A general automobile brake high-efficiency heat dissipation assembly based on an inner-small-and-outer-large gradual change closed structure

Abstract

This invention discloses a universal high-efficiency heat dissipation assembly for automotive brakes based on a gradually enclosed structure with a smaller inner diameter and a larger outer diameter, belonging to the field of automotive braking system thermal management technology. This assembly is an independent original technical solution, applicable to disc brakes, calipers, and drum brakes. The core features a gradually enlarged inner diameter heat dissipation channel, radially arranged along the principal stress direction, and an externally closed, non-perforated structure. The brake disc's front friction surface is completely free of holes, and radially radially enlarged heat dissipation channels are opened inside the disc, with the inner channel being smaller and the outer channel larger, unidirectionally guiding airflow according to centrifugal force. A closed ring is provided at the outer edge, without openings or perforations, providing waterproofing, dustproofing, and protection against mud and sand. The channels are arranged along the principal stress direction, with reinforcing ribs formed between the holes to improve crack and deformation resistance. In non-stressed, non-sealed, and non-oil circuit areas, the brake caliper has gradually enlarged inner diameter channels, without drilling through them or affecting hydraulic pressure and sealing. The brake pads maintain a complete and dense structure, without drilling, slotting, or carving. The drum brake's outer surface is completely closed without holes, and radially radially enlarged channels are opened internally, without opening the outer wall. The entire system achieves unified directional and coordinated efficient heat dissipation, structurally reducing the risk of brake fade. The entire unit can be directly cast without subsequent drilling, making it suitable for new vehicle installations and low-cost upgrades to existing vehicles. This invention effectively alleviates brake fade, improves continuous braking safety, protects millions of families with braking safety, reduces braking accidents at the source, and minimizes loss of life and property.

Description

Technical Field

[0001] This invention relates to the field of automotive braking system thermal management technology, specifically a universal and efficient heat dissipation assembly applicable to disc brakes, calipers, and drum brakes, belonging to the categories of automotive chassis safety components, brake thermal management, and automotive-grade structural design. Background Technology

[0002] Traditional automotive braking systems suffer from six long-standing technical bottlenecks that have not been properly addressed.

[0003] First, continuous braking easily leads to brake fade, resulting in decreased braking force and increased braking distance. On long downhill slopes or under high-frequency braking conditions, the large amount of heat generated by the friction between the brake disc and brake pads cannot dissipate in time, causing the brake disc temperature to rise sharply. When the temperature exceeds the tolerance limit of the braking material, the coefficient of friction decreases significantly, and the braking distance is significantly extended. For heavy-duty trucks driving on mountain roads, brake fade is one of the main causes of brake failure and traffic accidents. Any driver can feel the brake pedal becoming softer and the braking distance increasing after a long downhill slope.

[0004] Secondly, vertical drilling into the brake disc damages the friction surface, leading to vibration, abnormal noise, stress concentration, and the risk of cracking. Traditional cooling solutions involve creating through-holes in the brake disc friction surface, which, while increasing the heat dissipation area, directly compromises the integrity of the friction surface. Uneven wear occurs on the brake pads at the edges of the holes, resulting in braking vibration and abnormal noise. More seriously, the through-holes disrupt the main stress transmission path within the brake disc, creating stress concentration points at the hole edges, which can easily become the initiation point of cracks under heavy braking conditions.

[0005] Third, the openwork design at the edges allows mud and sand to enter, reducing structural strength. The ventilation slots on the outer edge of the brake disc are directly exposed to the external environment. When driving through water or on muddy roads in rainy weather, mud and moisture can easily enter the ventilation slots, accelerating the wear of the brake disc and brake pads.

[0006] Fourth, the cooling airflow is disordered, resulting in hot air recirculation and low cooling efficiency. The ventilation structure of traditional brake discs lacks directional airflow design, causing heat to dissipate randomly. Hot air easily forms a recirculation around the brake disc, reducing cooling efficiency.

[0007] Fifth, there is no unified and coordinated heat dissipation solution for disc brakes, calipers, and drum brakes. The three types of brakes each use different heat dissipation structures, which cannot form a unified and coordinated heat dissipation system, resulting in low overall thermal management efficiency of the braking system.

