Low Density Cloth Preform Needling for Carbon Matrix Infiltration
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Solution Overview
Problem
The manufacturing of high-performance brake rotors for aircraft and vehicles faces challenges with the density of brake rotor preforms, as existing methods require capital-intensive carbon vapor deposition or high-pressure resin infiltration, which can lead to delamination and higher costs due to the need for dense preforms.
Innovation Solution
A low-density cloth preform is manufactured using a needling machine with a foam base and barbed needles, configured to minimize vertical deflection and ensure uniform needling depth, allowing for more rapid and cost-effective addition of matrix carbon through less expensive sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional needling machines are used to manufacture brake rotor preforms, then the preforms achieve sufficient density for structural integrity, but the manufacturing process requires greater needling depth which increases complexity and time
Solution Approach 1:
The patent changes the physical parameters of the needling machine by replacing the traditional rigid base with a compliant base having controlled mechanical properties. This allows the base to deform and rebound in response to needling forces, automatically compensating for variations in preform density and thickness without requiring complex control systems or sensors.
Solution Approach 2:
The compliant base acts as an intermediary element between the needling needles and the preform material. It mediates the interaction by absorbing and distributing the mechanical forces during needling, ensuring uniform penetration depth across the entire preform surface while simplifying the overall machine structure.
2Productivity
If high-pressure resin infiltration is used to add matrix carbon to preforms, then carbon is added rapidly and cost-effectively, but the preforms blow apart or become delaminated during the process
Solution Approach 1:
The patent modifies the density parameter of the preform by adjusting the needling process using the compliant base. This creates an optimal density range that is low enough to allow rapid carbon infiltration but high enough to maintain structural integrity during the high-pressure resin infiltration process, eliminating delamination issues.
3Reliability
If carbon vapor deposition is used to add matrix carbon to preforms, then the process is reliable, but it is capital-intensive and time-consuming
Solution Approach 1:
The patent optimizes the preform density parameter through compliant base needling to enable the use of faster, more cost-effective carbon addition methods such as resin infiltration or slurry dipping, while maintaining sufficient structural integrity. This eliminates the need for capital-intensive and time-consuming CVD processes.
4Reliability
If greater needling depth is used to ensure uniform needling throughout the preform, then manufacturing reliability improves, but the preform density increases making it less suitable for rapid carbon addition
Solution Approach 1:
The compliant base serves as a mechanical intermediary that automatically regulates needling depth through its deformation and rebound characteristics. This passive mechanical control achieves uniform needling throughout the preform without over-compression, maintaining optimal density for subsequent carbon addition 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
The solution results in a preform with reduced density, enhancing its suitability for various carbon matrix addition processes, reducing delamination, and lowering production costs while maintaining structural integrity.
Implementation Method 1
The resilient material is selected and the barbed needles are geometrically arranged and positioned relative to a sensor for determining the elevation of the preform material's top surface, such that the top surfaces of the foam base and preform material have a sufficient amount time to rebound substantially to their respective pre-needled elevations before encountering the sensor.
Implementation Method 2
The segments are needled together in the vertical direction with a needling machine in an attempt to form a unitary structure from the layers of annular-shaped segments.
Data Source
AI summary
The disclosure describes a low density cloth preform, and apparatuses and methods for manufacturing the same. The low density cloth preform has a lower density than other preforms manufactured using prior apparatuses and methods, thereby rendering the low density cloth preform more amenable to the addition of matrix carbon thereto through the use of less expensive carbon sources and more rapid processes for adding matrix carbon. The apparatuses and methods for manufacturing the low density cloth preform comprise preform needling machines configured and preform needling processes operable to provide a more uniform and lesser needling depth with the result being a preform having a lower density. The preform needling machines utilize foam bases formed from resilient materials having appropriate rebound rates, arrangements of barbed needles in one or more groups and needling stages, and positioning of the barbed needles to minimize deflection of the foam bases and preform material.