Carbon composite brake disc with positive vibration damping

A method for providing an integral carbon-carbon composite brake component having carbon material disposed about an internal damping insert member, comprising the steps of molding a mixture of chopped carbon fiber, thermosetting resin, and a damping insert member into the shape of a brake component, heating the molded mixture in order to convert the thermosetting resin to glassy carbon, densifying the carbon material in order to reduce porosity thereof by depositing additional carbon therein, heating the carbon material to a temperature range of 1600.degree.-2800.degree. C., and machining the carbon material to the final dimensions of the brake component, the insert member effecting positive damping of the brake component to minimize dynamic vibrations.

A method for providing an integral carbon/carbon composite brake component having carbon material disposed about a damping insert member, comprising the steps of impregnating a carbon fabric material in a resin bath, heating the fabric material to a low temperature of less than 200.degree. C. in order to remove volatiles therefrom and to provide a prepreg, forming layers of the prepeg and the damping insert member to a desired shape, molding the layers and member under pressure and heat to form a carbon fabric brake material, heating the carbon fabric brake material to a temperature of at least 800.degree. C. to produce a porous substrate with a glassy carbon matrix, densifying the porous substrate in order to reduce porosity and add additional carbon thereto, heat treating the resulting composite to a temperature in the range of 1600.degree.-2800.degree. C., and machining the composite to dimension to provide the carbon brake component, the insert member effecting positive damping of the brake component to minimize dynamic vibrations.

A method of providing an integral carbon-carbon composite brake component having a carbon material disposed about a damping insert member, comprising the steps of placing a plurality of carbon fiber layers about a layer comprising the damping insert member, reinforcing the layers by one of needling, sewing or tufting to provide a preform, densifying the preform in order to reduce porosity and add additional carbon thereto, heat treating the resulting composite to a temperature in the range of 1600.degree.-2800.degree. C., and machining the composite to dimension to provide the composite brake component, the insert member effecting positive damping of the brake component to minimize dynamic vibrations.

A friction mechanism including a brake or clutch having spaced-apart nonrotatable discs, rotatable discs positioned adjacent said nonrotatable discs for friction engagement with said nonrotatable discs, at least one disc comprising an integral disc member made of carbon composite friction material which includes an internal insert member disposed completely within said disc member, the insert member effecting positive damping of the disc member during dynamic operation of said friction mechanism.