A universal assembly for uniform heat dissipation with a gradually expanding diameter (smaller inner diameter and larger outer diameter) and flow guidance.

Abstract

This invention discloses a universal assembly for uniform heat dissipation with a gradient expansion channel that is smaller inside and larger outside, belonging to the technical field of integrated mechanical thermal management, structural heat dissipation, aerodynamic flow guidance, and structural strength. This assembly is an independent original technical solution. It features a gradient expansion channel with a smaller inner diameter and a larger outer diameter inside the device body. The channel's diameter gradually increases from the inside to the outside, forming a directional flow guidance structure. The outside of the channel is sealed and not open, forming a closed heat dissipation cavity inside. Heat is uniformly dissipated along the channel from the inside to the outside, achieving balanced heat dissipation throughout the entire area and preventing localized overheating and thermal deformation. The channel is arranged along the principal stress direction, forming a reinforcing structure between the holes, improving overall strength and deformation resistance. It also has waterproof, dustproof, and sediment-proof functions. The cross-sectional shape of the channel can be flexibly designed into a circular, rhomboid, triangular, trapezoidal, fan-shaped, or irregular shape according to the stress state of the equipment to adapt to different principal stress distributions. This assembly has a simple structure and can be integrally cast or manufactured through various processes such as additive manufacturing, powder metallurgy, diffusion welding, or welding after separate processing. This assembly is applicable to various rotating, reciprocating, and stationary heat-generating mechanical equipment, including brake discs, brake drums, hubs, flywheels, rotors, impellers, engine housings, compressor housings, motor housings, reducer housings, engineering machinery components, and marine equipment components. For any mechanical structure with triple requirements of "heat dissipation-strength-protection," the heat dissipation channel design paradigm disclosed in this invention—characterized by a small inner diameter and a large outer diameter, external enclosure, and a gradually expanding diameter along the stress direction—constitutes a universal solution. This invention fundamentally solves problems such as uneven heat dissipation, localized overheating, thermal deformation, thermal decay, dust ingress, and reduced strength associated with traditional heat dissipation structures, significantly improving equipment safety, stability, and service life.

Description

Technical Field

[0001] This invention relates to the field of integrated technologies of mechanical thermal management, structural heat dissipation, aerodynamic airflow guidance, and structural strength. Specifically, it relates to a general mechanical heat dissipation assembly with a gradually expanding inner diameter and a larger outer diameter, external enclosure, gradient airflow guidance, and uniform heat dissipation throughout the entire area, which is suitable for various rotating, reciprocating, and stationary heat-generating mechanical equipment. Background Technology

[0002] Existing mechanical heat dissipation structures generally employ methods such as straight holes, through holes, hollowing out, and slotting, and there are six long-standing technical bottlenecks that have not been properly resolved.

[0003] First, uneven heat dissipation and localized overheating. While traditional through-hole or perforated structures may seem to increase the heat dissipation area, heat is not actually dissipated evenly from every hole. The heat dissipation conditions in the perforated areas are far better than in the unperforated areas, resulting in a significant temperature difference between the solid and hollow parts. The greater the temperature difference, the more severe the thermal deformation, and the more prone the parts are to warping and cracking after long-term operation.

[0004] Secondly, brake fade is a serious problem. During long downhill stretches or high-frequency braking conditions, the temperature of the brake discs and pads rises sharply. As the temperature increases, the coefficient of friction decreases significantly, resulting in a marked increase in braking distance and obvious brake fade. For heavy-duty trucks traveling on mountainous roads, brake fade is one of the main causes of brake failure and traffic accidents.

[0005] Third, through holes weaken structural strength. Traditional heat dissipation holes are designed to penetrate the material, disrupting the stress transmission path and creating stress concentration points at the hole edges. Under heavy loads, high frequencies, and impact conditions, these stress concentration points can easily become crack initiation sites, leading to fatigue fracture of the component.

[0006] Fourth, the perforated structure is prone to dust, water, and mud. The through-holes are directly exposed to the external environment, and in dusty and muddy conditions such as in the field, construction sites, and mining areas, the holes are easily clogged. Once clogged, the heat dissipation function is completely lost, turning the area into a dead zone where heat accumulates.

[0007] Fifth, traditional heat dissipation structures lack directional airflow capability. The direction of heat dissipation from the holes is random, making it impossible to form an orderly airflow organization. Hot air easily forms backflow around the components, reducing heat dissipation efficiency.

