| abstract |
A carbon fiber reinforced ceramic brake disc or pad is formed from a rapidly hot-pressed carbon/carbon composite material. First, a reinforcement material, preferably including carbon fibers, is combined with a carbonizable matrix material to form a green preform. The green preform is heated and a portion of the matrix material is at least partially carbonized so as to form a carbon/carbon composite. Optionally, a carbonizable material is introduced into voids in the carbon/carbon composite. The product is then heated to carbonize the carbonizable material. The carbonizable material infiltration and baking steps are optionally repeated to increase the density of the composite. A pre-ceramic polymer material is introduced into voids of the carbon/carbon composite and heat-treated so as to pyrolytically decompose the pre-ceramic polymer. Finally, the carbon/ceramic composite is then high-temperature heat treated so as to form a carbon fiber reinforced ceramic material. |