Composite / Carbon Fiber Disks

 

LeapTech Composites has engineered a composite material form described as a COMPOSITE DISC that replaces STEEL and ALUMINUM discs in STATIC and DYNAMIC industrial machine applications.

 
Composite disc material’s are produced from a Composite Sandwich structure. The sandwich structure is a staple product in Aircraft composite construction. Composite Disc materials for industrial products are designed using high performance carbon fiber skins separated by a closed rigid cell foam.  
   Composite Disc Material Forms      
Basic Composite Disc – BCD   Webbed Composite Disc – WCD  
        
Basic Composite Disc’s for structures that are subjected to low loads.   This Webbed Composite Disc provides high shear stiffness.  
Ribbed Composite Disc – RCD   Special Composite Disc – SCD  
        
Ribbed Composite Disc’s provide high flexural and shear stiffness structures.   Special Composite Disc’s are used primerly for structures that require machining.   
          
  A 42 inch Diameter Basic Composite Disc.    
Composite Disc Foam Materials         
Composite Disc’s are used in a wide range of industrial applications. To meet these varied needs Composite Disc’s are manufactured using several foams.   
  
2 lb/ft^3 Unreinforced Foam – Polyisocynurate (PU) foam. Used in the manufacture of Basic, Ribbed and Special Composite Disc’s   5 lb/ft^3 Unreinforced Foam – Polyvinyl Chloride (PVC) foam. Used in the manufacture of Basic, Ribbed and Special Composite Disc’s. 
       
6 lb/ft^3 Unreinforced Foam – Polyisocynurate (PU) foam. Used in the manufacture of Basic, Ribbed and Special Composite Disc’s.   Reinforced Foam – Polyurethane (PU) foam reinforced with glass-cloth. Used in the manufacture of Webbed Composite Disc’s.     
Foam Material (manufactures values)Density lb/ft^3 Temperature Capability (oF) Shear Modulus ps (Parallel)  Shear Modulus, psi (Transverse)
Glass Reinforced Polyurethane  6  200 19,000  800  
Polyvinyl Chloride  5  200 3,581  3,581  
Polyisocynurate  2  300 230  177  
Polyisocynurate  6  300 672  571 
    LeapTech Composites Reference      
   Foam   A      
   Glass Reinforced Polyurethane       
   Polyvinyl Chloride  B      
   Polyisocynurate  C2 and C6      
Composite Disc Carbon Fiber Radial Laminate       
The Composite Disc strength and stiffness is provided by a Carbon Fiber Radial Laminate. The Carbon Fiber Radial Laminate is built from layers. The number of layers dictated by the Composite Disc application and laminate balance. Shown in the table are Composite Disc’s with Radial Laminates with up to six layers. Depending on the application more layers can be added to the laminate to increase stiffness and strength.
 Radial Laminate DESIGNATION  Number of Carbon Fiber Layers per Laminate  Total Number of CARBON LAYERS per Composite Disc   
 R02  1  2   
 R04  2  4   
 R08  4  8   
 R12  6  12   
Composite Disc Surface Skin         
The Composite Disc Radial Laminate is protected by a Carbon Fiber Hybrid Surface Skin. Surface Skin material and coating options are available.     

 

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