Split Friction Disk Assembly With Carbon Foam Vibration Damping
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Solution Overview
Problem
Aircraft brake systems experience vibrations during operation due to high torque, leading to reduced effectiveness and potential structural damage, as conventional carbon friction disks are poor at damping vibrations.
Innovation Solution
The use of split friction disk assemblies with a carbon foam damping feature between disk halves, which reduces vibration and noise by employing a less dense carbon foam material that absorbs energy and is integrated into the disk brake system to enhance damping characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon friction disks are used in brake systems, then compressive strength is improved, but vibration damping capability deteriorates
Solution Approach 1:
The patent employs a composite material structure consisting of a carbon friction disk with a carbon foam core. The carbon friction disk provides high compressive strength and friction properties, while the carbon foam core provides vibration damping capability. This composite structure resolves the contradiction by combining materials with complementary properties - the dense carbon friction material for strength and the less dense carbon foam for damping vibrations.
Solution Approach 2:
The patent applies local quality by creating a differentiated structure where the carbon friction disk has varying density - a denser outer friction surface for strength and wear resistance, and a less dense carbon foam core for vibration damping. This local variation in material properties allows the single component to simultaneously achieve both high compressive strength and effective vibration damping.
2Object-affected harmful factors
If less dense carbon foam material is used for damping, then vibration damping capability is improved, but structural strength may deteriorate
Solution Approach 1:
The patent uses a composite material system where the carbon foam core is integrated within the carbon friction disk structure. The carbon foam provides the necessary vibration damping with its cellular structure, while the surrounding carbon friction material provides structural support and strength. This composite approach allows the less dense damping material to function effectively without compromising overall structural integrity.
Solution Approach 2:
The patent segments the friction disk into functional zones - an outer friction surface layer for structural strength and braking function, and an inner carbon foam core for vibration damping. This segmentation allows each zone to be optimized for its specific function while working together as an integrated component, resolving the contradiction between density for damping and structural strength.
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 carbon foam damping feature effectively reduces vibrations and noise in aircraft brake systems, improving their operational effectiveness and structural integrity by tuning the damping characteristics of the disk brake system.
Implementation Method 1
carbon foam damping feature between disk halves, which reduces vibration and noise by employing a less dense carbon foam material that absorbs energy
Implementation Method 2
less dense carbon foam material that absorbs energy
Data Source
Figure 1
Figure 2A~2B
AI summary
A friction disk brake system may comprise a plurality of rotor friction disks (42) and a plurality of stator friction disks (40). At least one of the friction disks (40, 42) may be a split disk friction disk (95). The split disk friction disk (95) may comprise a first disk half (82) and a second disk half (83). A carbon foam damping feature (50) may be located between the first disk half (82) and the second disk half (83).