Preventing carbon AO migration by limiting surface porosity

Patent metadata

Field	Value
Publication number	US-9709109-B2
Application number	US-201414455259-A
Country	US
Kind code	B2
Filing date	Aug 8, 2014
Priority date	Nov 25, 2008
Publication date	Jul 18, 2017
Grant date	Jul 18, 2017

Abstract

In the manufacture of carbon-carbon composite brake discs, migration of anti-oxidant substances into the friction surfaces is prevented by limiting or eliminating surface porosity in the carbon-carbon composite brake materials. The method includes infusing a suitable resin into pores in surface layers of the carbon-carbon composite disc and then charring the resin-infused disc to convert the resin in the pores to pyrolytic carbon. The resin may be infused into the carbon disc by submerging the disc in a molten resin. Prior to submerging the disc in the molten resin, the disc may subjected to a vacuum to remove air from the pores. While the disc is submerged in the molten resin, the pressure in the pressurizable vessel may increased to force the molten resin into the open porosity of the disc.

First claim

What is claimed is:

1. A brake disc comprising:
a heat-treated carbon-carbon composite friction disc body having a density of between about 1.6 g/cm 3 and about 1.9 g/cm 3 , wherein the heat-treated carbon-carbon composite friction disc body has undergone heat treatment at a temperature greater than about 1600 Celsius, and wherein the heat-treated carbon-carbon composite friction disc body comprises surface layers that define pores in the surface layers; and
a pyrolytic carbon formed within at least some of the pores in the surface layers of the heat-treated carbon-carbon composite friction disc body, wherein the pyrolytic carbon substantially seals the pores in the surface layers, and
wherein the pyrolytic carbon comprises a charred phenolic resin, a charred epoxy resin, or a charred cyanate ester resin.

2. The brake disc of claim 1 , further comprising a liquid anti-oxidation solution coated over the heat-treated carbon-carbon composite friction disc body and the pyrolytic carbon formed within the pores, wherein the pyrolytic carbon substantially prevents migration of the anti-oxidation solution into the heat-treated carbon-carbon composite friction disc body.

3. The brake disc of claim 2 , wherein the liquid anti-oxidation solution is not coated over a working surface of the heat-treated carbon-carbon composite friction disc body.

4. The brake disc of claim 2 , wherein there is no capillary path for the liquid anti-oxidation solution to migrate into the heat-treated carbon-carbon composite friction disc.

5. The brake disc of claim 1 , further comprising an anti-oxidant coating over the heat-treated carbon-carbon composite friction disc body and the pyrolytic carbon formed within the pores.

6. The brake disc of claim 1 , wherein the pyrolytic carbon is the charred phenolic resin.

7. The brake disc of claim 1 , wherein the pyrolytic carbon is the charred epoxy resin.

8. The brake disc of claim 1 , wherein the pyrolytic carbon is the charred cyanate ester resin.

9. The brake disc of claim 1 , wherein the pyrolytic carbon includes charred phenolic and epoxy resins.

10. The brake disc of claim 1 , further comprising an anti-oxidant over at least some surfaces of the heat-treated carbon-carbon composite friction disc body.

Assignees

• Honeywell Int Inc

Inventors

• Fryska Slawomir T
• La Forest Mark L
• Simpson Allen H
• Braunisch Peter Franz

Classifications

• F16D65/126 Primary

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

• C04B2235/616

  Liquid infiltration of green bodies or pre-forms · CPC title

• C04B35/6267

  Pyrolysis, carbonisation or auto-combustion reactions · CPC title

• F16D2250/0038

  Surface treatment · CPC title

• F16D2200/0052

  Carbon · CPC title