[0008] Sixth, there is no existing brake cooling assembly that integrates a gradually changing inner channel with a smaller outer channel, an externally closed design, reinforcing ribs arranged along the main stress direction, and is compatible with both disc calipers and drum brakes. Summary of the Invention

[0009] 3.1 Purpose of the Invention This invention aims to solve the problems of brake fade, damaged friction surfaces, insufficient strength, low heat dissipation efficiency, poor waterproofing and dustproofing, difficulty in mass production, and inability to upgrade existing vehicles at low cost. It provides a high-efficiency automotive brake cooling assembly with high structural strength, efficient heat dissipation, waterproofing and dustproofing, easy mass production, and strong versatility. This invention is an independent and complete original technology system; the entire structure, principle, manufacturing, and operation scheme are disclosed completely for the first time.

[0010] 3.2 The Formation Process of Technical Ideas and Underlying Design Principles The technical concept of this invention stems from the inventor's deep concern about the thermal fade phenomenon of braking systems and a systematic analysis of the structural defects of traditional brake disc heat dissipation holes. Through layer-by-layer deduction in three aspects—thermodynamic analysis, structural mechanics optimization, and aerodynamic design—a complete technical solution was finally established, featuring a gradually changing channel with a smaller inner diameter and a larger outer diameter, an externally closed and non-interconnected design, an arrangement along the principal stress direction, and compatibility with both disc calipers and drum brakes.

[0011] Step 1: Starting with brake fade – Why do brakes become softer on long downhill slopes? Any driver will experience a softening of the brake pedal and a longer braking distance after a long downhill slope or frequent braking; this is a typical manifestation of brake fade. The brake disc and brake pads generate a large amount of heat during friction. If this heat cannot be dissipated effectively and promptly, the brake disc temperature will rise rapidly. When the temperature exceeds the tolerance limit of the brake material, the coefficient of friction drops significantly, and braking performance is severely diminished. For heavy-duty trucks driving on mountain roads, brake fade is one of the main causes of brake failure and traffic accidents.

[0012] The inventors thus established the core design goal: to create an efficient heat dissipation channel inside the brake disc to quickly dissipate the heat generated by braking friction from the vicinity of the friction surface into the air, thereby fundamentally delaying the occurrence of heat fade.

[0013] Step 2: Starting from the integrity of the friction surface – why you can't drill holes perpendicularly. Traditional heat dissipation solutions involve creating through-holes on the brake disc's friction surface. While this increases the heat dissipation area, the inventors discovered an irreconcilable contradiction in this design. The friction surface is the working surface where the brake disc and brake pads directly contact each other, and its integrity directly affects braking smoothness and service life. Through-holes disrupt the continuity of the friction surface, causing uneven wear on the brake pads at the hole edges, resulting in brake vibration and abnormal noise. More seriously, through-holes interrupt the main stress transmission path within the brake disc, creating stress concentration points at the hole edges, which can easily become the initiation point of cracks under heavy braking conditions.

[0014] The inventors thus established a completely new design principle: the heat dissipation channel must be opened inside the brake disc, the friction surface must be kept intact and without holes, and the heat is directionally dissipated from the inside by the centrifugal force of the brake disc's own rotation.

[0015] Step 3: Starting with the shape of the channel – why does it gradually change from small inside to large outside? The inventors further analyzed the heat diffusion pattern inside the brake disc. Heat always diffuses naturally from high-temperature areas to low-temperature areas, radiating outwards from the central heat source. This pattern determines the optimal heat dissipation channel shape—the channel should follow the natural direction of heat diffusion, gradually expanding from the inner end near the friction surface to the outer end. The inner end aperture is designed to be smaller, densely distributed in the area near the heat source on the friction surface, quickly absorbing the heat generated by braking friction. The outer end aperture gradually expands, forming an expanding flow channel that guides heat to diffuse evenly outwards along the channel, and utilizes the centrifugal force generated by the rotation of the brake disc to directionally throw the heat out. This gradually expanding diameter structure, with a smaller inner diameter and a larger outer diameter, conforms to the natural trend of heat diffusion and the direction of centrifugal force, achieving directional and efficient flow guidance from the heat source to the outside.

[0016] Step 4: Starting from the external enclosure – Why can't it be opened up? Traditional brake disc ventilation slots are directly exposed to the external environment, making them highly susceptible to water and mud entry during rainy or muddy driving. The inventors have adopted a closed, non-perforated design. A complete, sealed heat dissipation chamber is formed between the inner and outer ends of the channel, allowing heat to be directionally conducted and diffused from the inside out within the chamber. The outer edge features a closed ring, preventing the intrusion of mud, dust, and moisture, while also ensuring the integrity of the outer surface and a uniform heat dissipation area.

