Composite brake disks with an integrated heat sink, methods for manufacturing the same, and methods for producing encapsulated heat sink material

• US 10,253,832 B2
• Filed: 10/07/2015
• Issued: 04/09/2019
• Est. Priority Date: 10/07/2015
• Status: Active Grant

• Current Assignee: Goodrich Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Original Assignee: Goodrich Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Opalka, Susanne M., Zafiris, Georgios S., Li, Weina
• Primary Examiner(s): Vetere, Robert A
• Application Number:
  US14/877,701
• Publication Number:
  US 20170102043A1
• Time in Patent Office: 1,280 Days
• CPC Class Codes: C04B 2111/00362 Friction materials, e.g. used as brake linings, anti-skid materials
• CPC Class Codes: C04B 2111/00982 as construction elements for space vehicles or aeroplanes
• CPC Class Codes: C04B 2235/3203 Lithium oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3206 Magnesium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3217 Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• CPC Class Codes: C04B 2235/3244 Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3418 Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint glass constituents C04B2235/36
• CPC Class Codes: C04B 2235/3813 Refractory metal borides
• CPC Class Codes: C04B 2235/3817 Carbides
• CPC Class Codes: C04B 2235/3821 Boron carbides
• CPC Class Codes: C04B 2235/3826 Silicon carbides
• CPC Class Codes: C04B 2235/3843 Titanium carbides
• CPC Class Codes: C04B 2235/386 Boron nitrides
• CPC Class Codes: C04B 2235/3873 Silicon nitrides, e.g. silicon carbonitride, silicon oxynitride
• CPC Class Codes: C04B 2235/3891 Silicides, e.g. molybdenum disilicide, iron silicide
• CPC Class Codes: C04B 2235/40 Metallic constituents or additives not added as binding phase
• CPC Class Codes: C04B 2235/401 Alkaline earth metals
• CPC Class Codes: C04B 2235/402 Aluminium
• CPC Class Codes: C04B 2235/407 Copper
• CPC Class Codes: C04B 2235/443 Nitrates or nitrites
• CPC Class Codes: C04B 2235/444 : Halide containing anions, e.g. bromide, iodate, chlorite
• CPC Class Codes: C04B 2235/5208 : Fibers
• CPC Class Codes: C04B 2235/5224 : Alumina or aluminates
• CPC Class Codes: C04B 2235/5228 : Silica and alumina, including aluminosilicates, e.g. mullite
• CPC Class Codes: C04B 2235/5244 : Silicon carbide
• CPC Class Codes: C04B 2235/5248 : Carbon, e.g. graphite
• CPC Class Codes: C04B 2235/614 : Gas infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/616 : Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/77 : Density
• CPC Class Codes: C04B 2235/80 : Phases present in the sintered or melt-cast ceramic products other than the main phase
• CPC Class Codes: C04B 2235/9607 : Thermal properties, e.g. thermal expansion coefficient
• CPC Class Codes: C04B 35/515 : based on non-oxide ceramics
• CPC Class Codes: C04B 35/573 : obtained by reaction sintering or recrystallisation
• CPC Class Codes: C04B 35/62227 : obtaining fibres
• CPC Class Codes: C04B 35/80 : Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 35/83 : Carbon fibres in a carbon matrix
• CPC Class Codes: C04B 41/009 : characterised by the material treated
• CPC Class Codes: C04B 41/4535 : applied as a solution, emulsion, dispersion or suspension
• CPC Class Codes: C04B 41/4552 : the end product being obtained by a multistep reaction or conversion
• CPC Class Codes: C04B 41/4554 : the coating or impregnating material being an organic or organo-metallic precursor of an inorganic material
• CPC Class Codes: C04B 41/5009 : containing nitrogen in the anion, e.g. nitrites
• CPC Class Codes: C04B 41/501 : containing carbon in the anion, e.g. carbonates
• CPC Class Codes: C04B 41/5012 : chlorides
• CPC Class Codes: C04B 41/5059 : Silicon carbide
• CPC Class Codes: C04B 41/5127 : Cu, e.g. Cu-CuO eutectic
• CPC Class Codes: C04B 41/515 : Other specific metals
• CPC Class Codes: C04B 41/5155 : Aluminium
• CPC Class Codes: C04B 41/85 : with inorganic materials
• CPC Class Codes: F16D 2200/0065 : Inorganic, e.g. non-asbestos mineral fibres
• CPC Class Codes: F16D 2200/0082 : Production methods therefor
• CPC Class Codes: F16D 65/126 : the material being of low mechanical strength, e.g. carbon, beryllium; Torque transmitting members therefor
• CPC Class Codes: F16D 65/128 : characterised by means for cooling
• CPC Class Codes: F16D 69/023 : Composite materials containing carbon and carbon fibres or fibres made of carbonizable material

Abstract

Brake disks with integrated heat sink are provided. Brake disk includes a fiber-reinforced composite material and an encapsulated heat sink material impregnated into the fiber-reinforced composite material. The encapsulated heat sink material comprises a heat sink material encapsulated within a silicon-containing encapsulation layer. Methods for manufacturing the brake disk with integrated heat sink and methods for producing the encapsulated heat sink material are also provided.

