Spiral Carbon Fiber Brake Disc Layup for Bending Crack Resistance
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Solution Overview
Problem
Traditional carbon-based disc-brake discs have regions with low resistance to bending, leading to cracks or fractures in extreme braking applications, such as sports cars or high-speed transportation, due to their stratified structure.
Innovation Solution
A manufacturing method involving a spiral-shaped carbon fibre fabric with overlapping coils, needling, impregnation with phenolic resin, and densification to create a continuous structure with reduced porosity and enhanced bonding between layers, which reduces the likelihood of fractures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional stratified carbon-based materials are used for disc brakes, then the material can be manufactured with standard processes, but the disc has regions with low resistance to bending that lead to cracks or fractures in extreme braking applications
Solution Approach 1:
The patent applies spiral curvature to the carbon fiber fabric, winding it in a continuous spiral pattern around the disc brake. This curved, spiral architecture distributes stress more evenly throughout the structure, eliminating the weak regions found in traditional straight-layer stratified materials and preventing crack propagation.
Solution Approach 2:
The invention creates a composite structure by combining carbon fiber fabric with a binding agent in a spiral configuration. This composite approach integrates multiple material properties - the tensile strength of carbon fibers with the binding properties of the resin - to achieve superior bending resistance and fracture toughness compared to traditional carbon-caron composite layers.
2Reliability
If spiral-shaped carbon fibre fabric with overlapping coils is used, then the continuous structure reduces fractures, but the manufacturing process becomes more complex
Solution Approach 1:
The spiral fabric structure is designed to self-interlock and self-bind through the overlapping coils. The continuous spiral pattern naturally creates mechanical interlocking between layers, and the binding agent simply needs to infiltrate this pre-formed structure, eliminating the need for complex fastening or assembly operations.
Solution Approach 2:
The carbon fiber fabric is pre-formed into a spiral shape with overlapping coils before being placed in the mold. This preliminary structuring creates the fracture-resistant architecture in advance, so that during manufacturing only simple infiltration and curing are needed, rather than building the complex spiral structure during the manufacturing process itself.
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 method and resulting material significantly decrease the occurrence of fractures while maintaining high strength and circular fibre arrangement, simplifying production and reducing costs, and eliminating the need for additional equipment or cutting steps.
Implementation Method 1
impregnating at least part of the layers of material 6 of step ii) or step iii) by means of an impregnating agent, preferably a phenolic resin
Implementation Method 2
densifying the product of step iii) or iv) up to a desired density range to obtain the shaped material 1,1'
Data Source
AI summary
A shaped material (1, 1′), for example a disk for a disk brake, preferably a ventilated disk, includes a plurality of layers of material (6) in a spiral shape, overlapping along a development axis (X). Each layer of material (6) it is formed by a fabric (2) predominantly or exclusively made of carbon fibres (8), at least part of the layers being impregnated by an impregnating agent. A method is for the manufacture of a shaped material.