[0017] Step 5: Starting from structural strength – Why arrange along the direction of principal stress? Brake discs bear enormous circumferential shear stress and radial tensile stress during braking. If the arrangement of the heat dissipation channels is not aligned with the principal stress direction, the channel walls will become weak points where stress concentrates. The inventors arranged the heat dissipation channels along the radial principal stress direction, forming natural reinforcing ribs between the channels. These ribs are precisely located on the path of principal stress transmission, significantly improving the structural strength of the brake disc while dissipating heat.

[0018] Step 6: Starting with system integration – Why disc brakes, calipers, and drum brakes need a unified solution The braking system consists of multiple components, including brake discs, brake calipers, brake pads, and drum brakes. If the heat dissipation structures of each component are independent and the heat flow direction is not uniform, the overall heat dissipation efficiency will be greatly reduced. The inventors have uniformly applied a gradually enclosed heat dissipation structure to the brake discs, calipers, and drum brakes, achieving unified, coordinated, and efficient heat dissipation throughout the system. The brake discs have radially radially tapered channels inside; the brake calipers have unidirectional tapered channels in non-stressed, non-sealed, and non-hydraulic areas; and the drum brakes have a completely enclosed outer surface and radially radially tapered channels inside. Heat is orderly dissipated in a unified direction throughout the entire braking system, without eddies or backflow.

[0019] 3.3 Core Structure This assembly includes brake discs, brake calipers, and brake pads. The overall structure adopts a gradually changing heat dissipation channel with a smaller inner diameter and a larger outer diameter, arranged radially along the main stress, and externally closed without any openings.

[0020] The brake disc has a completely smooth, hole-free front friction surface, with radially tapered heat dissipation channels inside the disc. These channels are wider at the outer edges and narrower at the inner edges, facilitating unidirectional airflow in accordance with centrifugal force. A closed ring is located at the outer edge, ensuring it is not perforated or hollowed out, thus preventing water, dust, and mud penetration. The channels are arranged along the radial principal stress direction, with reinforcing ribs between the channels to enhance crack and deformation resistance.

[0021] The brake caliper features a gradually widening channel (smaller inner channel, larger outer channel) in non-load-bearing, non-sealed, and non-oil-circuit areas, without drilling through or affecting hydraulic pressure or sealing. The air duct runs in the same direction as the brake disc, allowing heat to be quickly dissipated, achieving both lightweight design and efficient heat dissipation.

[0022] Brake pads maintain a complete and dense structure, without drilling, slotting, or carving. They serve only as heat transfer friction components, resulting in high strength and uniform wear.

[0023] The outer surface of the drum brake is completely sealed without holes, while the interior has radially tapered channels that do not penetrate the outer wall. It relies on centrifugal force and heat conduction to quickly dissipate heat, mitigating the problems of heat fade and dust ingress in drum brakes.

[0024] The entire unit can be directly cast without the need for subsequent drilling. Upgrades can be achieved by replacing the brake discs or drums separately, without needing to replace the calipers simultaneously. It is suitable for all types of braking systems, including disc, caliper, and drum brakes, covering upgrades for passenger cars, commercial vehicles, heavy-duty vehicles, and existing vehicles.

[0025] 3.4 Working Principle Heat generated during braking is transferred from the brake pads to the brake disc, brake drum, and caliper. Under the combined effects of centrifugal force and heat conduction, the heat is directionally discharged from the inside out along a gradually widening channel, preventing eddies and backflow. An external enclosed structure prevents water and sand from entering. The channels are arranged along the principal stress lines to ensure strength. The entire system achieves unified, coordinated, and efficient heat dissipation, structurally reducing the risk of thermal fade.

[0026] 3.5 Beneficial Effects First, it effectively alleviates brake fade, significantly reduces the risk of continuous brake decline, and decreases the possibility of brake failure.

[0027] Second, the friction surface is intact, and the braking is smooth, without shaking, abnormal noise, or uneven wear.

[0028] Third, it is externally enclosed, waterproof, dustproof, and sandproof, suitable for all road conditions.

[0029] Fourth, it is arranged along the principal stress and has built-in reinforcing ribs, making it stronger than traditional solid structures.

[0030] Fifth, the gradient airflow directional guides the airflow, significantly improving heat dissipation efficiency.

[0031] Sixth, it requires no additional heat sink, has a simple structure, is lightweight, and has low cost.

[0032] Seventh, it is compatible with disc brakes, calipers, and drum brakes, making it suitable for a very wide range of applications.

[0033] Eighth, it can be directly cast, which is simple in process and has low mass production cost.

