# US 10,865,841 B2 · Composite brake disks with an integrated heat sink, methods for manufacturing the same, and methods for producing encapsulated heat sink material

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- Number: US 10,865,841 B2
- Document ID: US10865841B2
- Status: Granted
- Kind: B2
- Application number: 16/262,576
- Filed: 2019-01-30
- Published: 2019-05-30
- Granted: 2020-12-15
- Earliest claimed: 2015-10-07
- Assignees: Raytheon Technologies Corporation
- Applicants: Goodrich Corporation
- Inventors: Susanne M. Opalka; Georgios S. Zafiris; Weina Li
- Web page: https://patentgrep.com/patent/US10865841B2

## CPC

- F16D 65/128: {characterised by means for cooling}
- C04B 35/515: based on non-oxide ceramics
- C04B 35/573: obtained by reaction sintering {or recrystallisation}
- C04B 35/62227: {obtaining fibres}
- C04B 35/80: Fibres, filaments, whiskers, platelets, or the like
- C04B 35/83: Carbon fibres in a carbon matrix
- C04B 41/009: {characterised by the material treated}
- C04B 41/501: {containing carbon in the anion, e.g. carbonates}
- C04B 41/5012: {chlorides}
- C04B 41/5155: {Aluminium}
- C04B 41/85: with inorganic materials
- F16D 65/126: {the material being of low mechanical strength, e.g. carbon, beryllium; Torque transmitting members therefor}
- F16D 69/023: {Composite materials containing carbon and carbon fibres or fibres made of carbonizable material}
- C04B 2111/00362: {Friction materials, e.g. used as brake linings, anti-skid materials}
- C04B 2111/00982: {as construction elements for space vehicles or aeroplanes}
- C04B 2235/3203: Lithium oxide or oxide-forming salts thereof
- C04B 2235/3206: Magnesium oxides or oxide-forming salts thereof
- C04B 2235/3217: Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
- C04B 2235/3244: Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
- C04B 2235/3418: Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
- C04B 2235/3813: Refractory metal borides
- C04B 2235/3817: Carbides
- C04B 2235/3821: Boron carbides
- C04B 2235/3826: Silicon carbides
- C04B 2235/3843: Titanium carbides
- C04B 2235/386: Boron nitrides
- C04B 2235/3873: Silicon nitrides, e.g. silicon carbonitride, silicon oxynitride
- C04B 2235/3891: Silicides, e.g. molybdenum disilicide, iron silicide
- C04B 2235/40: Metallic constituents or additives not added as binding phase
- C04B 2235/401: Alkaline earth metals
- C04B 2235/402: Aluminium
- C04B 2235/407: Copper
- C04B 2235/443: Nitrates or nitrites
- C04B 2235/444: Halide containing anions, e.g. bromide, iodate, chlorite
- C04B 2235/5208: Fibers
- C04B 2235/5224: Alumina or aluminates
- C04B 2235/5228: Silica and alumina, including aluminosilicates, e.g. mullite
- C04B 2235/5244: Silicon carbide
- C04B 2235/5248: Carbon, e.g. graphite
- C04B 2235/614: Gas infiltration of green bodies or pre-forms
- C04B 2235/616: Liquid infiltration of green bodies or pre-forms
- C04B 2235/77: Density
- C04B 2235/80: Phases present in the sintered or melt-cast ceramic products other than the main phase
- C04B 2235/9607: Thermal properties, e.g. thermal expansion coefficient
- F16D 2200/0065: Inorganic, e.g. non-asbestos mineral fibres
- F16D 2200/0082: Production methods therefor
- F16D: COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE

## Abstract

Brake disks with integrated heat sink are provided. Brake disk includes a fiber-reinforced composite material and an encapsulated heat sink material impregnated into the fiber-reinforced composite material. The encapsulated heat sink material comprises a heat sink material encapsulated within a silicon-containing encapsulation layer. Methods for manufacturing the brake disk with integrated heat sink and methods for producing the encapsulated heat sink material are also provided.

## Claims

### Claim 1

A method for producing an encapsulated heat sink material, the method comprising:
dispersing particles of a heat sink material in a solvent containing a surfactant to form a dispersion;
adding an organic silicon precursor to the dispersion, the organic silicon precursor comprising a polycarbosilane; and
forming a silicon-containing encapsulation layer around the heat sink material from the organic silicon precursor, the silicon-containing encapsulation layer comprising SiC.

### Claim 2 (depends on 1)

The method of claim 1, wherein the surfactant comprises at least one of polyvinylpyrrolidone (PVP) polymer, polyvinylalcohol (PVA), polyethylene oxide (PEO), polypropylene oxide (PPO), or acetylenic diol based chemicals.

### Claim 3 (depends on 1)

The method of claim 1, wherein the solvent comprises at least one of ethanol, 1-propanol, 2-propanol, 1-butanol, or 2-butanol.

### Claim 4 (depends on 1)

The method of claim 1, wherein the encapsulated heat sink material comprises:
the heat sink material; and
the silicon-containing encapsulation layer encapsulating the heat sink material.

### Claim 5 (depends on 1)

The method of claim 1, wherein the heat sink material comprises at least one of a eutectic salt, a eutectic alloy, or a material with a melting temperature greater than about 300° C. to about 1100° C., a transition temperature greater than about 300° C. and less than about 1100° C., and a density of less than 3.5 g/cm3.

### Claim 6 (depends on 1)

The method of claim 1, wherein forming the silicon-containing encapsulation layer comprises decomposing the organic silicon precursor by at least one of a heat treatment or a condensation reaction.

### Claim 7

A method for manufacturing a brake disk with an integrated heat sink, the method comprising:
infiltrating the brake disk or preform thereof with encapsulated heat sink material in a solvent, the encapsulated heat sink material comprising a heat sink material encapsulated within a silicon-containing encapsulation layer, the silicon-containing encapsulation layer comprising silicon dioxide;
converting the silicon dioxide of the silicon-containing encapsulation layer into silicon carbide by carburizing the silicon dioxide; and
removing the solvent.

### Claim 8 (depends on 7)

The method of claim 7, further comprising producing the encapsulated heat sink material by:
dispersing particles of the heat sink material in the solvent containing a surfactant;
adding an organic silicon precursor to the solvent after the dispersing; and
forming the silicon-containing encapsulation layer around the particles of the heat sink material from the organic silicon precursor.

### Claim 9 (depends on 8)

The method of claim 8, wherein forming the silicon-containing encapsulation layer is performed prior to infiltrating the brake disk or preform thereof.

### Claim 10 (depends on 8)

The method of claim 8, wherein the forming the silicon containing encapsulation layer and the carburizing the silicon dioxide are performed simultaneously.

### Claim 11 (depends on 8)

The method of claim 8, wherein converting the silicon dioxide of the silicon-containing encapsulation layer into silicon carbide is performed after removing the solvent.