公开(公告)号：WO2002081942A1

公开(公告)日：2002-10-17

申请号：PCT/US2002/010883

申请日：2002-04-08

Applicant: HONEYWELL INTERNATIONAL INC.

Inventor： JAMES, Mark, C. ,  MURDIE, Neil ,  WALKER, Terence, B.

IPC: F16D69/02

CPC classification number: F16D69/023 ,  C04B35/83 ,  D04H3/105 ,  D04H18/02 ,  Y10T29/49789 ,  Y10T29/49801

Abstract: Carbon fiber brake preforms (20), specifically, annular discs built up of fabric arc segments (21) composed of continuous fibers (25) and staple fibers (26). Most of the continuous fibers (25) in the fabric segments (21) are arranged to be located within 60° of radially from the inner diameter to the outer diameter of the annular disc (20). The fabric arc segments have substantially all of their continuous fibers oriented in the radial direction and parallel to the segment arc bisector, or the segments are arranged in alternating layers in which, respectively, half the continuous fibers are oriented at a +45 degree angle with respect to the segment arc bisector and half the continuous fibers are oriented at a -45 degree angle with respect thereto. Methods for making preform composites comprise providing needle-punched nonwoven fabric of unidirectional continuous fibers and staple fibers, making a plurality of fabric segments, arranging the segments in a multilayered intermediate, heating the multilayered intermediate to convert the fibers to carbon, and densifying the carbonized product. In brake discs made as described, fiber pull-out is minimized , reducing mechanical wear. The disclosed preform fiber architecture reduces wear rates while maintaining brake disc strength.

Abstract translation: 碳纤维制动预成型件（20）具体地，由连续纤维（25）和短纤维（26）构成的织物弧段（21）构成的环形盘。 织物片段（21）中的大部分连续纤维（25）布置成位于径向从环形盘（20）的内径到外直径的60°内。 织物弧段具有基本上所有的连续纤维在径向方向上定向并平行于弧段平分线，或者分段以交替的层布置，其中连续纤维的一半分别与+45度角定向， 相对于分段弧平分线，连续光纤的一半相对于其成一角度-45度。 制备预成型复合材料的方法包括提供单向连续纤维和短纤维的针刺非织造织物，制成多个织物片段，将片段设置在多层中间体中，加热多层中间体以将纤维转化成碳，并使碳化 产品。 在如上所述制造的制动盘中，光纤拉出最小化，减少机械磨损。 所公开的预制纤维结构在保持制动盘强度的同时降低了磨损率。

公开(公告)号：WO2005115944A3

公开(公告)日：2005-12-08

申请号：PCT/US2005/018352

申请日：2005-05-25

Applicant: HONEYWELL INTERNATIONAL INC. ,  LA FOREST, Mark, L. ,  CIPRA, Raymond, J. ,  PARKER, Charles, A. ,  WOOD, Michael, D. ,  BRAUNISCH, Peter, F. ,  MURDIE, Neil ,  FATZ, Alan, E. ,  DILLION, Frank ,  CORDELL, Tobey ,  SIEGMUND, Thomas, H.

Inventor： LA FOREST, Mark, L. ,  CIPRA, Raymond, J. ,  PARKER, Charles, A. ,  WOOD, Michael, D. ,  BRAUNISCH, Peter, F. ,  MURDIE, Neil ,  FATZ, Alan, E. ,  DILLION, Frank ,  CORDELL, Tobey ,  SIEGMUND, Thomas, H.

IPC: F16D69/02

Abstract: Annular brake disc preform (15), wherein 40 to 80 layers of reinforcement fibers of at least two different lengths (11, 19) ranging from 10-60 mm are distributed in a planar gradient throughout the body of the preform, with the reinforcement fibers located near the exterior planes of the disc being predominately shorter fibers (11) and with the reinforcement fibers located in the central planes of the disc being predominately longer fibers (19). Also, process of making carbon-carbon composite preforms by: providing chopped pitch or PAN fibers (11, 19) of at least two different lengths; directing a robotic spraying apparatus to spray the chopped fibers into an annular mold (5) in 40 to 80 concentric iterations of chopped fiber deposition to provide a matrix of fibers in the mold; depositing a curable binder into the mold to intermix the binder with the fiber matrix; compressing the fiber matrix and curable binder within the mold; curing the binder to form a preform matrix; filling the preform matrix with pitch to form a pitch matrix; and subjecting the pitch matrix to chemical vapor deposition to form a carbon-carbon composite preform (15).