The patent badge is an abbreviated version of the USPTO patent document. The patent badge does contain a link to the full patent document.
The patent badge is an abbreviated version of the USPTO patent document. The patent badge covers the following: Patent number, Date patent was issued, Date patent was filed, Title of the patent, Applicant, Inventor, Assignee, Attorney firm, Primary examiner, Assistant examiner, CPCs, and Abstract. The patent badge does contain a link to the full patent document (in Adobe Acrobat format, aka pdf). To download or print any patent click here.
Patent No.:
Date of Patent:
Feb. 17, 2004
Filed:
Nov. 08, 2001
Mark C. James, South Bend, IN (US);
Terence B. Walker, South Bend, IN (US);
Neil Murdie, Granger, IN (US);
Honeywell International Inc., Morristown, NJ (US);
Abstract
Carbon fiber brake preforms ( ), specifically, annular discs built up of fabric arc segments ( ) composed of continuous fibers ( ) and staple fibers ( ). Most of the continuous fibers ( ) in the fabric segments ( ) are arranged to be located within 60° of radially from the inner diameter to the outer diameter of the annular disc ( ). The fabric arc segments have substantially all of their continuous fibers oriented in the radial direction and parallel to the segment arc bisector, or the segments are arranged in alternating layers in which, respectively, half the continuous fibers are oriented at a +45 degree angle with respect to the segment arc bisector and half the continuous fibers are oriented at a −45 degree angle with respect thereto. Methods for making preform composites comprise providing needle-punched nonwoven fabric of unidirectional continuous fibers and staple fibers, making a plurality of fabric segments, arranging the segments in a multilayered intermediate, heating the multilayered intermediate to convert the fibers to carbon, and densifying the carbonized product. In brake discs made as described, fiber pull-out is minimized, reducing mechanical wear. The disclosed preform fiber architecture reduces wear rates while maintaining brake disc strength.