Composites and methods of forming composites having ceramic inserts

Patent metadata

Field	Value
Publication number	US-11448274-B2
Application number	US-202016779873-A
Country	US
Kind code	B2
Filing date	Feb 3, 2020
Priority date	Feb 3, 2020
Publication date	Sep 20, 2022
Grant date	Sep 20, 2022

Abstract

A brake disk may comprise a friction disk formed of at least one of a carbon fiber-ceramic matrix composite material or a carbon fiber-carbon matrix composite material. A first surface of the friction disk defines a first recess. A first ceramic insert comprising ceramic powder may be located in the first recess.

First claim

What is claimed is:

1. A brake disk, comprising:
a first friction disk formed of at least one of a carbon fiber-ceramic matrix composite material or a carbon fiber-carbon matrix composite material, wherein a first surface of the first friction disk defines a first recess, the first surface extending from an inner diameter to an outer diameter of the first friction disk;
a first ceramic insert comprising ceramic powder located in the first recess; and
a second ceramic insert located in a second recess of the first friction disk, wherein the second recess is defined by a second surface of the first friction disk, the second surface being oriented away from the first surface,
wherein the first friction disk comprises at least one of a rotor core or a stator core.

2. The brake disk of claim 1 , wherein the ceramic powder comprises boron carbide.

3. The brake disk of claim 1 , wherein the first ceramic insert further comprises chopped fibers.

4. The brake disk of claim 1 , further comprising a wear liner coupled to the first friction disk.

5. A method of making a friction disk, comprising:
densifying a fibrous preform to form a densified fibrous preform;
forming a plurality of first recesses in a first surface of the densified fibrous preform;
depositing a ceramic powder in the plurality of first recesses; and
depositing carbon around the ceramic powder in the plurality of first recesses using chemical vapor infiltration.

6. The method of claim 5 , further comprising performing a silicon melt infiltration.

7. The method of claim 5 , further comprising:
forming a plurality of second recesses in a second surface of the densified fibrous preform; and
depositing ceramic powder in the plurality of second recesses.

8. The method of claim 5 , wherein the densified fibrous preform comprises carbon fiber-carbon matrix composite material.

9. The method of claim 5 , wherein the ceramic powder in the plurality of first recesses comprises boron carbide.

10. The method of claim 5 , further comprising depositing chopped fibers in the plurality of first recesses.

11. A method of making a brake disk, comprising:
forming a first friction disk by:
forming a plurality of first recesses in a first surface of a first fibrous preform;
depositing a ceramic powder in the plurality of first recesses; and
depositing carbon around the ceramic powder in the plurality of first recesses using chemical vapor infiltration.

12. The method of claim 11 , further comprising coupling a first wear liner over the first surface of the first friction disk.

13. The method of claim 12 , wherein forming the first friction disk further comprises:
forming a plurality of second recesses in a second surface of the first fibrous preform, the second surface being axially opposite the first surface;
depositing ceramic powder in the plurality of second recesses; and
depositing carbon around the ceramic powder in the plurality of second recesses using chemical vapor infiltration.

14. The method of claim 11 , further comprising depositing chopped fibers in the plurality of first recesses.

15. The method of claim 14 , further comprising densifying the first fibrous preform prior to forming the plurality of first recesses.

16. The method of claim 11 , further comprising:
forming a second friction disk by:
forming a plurality of second recesses in a non-wear surface of a second fibrous preform;
depositing ceramic powder in the plurality of second recesses; and
depositing carbon around the ceramic powder in the plurality of second recesses using chemical vapor infiltration; and

coupling the second friction disk to the first friction disk with the non-wear surface of the second friction disk oriented toward the first surface of the first friction disk.

Assignees

• Goodrich Corp

Inventors

• Kirkpatrick Christopher T

Classifications

• F16D65/126 Primary

  the material being of low mechanical strength, e.g. carbon, beryllium; Torque transmitting members therefor · CPC title

• F16D2250/0023

  Shaping by pressure · CPC title

• F16D2065/1324

  carrying friction elements · CPC title

• F16D2065/132

  layered · CPC title

• F16D69/023

  Composite materials containing carbon and carbon fibres or fibres made of carbonizable material · CPC title