Patent ID: 9017761
Filing Date: 2015-04-28
Classification: C04B,D04H,F16D

Abstract:
1. A method of making a carbon-carbon composite brake disc or pad, the method comprising: needling, via a needler, two layers of a fibrous fabric to one another at a needling rate greater than 700 strokes per minute, wherein the fibrous fabric comprises at least one of oxidized polyacrylonitrile fibers, pitch fibers, or rayon fibers; needling, via the needler, subsequent layers of the fibrous fabric on top of the two needled layers at the needling rate greater than 700 strokes per minute until the fibrous fabric layers form a brake disc or pad preform defined by a target thickness; carbonizing the preform to reduce a fiber volume fraction of the preform, wherein carbonizing comprises carbonizing the preform until the fiber volume fraction of the preform is between approximately 17% and approximately 30%; and infiltrating the carbonized preform via chemical vapor deposition/chemical vapor infiltration (CVD/CVI) processing until the infiltrated carbonized preform forms the carbon-carbon composite brake disc or pad defined by a density of at least 1.70 grams per cubic centimeter.