Shaped Composite Disc Brake Material
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Solution Overview
Problem
Ceramic composite materials (CCM-R) used in disc brakes for extreme applications are costly due to high production costs associated with machining ventilation holes, which is not feasible for conventional production plants and increases material wastage.
Innovation Solution
A shaped composite material comprising an inner layer of CCM with short, disorderly carbon filaments and outer layers of CCM-R with orderly fabric structure, allowing for moulding and reducing production costs through a process involving carbon densification, silicon infiltration, and pyrolysis, enabling the creation of ventilated discs with high performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If CCM-R material with orderly fabric structure is used for high performance applications, then mechanical strength and heat conductivity are improved, but manufacturing cost increases due to inability to mould and requirement for machining ventilation holes
Solution Approach 1:
The invention divides the disc into two distinct layers: an inner layer made of mouldable CCM material containing ventilation holes, and outer layers made of high-performance CCM-R material. This segmentation allows each layer to contribute its specific advantages while overcoming the limitations of using solely expensive CCM-R material throughout the entire disc structure.
Solution Approach 2:
The invention applies different material qualities to different regions of the disc. The inner layer uses mouldable CCM material suitable for creating ventilation structures, while the outer layers use high-strength CCM-R material where maximum mechanical performance is required. This local differentiation optimizes both manufacturing ease and structural strength.
2Temperature
If CCM-R material is used for extreme applications, then heat conductivity is improved, but material wastage increases due to machining requirements
Solution Approach 1:
By segmenting the disc into an inner mouldable layer and outer CCM-R layers, the invention enables ventilation holes to be created during moulding of the inner layer rather than through subsequent machining of the entire disc. This significantly reduces material wastage while preserving the high heat conductivity of CCM-R in the outer layers where it is most needed for thermal management.
3Ease of manufacture
If conventional CCM material is used for road applications, then production cost is reduced, but mechanical strength and heat conductivity are insufficient for extreme applications
Solution Approach 1:
The invention applies high-strength CCM-R material specifically to the outer layers where maximum mechanical strength and heat conductivity are critical for extreme applications, while using more economical mouldable CCM material for the inner layer. This local quality differentiation ensures performance adequacy for extreme conditions while optimizing production costs.
Solution Approach 2:
The invention creates a composite structure combining two different carbon composite materials: mouldable CCM and high-performance CCM-R. This composite approach allows the disc to exhibit properties of both materials, achieving a balance between cost-effectiveness and extreme application performance that neither material could provide alone.
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 disc brake material with optimal mechanical strength and heat conductivity at a lower cost, maintaining high performance while reducing production expenses and material wastage, suitable for both extreme and road applications.
Implementation Method 1
subsequent suitable heat treatments that lead to an increase in heat conductivity and carbon densifying processes, for example through CVD (Chemical Vapour Deposition)
Implementation Method 2
subsequent suitable heat treatments that lead to an increase in heat conductivity and carbon densifying processes, for example through CVI (Chemical Vapour Infiltration)
Implementation Method 3
the C/C preforms of these materials can, in a subsequent process stage, be infiltrated with silicon at high temperatures
Implementation Method 4
part of the carbon forms silicon carbide (SiC) by reaction with part of the infiltrated silicon (Si)
Implementation Method 5
a process involving carbon densification, silicon infiltration, and pyrolysis
Data Source
Figure 1~3
AI summary
The present invention concerns a shaped composite material and a method for producing it. More specifically, the invention concerns a disc for a disc brake made from ceramic composite materials, usually known as "CMC", i.e. "Carbon Material Ceramic" or "CCM", i.e. "Carbon Ceramic Material". These materials consist of carbon matrices containing carbon fibres usually infiltrated with silicon and a product of reaction between C and Si, silicon carbide (SiC). More specifically, the invention concerns a shaped composite material comprising a inner layer (3; 103) of CCM C/SiC/Si material comprising disorderly short filaments consisting mainly of carbon and respective outer layers (2, 2'; 102, 102') of C/SiC/Si material and having an orderly fabric structure of mainly carbon fibres.