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US 12,221,388 B2Granted
Method for manufacturing composite fiber preform for disc brakes
AssigneeHoneywell International Inc.
InventorsStefan Glen, David Lane Charles, Long Gui Tang, Yanmei Piao, Neil Murdie, Mark C. James
Life of this patent
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Abstract
An example method includes combining an interlayer and a carbon fiber fabric, wherein the interlayer comprises a highly oriented milled carbon fiber ply comprising a plurality of out-of-plane carbon fibers. The method further includes winding the interlayer and the carbon 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.
Claims15
A method comprising:
- combining an interlayer and a carbon fiber fabric, wherein the interlayer comprises a highly oriented milled carbon fiber ply comprising a plurality of out-of-plane carbon fibers, wherein the plurality of out-of-plane carbon fibers of the interlayer are oriented out-of-plane and substantially parallel with a thickness of the interlayer without needling and before combining the interlayer and the carbon fiber fabric, wherein the carbon fiber fabric comprises a plurality of in-plane carbon fibers oriented substantially perpendicularly to the plurality of out-of-plane carbon fibers before combining the interlayer and the carbon fiber fabric;
- winding the interlayer and the carbon 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, for each layer of the plurality of layers, the interlayer is wound between adjacent carbon fiber fabric layers,
- wherein the plurality of out-of-plane carbon fibers of the interlayer are oriented substantially radially from the central axis after winding the interlayer and the carbon fiber fabric around the core,
- wherein the plurality of in-plane carbon fibers are oriented substantially parallel to the central axis or substantially circumferentially about the central axis after winding the interlayer and the carbon fiber fabric around the core;
- and
- densifying the composite fiber preform.
4 more elements
A system comprising:
- a fabric source comprising a carbon fiber fabric;
- an interlayer source comprising an interlayer comprising a plurality of out-of-plane carbon fibers, wherein the plurality of out-of-plane carbon fibers of the interlayer are oriented out-of-plane and substantially parallel with a thickness of the interlayer without needling and before winding the interlayer and 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 composite 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 of the plurality of carbon fiber fabric layers comprises a plurality of elongate carbon fibers oriented substantially parallel with the axial and circumferential directions;
- and
- a plurality of 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 plurality of out-of-plane carbon fibers of interlayers are oriented substantially parallel with the radial direction and configured to mechanically bind one or more adjacent carbon fiber fabric layers.
4 more elements
Dependencies are inferred from the claim text.