Claims

1. A brake disk comprising:

a fiber-reinforced composite material; and

an encapsulated heat sink material impregnated into the fiber-reinforced composite material, the encapsulated heat sink material comprising a heat sink material sealed within a silicon-containing encapsulation layer, wherein the silicon-containing encapsulation layer comprises silicon carbide, and wherein a matrix material of the fiber-reinforced composite material defines a volume having a diameter of about 10 micrometers or less, and wherein the encapsulated heat sink material is located within the volume.

2. The brake disk of claim 1, wherein the fiber-reinforced composite material comprises at least one of a fiber-reinforced/carbon matrix composite material or a fiber-reinforced/ceramic matrix composite material.

3. The brake disk of claim 2, wherein a fiber of the fiber-reinforced composite material comprises at least one of a carbon fiber, a silicon carbide fiber, an alumina fiber, an aluminosilicate fiber, or a glass fiber, wherein the fiber-reinforced/carbon matrix composite material comprises a carbon fiber-reinforced/carbon (C/C) matrix composite material if the fiber comprises the carbon fiber.

4. The brake disk of claim 2, wherein the ceramic matrix composite material comprises at least one of a boride, a carbide, a nitride, an oxide, or a silicide.

5. The brake disk of claim 4, wherein the boride comprises at least one of SiB₂, SiB₆, TiB₂, or ZrB₂, the carbide comprises at least one of SiC, B₄C, HfC, TiC, or ZrC, the nitride comprises at least one of BN or Si₃N₄, the oxide comprises at least one of Al₂O₃, ZrO₂, or SiO₂, and the silicide comprises at least one of TiSi₂ or MoSi₂.

6. The brake disk of claim 1, wherein the heat sink material comprises at least one of an eutectic salt or a eutectic alloy.

7. The brake disk of claim 1, wherein the heat sink material comprises a material with a melting temperature greater than about 300°

C. to about 1100°

C., a transition temperature greater than about 300°

C. and less than about 1100°

C., and a density of less than 3.5 g/cm³.

8. A brake disk comprising:

a fiber-reinforced composite material; and

an encapsulated heat sink material impregnated into the fiber-reinforced composite material, the encapsulated heat sink material comprising a heat sink material sealed within a silicon-containing encapsulation layer, wherein the silicon-containing encapsulation layer comprises silicon carbide, and wherein the heat sink material comprises at least one of an eutectic salt or a eutectic alloy, and wherein a matrix material of the fiber-reinforced composite material defines a volume having a diameter of about 10 micrometers or less, and wherein the encapsulated heat sink material is located within the volume.

9. The brake disk of claim 8, wherein the encapsulated heat sink material comprises a diameter of about 10 micrometers or less.

10. The brake disk of claim 8, wherein a fiber of the fiber-reinforced composite material comprises at least one of a carbon fiber, a silicon carbide fiber, an alumina fiber, an aluminosilicate fiber, or a glass fiber.

11. The brake disk of claim 8, wherein the fiber-reinforced composite material comprises at least one of a fiber-reinforced/carbon matrix composite material or a fiber-reinforced/ceramic matrix composite material.

12. The brake disk of claim 11, wherein the ceramic matrix composite material comprises at least one of a boride, a carbide, a nitride, an oxide, or a silicide.

13. The brake disk of claim 12, wherein the boride comprises at least one of SiB₂, SiB₆, TiB₂, or ZrB₂, the carbide comprises at least one of SiC, B₄C, HfC, TiC, or ZrC, the nitride comprises at least one of BN or Si₃N₄, the oxide comprises at least one of Al₂O₃, ZrO₂, or SiO₂, and the silicide comprises at least one of TiSi₂ or MoSi₂.

14. The brake disk of claim 8, wherein the at least one of the eutectic salt or the eutectic alloy comprises a material with a melting temperature greater than about 300°

C. to about 1100°

C., a transition temperature greater than about 300°

C. and less than about 1100°

C., and a density of less than 3.5 g/cm³.

15. A brake disk, comprising

a fiber-reinforced composite material;

and

a plurality of encapsulated heat sinks impregnated into a matrix material of the fiber-reinforced composite material, wherein each encapsulated heat sink of the plurality of encapsulated heat sinks is fixed within the matrix material, and wherein the plurality of encapsulated heat sinks each comprise a heat sink material sealed within a silicon-containing encapsulation layer, and wherein each encapsulated heat sink is located within a separate volume defined by the matrix material, each separate volume having a diameter equal to a diameter of the encapsulated heat sink located therein.

16. The brake disk of claim 15, wherein the diameter of each heat sink is 10 micrometers or less.

17. The brake disk of claim 16, wherein the heat sink material comprises at least one of an eutectic salt or a eutectic alloy.

18. The brake disk of claim 15, wherein the heat sink material comprises a material with a melting temperature greater than about 300°

C. to about 1100°

C., a transition temperature greater than about 300°

C. and less than about 1100°

C., and a density of less than 3.5 g/cm³.

19. The brake disk of claim 15, wherein the silicon-containing encapsulation layer comprises silicon carbide.