Needle-Punched Fibrous Preform for Controlled Z-Axis Fibre Alignment
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Solution Overview
Problem
Current methods for producing carbon fibre preforms for braking systems, such as carbon/carbon (C/C) brake discs, fail to distribute fibres in a controlled manner both on the main plane and orthogonal to it without causing fibre damage, leading to inadequate mechanical and thermal properties.
Innovation Solution
A method involving the superposition of carbon fibre layers, followed by needle-punching with a device equipped with barbs to orient fibres parallel to a predefined axis, using non-woven layers to protect woven layers and control fibre distribution, allowing for controlled fibre arrangement without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If needle-punching is used to arrange fibres parallel to the superposition axis, then fibres are distributed homogeneously on the axis Z, but fibres are forced damaged reducing mechanical features
Solution Approach 1:
The invention separates fibre placement into two distinct mechanisms: non-woven layers provide homogeneous orthogonal distribution through needle-punching, while woven layers preserve fibre integrity for in-plane strength. This segmentation allows homogeneous distribution without the harmful effects of forced fibre arrangement
Solution Approach 2:
The non-woven layer acts as an intermediary that enables homogeneous fibre distribution along the axis Z without directly damaging the more critical woven fibres. The non-woven fibres serve as a sacrificial medium that achieves distribution homogeneity while protecting the structural integrity of the woven fibre system
2Ease of manufacture
If impregnation and moulding of short fibres is used, then production cost and simplicity are reduced, but fibres along the axis Z are almost totally absent resulting in poor technical features
Solution Approach 1:
The invention performs preliminary arrangement of fibres in specific configurations (woven and non-woven layers) before the impregnation and moulding process. This preliminary structuring ensures that fibres are already positioned to provide both in-plane and orthogonal strength, eliminating the need for complex post-processing while maintaining simple production methods
Solution Approach 2:
The invention uses a composite structure combining woven and non-woven fibre layers, each contributing different properties. The woven layers provide in-plane strength while the non-woven layers provide orthogonal fibre distribution, achieving superior technical features while maintaining the simplicity of impregnation and moulding processes
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 enables controlled fibre distribution, enhancing mechanical strength and thermal conductivity of C/C brake discs by ensuring fibres are aligned appropriately, improving the overall performance of braking systems while maintaining fibre integrity.
Implementation Method 1
a step b) of needle-punching by means of least one first needle-punching device the multilayer body in a needle-punching direction substantially parallel to the superposition axis to arrange at least part of the fibres parallel to the superposition axis
Implementation Method 2
using non-woven layers to protect woven layers and control fibre distribution, allowing for controlled fibre arrangement without damage
Data Source
AI summary
A method of making a fibrous preform in carbon and/or fibres of a carbon precursor may include superposing at least two layers of carbon fibres and/or fibres of a carbon precursor according to a predefined superposition axis Z so as to form a multilayer body. The method may also include needle-punching via least one first needle-punching device the multilayer body in a needle-punching direction substantially parallel to the superposition axis Z to arrange at least part of the fibres parallel to the superposition axis Z, so as to obtain a needle-punched multilayer body. An optional step may include superposing with each other according to the superposition axis Z two or more of the needle-punched multilayer bodies, obtained separately by applying the above steps.