Segmented Carbon Wear Liner Structure for Aircraft Brake Warpage
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Solution Overview
Problem
Aircraft brake systems face issues with wear liners warping due to wear, leading to reduced effectiveness and increased material waste, as existing solutions do not adequately address the structural and frictional challenges at high brake energy conditions.
Innovation Solution
The implementation of segmented wear liners, composed of carbon composite material, which are coupled to the friction disk core via fasteners through protrusions or flanges, allowing for thermal expansion and reducing warpage by distributing wear evenly across multiple segments, thereby extending the lifespan and reducing material consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wear liners are made as single-piece continuous structure, then manufacturing is simpler, but they become susceptible to warpage and structural deformation under high brake energy conditions
Solution Approach 1:
The wear liner is divided into multiple discrete segments (typically 3-6 segments per liner) that are coupled to the friction disk core via fasteners. Each segment is independently attachable and removable, allowing the wear liner to accommodate thermal expansion and contraction without warping while maintaining structural integrity under high brake energy conditions.
2Loss of substance
If wear liners are made thinner to reduce material waste, then material consumption decreases, but they become more susceptible to warpage and structural failure
Solution Approach 1:
The segmented design allows each individual segment to be thinner and more flexible, reducing overall material consumption while the distribution across multiple segments prevents warpage and structural failure that would occur in a single thick piece.
Solution Approach 2:
The wear liner segments are designed as replaceable components that can be individually removed and replaced when worn, allowing the reusable core to be retained and the worn segments to be discarded, thereby reducing material waste while maintaining structural integrity.
3Duration of action of moving object
If wear liners are made thicker to increase lifespan and reduce replacement frequency, then operational longevity increases, but they become more prone to warpage and structural deformation
Solution Approach 1:
The segmented structure allows each segment to independently accommodate thermal expansion and contraction, preventing the warpage and structural deformation that would occur in a single thick piece, while still providing sufficient thickness for extended operational lifespan.
4Ease of manufacture
If conventional wear liner materials are used, then material availability and cost are favorable, but they do not adequately address structural and frictional challenges at high brake energy conditions
Solution Approach 1:
The wear liner segments are constructed from composite materials that combine the structural integrity needed to withstand high brake energy conditions with the frictional properties required for effective braking, while maintaining the segmented design for warpage resistance.
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 segmented design enhances the operational longevity of wear liners, reduces material waste, and maintains effective braking performance by minimizing warpage and allowing for greater wear before replacement, while providing structural and frictional advantages through the use of carbon composite materials.
Implementation Method 1
allowing for thermal expansion and reducing warpage by distributing wear evenly across multiple segments
Implementation Method 2
Aircraft brake systems typically employ a series of friction disks that may be forced into contact with one another to stop the aircraft
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A friction disk comprises a friction disk core and a wear liner (50) coupled to the friction disk core. A depression (120) is formed in a surface of the friction disk core. The wear liner comprises a protrusion (160) extending from a non-wear surface of the wear liner. The protrusion is positioned within the depression of the friction disk core.