Composite Friction Disk With Ceramic Inserts for Brake Heat Capacity
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Solution Overview
Problem
Existing aircraft brake systems face challenges in incorporating boron or boron carbide materials into carbon fiber structures due to limitations on size and amount, leading to difficulties in achieving the required heat capacity and thermal stability for next-generation heat sinks.
Innovation Solution
A method of forming friction disks with ceramic inserts by depositing ceramic powder, such as boron carbide, into recesses of carbon fiber-ceramic matrix composite materials, and securing it with a carbon matrix using chemical vapor infiltration, allowing for improved heat dissipation and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If boron or boron carbide materials are incorporated into carbon fiber structures, then heat capacity and thermal stability are improved, but limitations on size and amount of high heat capacity materials arise
Solution Approach 1:
The invention utilizes the porous structure of carbon fiber preforms to incorporate ceramic materials. The preform's porosity allows embedding of ceramic fibers, powders, or solid structures throughout the volume, enabling high heat capacity material incorporation without compromising the carbon fiber structure's integrity or mechanical properties
Solution Approach 2:
The invention creates a composite structure combining carbon fiber preform with ceramic materials (boron, boron carbide, silicon carbide, etc.). This composite approach allows the friction disk to benefit from both the mechanical properties of carbon fiber and the thermal properties of ceramic materials, resolving the contradiction between heat capacity and material quantity limitations
2Temperature
If solid disks of boron carbide are used, then heat capacity is improved, but they are susceptible to fracture and cost increases
Solution Approach 1:
The invention applies ceramic materials locally within recesses or embedded in the carbon fiber preform rather than using solid ceramic disks. This localized approach provides thermal enhancement where needed while maintaining the overall structural integrity and fracture resistance of the composite friction disk
Solution Approach 2:
By creating a composite structure where ceramic materials are embedded within or coupled to carbon fiber-based friction disks, the invention combines the high heat capacity of ceramics with the toughness and fracture resistance of carbon fiber composites, eliminating the brittleness issue of solid ceramic disks
3Reliability
If ceramic powder is deposited into recesses and secured with carbon matrix using chemical vapor infiltration, then wear resistance and heat dissipation are improved, but manufacturing complexity increases
Solution Approach 1:
The invention performs preliminary actions by forming recesses in the friction disk before final ceramic powder deposition. This allows for controlled embedding of ceramic materials in specific locations and orientations, improving wear resistance and heat dissipation while maintaining manageable manufacturing complexity through structured process sequencing
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
The method enhances the heat capacity and wear performance of friction disks, enabling them to withstand and dissipate heat effectively during braking actions.
Implementation Method 1
depositing carbon around the ceramic powder in the plurality of second recesses using chemical vapor infiltration
Data Source
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Figure 3A
AI summary
The invention relates to a brake disk comprising a friction disk (100a) formed of at least one of a carbon fiber-ceramic matrix composite material or a carbon fiber-carbon matrix composite material. A first surface (104a) of the friction disk defines a first recess (112a). A first ceramic insert (110a) comprising ceramic powder may be located in the first recess. Further aspect of the invention relates to a method of making a friction disk.