Layered Carbon-Ceramic Brake Disc for Cost-Strength Balance
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Solution Overview
Problem
Carbon-ceramic brake discs face challenges in achieving superior mechanical performance while maintaining low manufacturing costs, with short-fiber discs prone to surface cracks and long-fiber discs being cost-prohibitive.
Innovation Solution
A carbon-ceramic brake disc design incorporating long fiber layers on opposite sides of a short fiber layer, with specific fiber length and thickness ratios, along with a manufacturing method using mixed powders and curing processes to create a three-layered structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If short fiber reinforced carbon-ceramic brake discs are used, then manufacturing cost is reduced, but mechanical strength and durability deteriorate due to surface cracks
Solution Approach 1:
The patent applies composite materials by combining short fiber reinforced layers with long fiber reinforced layers to create a multi-layer carbon-ceramic brake disc. The short fiber layers provide cost-effective bulk structure while the long fiber layers (with fibers ≥60mm) provide enhanced surface strength and crack resistance where braking forces are applied, thus resolving the contradiction between manufacturing cost and mechanical strength.
Solution Approach 2:
The patent implements local quality by using different fiber lengths in different layers of the brake disc. The long fiber layers are positioned at the surfaces where mechanical strength is most critical for withstanding braking shear forces, while the short fiber layers are used in intermediate or non-critical areas to reduce manufacturing cost. This localized optimization resolves the contradiction between cost and strength.
2Strength
If long fiber reinforced carbon-ceramic brake discs are used, then mechanical strength and durability are improved, but manufacturing cost increases
Solution Approach 1:
The patent uses composite materials structure with multiple layers having different fiber characteristics. By combining long fiber layers (for strength) with short fiber layers (for cost efficiency), the overall mechanical strength is improved compared to pure short fiber discs, while the manufacturing cost is reduced compared to pure long fiber discs, thus resolving the contradiction between strength and manufacturing cost.
Solution Approach 2:
The patent applies local quality by strategically placing long fiber layers only where mechanical strength is most needed (surface layers contacting brake pads), while using shorter fibers in other regions. This localized approach ensures improved strength at critical areas without incurring the full manufacturing cost of using long fibers throughout the entire disc.
3Ease of manufacture
If short fiber carbon-ceramic discs are used, then manufacturing cost is low, but service life deteriorates due to surface cracks from shear forces
Solution Approach 1:
The patent employs composite materials by integrating long fiber reinforced layers into the short fiber carbon-ceramic disc structure. The long fibers (≥60mm) in the surface layers provide enhanced resistance to shear forces and surface crack formation, thereby extending service life, while the majority of the disc structure uses cost-effective short fibers, maintaining low manufacturing cost.
Solution Approach 2:
The patent implements local quality by reinforcing only the critical surface layers with long fibers that are resistant to shear forces and cracking, while keeping the core or non-critical layers with short fibers. This localized reinforcement extends service life at the crack-prone surfaces without significantly increasing manufacturing cost across the entire disc.
Data Source
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AI summary
A carbon-ceramic brake disc and a manufacturing method therefor, and a vehicle. The carbon-ceramic brake disc comprises long fiber layers and a short fiber layer; the long fiber layers are arranged on the two opposite sides of the short fiber layer; the fiber length S2 of the long fiber layers is greater than or equal to 60 mm, and the fiber length S1 of the short fiber layer is less than or equal to 30 mm.