Annular filamentary structures and methods of making

Abstract

Fibrous substrates for the production of carbon and/or ceramic (including mixtures of these) fiber reinforced carbon and/or ceramic (including mixtures of these) composites and to methods of manufacture of same. A multilayered annular shaped fibrous structure (10, 40) having a radius and a thickness, suitable for use in the manufacture of a friction disk, is made by forming a multidirectional fabric (30, 50) having filaments (12) or fibers extending in at least two directions; cutting arcuate or trapezoidal sectors (20, 20') of an annular shape from the multidirectional fabric, each sector having a radial width generally corresponding to the radial width of the fibrous structure (10, 40) to be formed; assembling the sectors in end to end or circumferentially overlapping contiguous relationship to form an annular layer having a radial width generally corresponding to the radial width of the fibrous structure to be formed; providing a stack of thus formed layers of fibrous material, one layer on top of another; and needlepunching the stacked layers to produce cross-linking of the layers by filaments displaced out of the layers and extending in a direction generally perpendicular to the faces of the layers. The multidirectional fabric is preferably a braided fabric (30) or a crosslapped fabric (50).

Dependencies are inferred from the claim text.