Composite Structure Forming via Vibratory Fiber Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming composite structures, such as carbon/carbon brake disks, face challenges in achieving precise fiber distribution and economical production, particularly in creating layers with optimal fiber content and heat dissipation properties for high-temperature applications like aircraft brake disks.
Innovation Solution
A method involving the rotation of a base layer with carbon short fibers transferred from vibratory feed ramps, where the fibers are vibrated and compressed to form dense fibrous layers, potentially incorporating secondary materials like ceramic particles, and densified using techniques like chemical vapor infiltration or pre-ceramic polymer infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional methods are used to form composite fiber layers, then production can be maintained at standard pace, but fiber distribution uniformity and layer precision deteriorate
Solution Approach 1:
The patent employs vibratory feed ramps that vibrate during the fiber transfer process. This mechanical vibration causes the carbon short fibers to bounce and redistribute themselves uniformly across the base layer, ensuring consistent fiber distribution and layer precision while maintaining economical production speeds.
2Manufacturing precision
If carbon fiber strands are cut into short fibers, then fiber distribution and heat dissipation improve, but fiber length and structural continuity worsen
Solution Approach 1:
The patent optimizes the fiber length parameter by cutting carbon fiber strands into short fibers of specific lengths (0.5-2 inches). This parameter change improves fiber distribution uniformity and heat dissipation properties while the vibratory transfer process compensates for the reduced continuity, achieving optimal balance for brake disk applications.
3Strength
If multiple fibrous layers are compressed and densified, then mechanical strength and heat resistance improve, but production complexity and process time worsen
Solution Approach 1:
The patent performs preliminary compression and densification of each fibrous layer during the layer formation process itself, using compression zones integrated into the rotating mold system. This preliminary action ensures proper density and strength development before subsequent processing steps, reducing overall process complexity and time.
Solution Approach 2:
The patent creates composite structures by combining multiple densified fibrous layers with secondary materials such as ceramic particles, powdery resin, carbon particles, or graphite particles. This composite approach enhances mechanical strength and heat resistance while the integrated processing method keeps complexity manageable.
4Temperature
If secondary materials are incorporated during fiber transfer, then high-temperature properties and heat dissipation improve, but manufacturing complexity worsens
Solution Approach 1:
The patent merges the transfer of carbon short fibers and secondary materials (ceramic particles, powdery resin, carbon particles, or graphite particles) through a single integrated vibratory feed ramp system. This combining approach allows simultaneous deposition of multiple materials during one processing pass, enhancing heat dissipation capability while avoiding the need for separate manufacturing steps.
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
This approach enables the creation of composite structures with uniform fiber distribution and enhanced high-temperature properties, improving heat dissipation and mechanical resilience for applications like aircraft brake disks.
Implementation Method 1
vibrating the first vibratory feed ramp during the transferring the carbon short fibers
Implementation Method 2
compressing each of the plurality of fibrous layers during the rotating the base layer at a compression zone of the apparatus
Implementation Method 3
densifying the carbon structure by chemical vapor infiltration
Data Source
Figure 1A~1B
Figure 2A
Figure 2B
AI summary
The present disclosure provides systems and methods for forming a composite structure comprising rotating a base layer (113) of an apparatus for forming the composite structure about an axis of rotation, transferring carbon short fibers from a first vibratory feed ramp (130) onto the base layer in order to form a plurality of fibrous layers in the composite structure, and vibrating the first vibratory feed ramp (120) during the transferring the carbon short fibers. The base layer may comprise an annular shape.