Method for making three dimension preform having high heat conductivity and method for making aircraft brake disc having the three dimension preform
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Solution Overview
Problem
Aircraft brake discs generate excessive heat due to increased friction areas as aircraft sizes grow, necessitating a method to rapidly discharge heat effectively.
Innovation Solution
A method involving the manufacturing of a three-dimensional preform with high thermal conductivity using unidirectional carbon fabrics infused with carbon nanomaterials, such as carbon nanotubes, graphine, or graphite powder, which are alternately bonded and stacked with web carbon fabrics, and then subjected to heat treatment and anti-oxidation coating to enhance thermal conductivity and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the sizes of pressure disc, rear disc, rotary discs, and fixing discs are increased to accommodate larger aircrafts, then the friction area increases and more heat is generated, but the ability to discharge heat rapidly deteriorates
Solution Approach 1:
The patent applies composite materials by combining unidirectional carbon fabrics with carbon nanomaterials (carbon nanotubes, graphine, or graphite powder) to create a three-dimensional preform structure. This composite structure maintains the large friction area needed for larger aircraft while introducing highly conductive carbon nanomaterials that create thermal paths for rapid heat discharge, thus resolving the contradiction between increased friction area and heat discharge ability.
Solution Approach 2:
The patent applies local quality by selectively distributing carbon nanomaterials within the carbon fabric structure at specific locations where heat generation occurs during friction. The carbon nanomaterials are impregnated into the unidirectional carbon fabrics and stacked alternately with web carbon fabrics, creating localized high-conductivity regions that facilitate rapid heat discharge from the friction surfaces while maintaining the overall large friction area.
2Temperature
If carbon nanomaterials are impregnated into unidirectional carbon fabrics and stacked alternately with web carbon fabrics, then thermal conductivity increases, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-impregnating carbon nanomaterials into the unidirectional carbon fabrics before stacking. The carbon nanomaterials are introduced into the fabric structure in advance, and the fabrics are pre-assembled in the alternating unidirectional and web configuration before final consolidation. This preliminary preparation simplifies the overall manufacturing process by avoiding complex in-situ nanomaterial deposition steps during assembly.
Solution Approach 2:
The patent uses the unidirectional carbon fabrics as an intermediary carrier to introduce carbon nanomaterials into the three-dimensional structure. Instead of directly depositing nanomaterials onto the final product, the nanomaterials are first impregnated into the fabric matrix, which then serves as a template and delivery mechanism for building the layered preform structure. This intermediary approach simplifies the manufacturing process while ensuring uniform nanomaterial distribution.
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 enables rapid heat dissipation through formed thermal paths, maintaining mechanical strength and friction characteristics, effectively managing increased heat generation during aircraft landings.
Implementation Method 1
a second step of impregnating carbon nanomaterials into the unidirectional carbon fabrics; a three dimension preform with high heat conductivity; rapid heat dissipation through formed thermal paths
Implementation Method 2
a fifth step of stacking the unidirectional carbon fabrics with web carbon fabrics, which are made of a heat resistant fiber, inserted between the unidirectional carbon fabrics; a sixth step of punching the stacked unidirectional carbon fabrics and the web carbon fabrics with a needle
Implementation Method 3
a third step of applying heat treatment, shaping, and anti-oxidation coating on the three dimension preform with carbon deposited thereon
Data Source
AI summary
A method of manufacturing a three dimension preform having high thermal conductivity includes: a first step of manufacturing a unidirectional carbon fabric from a heat resistant fiber; a second step of putting the unidirectional carbon fabric into an aqueous solution with carbon nanomaterials contained in a vessel; a third step of taking the unidirectional carbon fabric out of the vessel and then drying the unidirectional carbon fabric; a fourth step of repeating the second step and the third step; a fifth step of stacking the unidirectional carbon fabrics with web carbon fabrics, which are made of a heat resistant fiber, inserted between the unidirectional carbon fabrics; and a sixth step of punching the stacked unidirectional carbon fabrics and the web carbon fabrics with a needle.