Keyed Brake Disk Assembly with Floating Core
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Solution Overview
Problem
Aircraft brake systems face challenges with high-temperature degradation of traditional steel friction disks and noise/vibration issues with carbon composite disks, which are expensive and less effective in braking performance during high-speed landings and rejected takeoffs.
Innovation Solution
The design incorporates rotatable friction disks with a floating core and wear liners that prevent rotation during braking, using carbon composite materials for structural and frictional advantages, and a multi-disk brake system with interleaved rotatable and non-rotatable disks to manage heat and vibration effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If steel friction disks are used, then cost is reduced, but braking effectiveness deteriorates under high temperatures
Solution Approach 1:
The friction disk uses a composite structure combining steel backplate with carbon composite friction material layers. This allows the disk to leverage the high-temperature resistance of carbon composites while maintaining the structural strength and cost-effectiveness of steel, resolving the contradiction between material performance and manufacturing cost
2Temperature
If carbon composite friction disks are used, then high temperature resistance is improved, but manufacturing cost increases
Solution Approach 1:
The friction disk employs a composite structure with a steel backplate and carbon composite friction layers. The steel backplate provides structural integrity and is more cost-effective, while the carbon composite layers provide high-temperature resistance, thus achieving heat resistance without fully incurring the high cost of solid carbon composite disks
Solution Approach 2:
The friction disk is divided into functional segments: a steel backplate for structural support and carbon composite layers for friction and heat resistance. This segmentation allows each material to be optimized for its specific function, reducing overall manufacturing cost while maintaining high-temperature performance
3Ease of operation
If friction disks are used, then braking function is achieved, but noise and vibration increase
Solution Approach 1:
A dampener layer is introduced as an intermediary between the friction surfaces and the disk structure. This dampener absorbs and dissipates vibration energy generated during braking, reducing noise and vibration while maintaining effective braking function
Solution Approach 2:
The friction disk design modifies physical parameters such as disk thickness, material density distribution, and damping characteristics to optimize the balance between braking effectiveness and vibration noise reduction
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 solution enhances braking effectiveness and durability by reducing noise and vibration, maintaining performance under high temperatures, and providing a cost-effective alternative to traditional materials while ensuring reliable operation during high-stress conditions.
Implementation Method 1
The friction disks withstand and dissipate the heat generated from contact between one another during braking
Implementation Method 2
friction disks forced into contact with each other to stop the aircraft
Data Source
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AI summary
Friction disks such as rotors and stators, including floating cores (300) are disclosed. The friction disks may include a carrier plate (49) and a wear liner (60) coupled to each side of the core (300). The floating core (300) may be located between the wear liners (60). The floating core (300) may include a key which is located within a key notch in the carrier plate (49). The key may prevent the floating core (300) from rotating relative to the carrier plate (49).