Method for manufacturing composite fiber preform for disc brakes

Patent metadata

Field	Value
Publication number	US-12371388-B2
Application number	US-202117407056-A
Country	US
Kind code	B2
Filing date	Aug 19, 2021
Priority date	Aug 19, 2021
Publication date	Jul 29, 2025
Grant date	Jul 29, 2025

Abstract

An example method includes forming an interlayer on a carbon fiber fabric to form a composite fiber fabric. The interlayer comprises a binder. The method further includes winding the composite fiber fabric around a core to form a composite fiber preform comprising a plurality of layers defining an annulus extending along a central axis. The method further includes densifying the composite fiber preform.

First claim

What is claimed is:

1. A method comprising:
forming an interlayer on a carbon fiber fabric to form a composite fiber fabric, wherein the interlayer comprises a binder;
winding the composite fiber fabric around a core to form a composite fiber preform comprising a plurality of layers defining an annulus extending along a central axis, wherein the interlayer is formed on the carbon fiber fabric without needling and prior to winding the composite fiber fabric, wherein a portion of carbon fibers of the carbon fiber fabric having a substantially in-plane orientation is greater than or equal to about 50%, wherein a portion of carbon fibers of the carbon fiber fabric having a substantially out-of-plane orientation is less than or equal to about 50%, wherein the out-of-plane orientation is parallel with a radial orientation of the composite fiber preform; and
densifying the composite fiber preform.

2. The method of claim 1 , wherein the binder comprises at least one of a resin, a thermoset resin, or a phenolic resin.

3. The method of claim 1 , wherein depositing the interlayer comprises:
depositing the binder in a dry powder form onto the carbon fiber fabric;
compressing the binder to the carbon fiber fabric prior to winding the composite fiber fabric; and
curing, after winding, the binder.

4. The method of claim 1 , wherein the interlayer comprises a plurality of nanoparticles in the binder, the method further comprising blending the plurality of nanoparticles with the binder prior to depositing the interlayer.

5. The method of claim 4 , wherein the plurality of nanoparticles comprise at least one of a carbon nanotube, a carbon nanofiber, or a graphene nanoplatelet.

6. The method of claim 1 , wherein depositing the interlayer comprises:
mixing the binder with a solvent to form a binder solution;
coating a surface of the carbon fiber fabric with the binder solution;
compressing the binder to the carbon fiber fabric prior to winding the composite fiber fabric;
drying the binder solution; and
curing, after winding, the binder.

7. The method of claim 6 , further comprising mixing a plurality of nanoparticles with the binder solution prior to coating the binder.

8. The method of claim 1 , further comprising consolidating the interlayer and the carbon fiber fabric to increase a carbon fiber volume fraction of the composite fiber preform via controlling a tension of the composite carbon fiber fabric.

9. The method of claim 8 , wherein controlling the tension of the composite carbon fiber fabric comprises controlling a percent of a carbon fiber volume relative to a total volume of the composite fiber preform between about 5% to about 35%.

10. The method of claim 1 , wherein the core comprises a filament wound carbon tow, wherein the composite fiber preform is removable from the core.

11. The method of claim 1 , further comprising wrapping a compaction layer around an outer diameter of the composite fiber preform, wherein the compaction layer is configured to maintain a compaction of the composite fiber preform, wherein the compaction layer comprises a filament wound carbon tow.

12. The method of claim 11 , further comprising thermal cycling the composite fiber preform to rigidize at least one of the core, the composite fiber preform, or the compaction layer.

13. The method of claim 1 , further comprising:
carbonizing at least a portion of the composite fiber preform,
wherein densifying the composite fiber preform comprises densifying the composite fiber preform via chemical vapor deposition.

14. The method of claim 1 , further comprising sectioning the densified composite fiber preform into one or more discs defining respective composite brake pads or discs.

15. A system comprising:
a fabric source comprising a carbon fiber fabric;
an interlayer source configured to form an interlayer on the carbon fiber fabric without needling and prior to winding the carbon fiber fabric and the interlayer, wherein a portion of carbon fibers of the carbon fiber fabric having a substantially in-plane orientation is greater than or equal to about 50%, wherein a portion of carbon fibers of the carbon fiber fabric having a substantially out-of-plane orientation is less than or equal to about 50%, wherein the out-of-plane orientation is parallel with a radial orientation of the carbon fiber fabric; and
a winding apparatus configured to wind the carbon fiber fabric and the interlayer around a core to form a composite fiber preform and defining an annulus extending along a central longitudinal axis, the fiber preform comprising:
a plurality carbon fiber fabric layers extending in an axial direction parallel with the longitudinal axis and a circumferential direction perpendicular to both the radial and axial directions, wherein each layer of the plurality of carbon fiber fabric layers comprises a plurality of elongate carbon fibers; and

a plurality interlayers extending in an axial direction parallel with the longitudinal axis and a circumferential direction perpendicular to both the radial and axial directions, wherein the interlayer comprises a binder configured to mechanically bind one or more adjacent carbon fiber fabric layers.

Assignees

• Honeywell Int Inc

Inventors

• Tang Long Gui
• Glen Stefan
• Piao Yanmei
• Murdie Neil
• James Mark C

Classifications

• F16D2200/0082

  Production methods therefor · CPC title

• F16D2200/0065

  Inorganic, e.g. non-asbestos mineral fibres · CPC title

• F16D2069/008

  Layers of fibrous materials · CPC title

• F16D69/023

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

• F16D65/126

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