Method of making near net shaped fibrous structures

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 shaped fibrous structure comprising at least a first fibrous tape layer of a width generally corresponding to that of the fibrous structure to be formed, the first fibrous tape layer superposed upon and joined to least one other fibrous layer by needlepunching to produce cross-linking of the layers by fibers displaced out of the layers and extending in a direction generally perpendicular to the faces of the layers, and methods of making same. A shaped fibrous structure comprising at least a first fibrous tape layer formed from a plurality of tape portions each having a width substantially less than that of the fibrous structure to be formed, the selvedges of the tape portions being partially overlapped, the first fibrous tape layer superposed upon and joined to least one other fibrous layer by needlepunching to produce cross-linking of the layers by fibers displaced out of the layers and extending in a direction generally perpendicular to the faces of the layers, and methods of making same. The structure may include a plurality of helically wound fibrous tapes arranged to form a flat annulus having a plurality of interleaved fibrous layers. The structure may be used in the production of friction pads or discs.