying the composite fiber preform.