[0034] Ninth, existing vehicles can be directly replaced without modifying other parts of the original vehicle. Attached Figure Description

[0035] Figure 1 Braking system assembly diagram Figure 2 Brake disc section view Figure 3 Brake caliper cross-section Figure 4 Cross-sectional view of a drum brake The attached diagram is labeled as follows: 1-Outer edge closed ring; 2-Gradual heat dissipation channel; 3-Drum-shaped gradual heat dissipation channel; 4-Drum-shaped outer edge closed ring. Detailed Implementation

[0036] Example 1: Application in family cars The brake disc employs a circular radial gradient channel design, with the channel cross-section being circular and evenly distributed radially. The inner diameter of the channel is smaller, densely distributed in the area below the friction surface, quickly absorbing braking heat. The outer diameter of the channel gradually increases, directing the heat outward in accordance with centrifugal force. A closed ring is provided at the outer edge. The caliper features a unidirectional gradient channel in the non-stress area. The brake pads maintain a complete and dense structure. Overall, it is lightweight, low-cost, and suitable for daily commuting.

[0037] Example 2: Passenger and Commercial Vehicle Applications The brake disc employs a diamond-shaped gradient channel with a diamond-shaped cross-section. The major axis of the diamond is arranged along the tangent of the brake disc's circumference, conforming to the direction of the principal shear stress during braking. This balances strength and heat dissipation. The caliper and brake pad configuration is the same as in Example 1.

[0038] Example 3: Applications in Heavy-Duty and High-Performance Vehicles The brake disc employs a trapezoidal or fan-shaped large-section channel, with thickened channel walls and increased reinforcing rib width. This design is suitable for high-intensity continuous braking conditions and effectively suppresses heat fade during heavy-load, long downhill driving. The caliper and brake pad configuration is the same as in Example 1.

[0039] Example 4: Drum Brake Application The drum brake employs an externally enclosed, internally tapered channel design. The outer surface is completely sealed without holes, while the interior features radially tapered channels without penetrating the outer wall. It utilizes centrifugal force and heat conduction for rapid heat dissipation, providing waterproofing, dustproofing, and highly efficient cooling. Upgrades can be achieved by replacing the brake drum alone, without needing to replace other components simultaneously.

[0040] Example 5: Upgrading Existing Vehicles Replacing only the brake discs or drums does not require replacing the calipers. The new brake discs or drums feature a gradient closed cooling structure, allowing for direct replacement of the original parts and improving both heat dissipation and safety performance.

Claims

1. A universal high-efficiency heat dissipation assembly for automotive braking based on a gradually changing closed structure with a smaller inner diameter and a larger outer diameter, characterized in that: It includes a brake disc, brake caliper, and brake pads; the front friction surface of the brake disc is complete and without holes, and radially arranged heat dissipation channels with a gradual change in size from small to large inside are opened inside the disc body. The channels are closed and not connected outside; a sealing ring is provided on the outer edge; the channels are arranged along the principal stress direction, and a reinforcing rib structure is formed between the channels; the whole relies on centrifugal force and heat conduction to achieve directional heat dissipation, which is waterproof, dustproof, high-strength, and efficient in heat dissipation.

2. The assembly according to claim 1, characterized in that, The brake disc has a complete friction surface without holes, and the internal gradient channel is smaller inside and larger outside, with the outer edge closed and not open or hollowed out.

3. The assembly according to claim 1, characterized in that, The brake caliper has a gradually changing channel with a smaller inner diameter and a larger outer diameter in non-stressed, non-sealed, and non-oil circuit areas, without drilling through or affecting the hydraulic sealing performance.

4. The assembly according to claim 1, characterized in that, The assembly also includes a drum brake, which has a completely sealed outer surface and a radially tapered channel inside, without penetrating the outer wall.

5. The assembly according to claim 1, characterized in that, The brake pads have a complete and dense structure, without drilling, grooving, or carving.

6. The assembly according to claim 1, characterized in that, The gradient channels are arranged along the radial principal stress direction, and reinforcing ribs are formed between the holes, resulting in a structural strength superior to that of traditional solid parts.

7. The assembly according to claim 1, characterized in that, The air ducts are uniformly unidirectional, from the inside out, with no eddies or hot air recirculation.

8. The assembly according to claim 1, characterized in that, The entire piece can be directly cast without the need for subsequent drilling.

9. The assembly according to claim 1, characterized in that, Upgrades can be achieved by replacing the brake discs or brake drums separately, without having to replace the calipers at the same time.

10. The assembly according to claim 1, characterized in that, It is suitable for all types of braking systems, including disc brakes, calipers, and drum brakes, covering passenger cars, commercial vehicles, heavy-duty vehicles, and upgrades of existing vehicles.

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