[0008] Sixth, existing technologies do not possess a universal heat dissipation assembly that integrates a gradually expanding inner diameter with a larger outer diameter, external closure, irregularly shaped holes arranged along the principal stress direction, and integrated heat dissipation and structural reinforcement. Furthermore, there is no universal design paradigm that uses the synergistic optimization of multiple physical fields (thermal-mechanical-fluid) as a design criterion for heat dissipation channels. Summary of the Invention

[0009] 3.1 Purpose of the Invention This invention aims to overcome all the shortcomings of existing heat dissipation structures, such as uneven heat dissipation, localized overheating, thermal deformation, thermal decay, easy dust ingress, and reduced strength. It provides a universal mechanical heat dissipation assembly with high structural strength, uniform heat dissipation, directional airflow, external dustproof enclosure, wide applicability, and ease of mass production. The core design paradigm of this invention—a gradually expanding diameter (smaller inside, larger outside), an externally sealed and non-perforated structure, and a coordinated arrangement along the principal stress direction and the flow field direction—is applicable to any mechanical structure with triple requirements for "heat dissipation-strength-protection." This invention is an independent and complete original technical 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 originates from in-depth observation of the thermal fade phenomenon of braking systems and systematic analysis of the defects of traditional heat dissipation hole structures. Through layer-by-layer deduction in three aspects: thermodynamic analysis, aerodynamic design and structural mechanics optimization, a complete technical solution of gradually expanding diameter with smaller inner diameter and larger outer diameter, external closure and irregular holes arranged along the principal stress direction was finally established.

[0011] Step 1: Starting with brake fade – Why traditional heat dissipation vents are wrong 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] To dissipate heat, traditional brake discs have numerous through-holes. However, the inventors discovered through analysis that this design has a fundamental physical flaw. While the through-holes increase the contact area with air, heat is not evenly dissipated from every hole. The heat dissipation conditions in the perforated areas are far better than in the unperforated areas, creating a significant temperature difference between the solid and hollow parts. The greater the temperature difference, the more uneven the thermal deformation, making the brake disc more prone to warping and deformation, which in turn exacerbates brake shudder and heat fade. More importantly, the through-holes disrupt the main stress transmission path inside the brake disc, creating stress concentration points at the hole edges, which can easily become the initiation points of cracks under heavy braking conditions.

[0013] The inventors thus established a completely new principle for heat dissipation design: heat dissipation channels must achieve directional and uniform flow from the heat concentration area to the outer area while maintaining structural integrity, rather than simply increasing the heat dissipation area by drilling holes.

[0014] Step Two: Starting with the laws of heat diffusion – Why is the inside smaller than the outside? The inventors further analyzed the heat diffusion pattern inside the metal component. Heat always diffuses naturally from high-temperature areas to low-temperature areas, radiating outwards from the central heat source. This pattern determines the optimal shape of the heat dissipation channel—the channel should follow the natural direction of heat diffusion, gradually expanding from the inner end near the heat source to the outer end.

[0015] The inner aperture is designed to be relatively small and densely distributed near the heat source. This maximizes the heat dissipation area near the heat source, allowing for rapid heat absorption at the source. The outer aperture gradually increases in size, forming an expanding flow channel that guides heat to diffuse evenly outwards. This gradually expanding diameter structure, with a smaller inner aperture and a larger outer aperture, follows the natural diffusion trend of heat, achieving directional and uniform flow from the heat source to the outside and preventing localized heat accumulation.

[0016] Step 3: Starting with the external enclosure design – Why can't we open it up? Traditional heat dissipation holes are designed to be through-holes, directly exposed to the external environment. In dusty and muddy conditions such as in the field, construction sites, and mining areas, these holes are easily clogged. Once clogged, the heat dissipation function is completely lost. At the same time, the through-holes disrupt the integrity of the component's outer surface; the outer surface is no longer a continuous heat dissipation surface but is fragmented into scattered pieces by the holes.

[0017] The inventors employed an externally sealed design. A complete, airtight heat dissipation cavity is formed between the inner and outer ends of the channel. Heat is directionally conducted and diffused from the inside out within the cavity, ultimately dissipating evenly into the air through the outer surface. This externally sealed structure not only prevents the intrusion of mud, dust, and moisture but also ensures the integrity of the outer surface and a uniform heat dissipation area. The entire outer surface becomes a continuous heat exchange surface, resulting in higher heat dissipation efficiency than a through-type design where the surface is divided by holes.

[0018] Step 4: Starting from structural strength – Why arrange irregularly shaped holes along the principal stress direction? Different mechanical components experience different principal stress directions. Brake discs primarily bear circumferential shear stress and radial tensile stress. Brake drums primarily bear radial expansion force and circumferential friction force. Engine housings primarily bear axial tensile and compressive stress and radial expansion stress. If the cooling channels are arranged in a direction inconsistent with the principal stress directions, the channel walls will become weak points where stress concentrates.

[0019] The inventors arranged the heat dissipation channels along the principal stress direction, and the cross-sectional shape of the channels can be flexibly designed into circles, rhombuses, triangles, trapezoids, fans, or irregular shapes according to the stress state. Natural reinforcing ribs are formed between the channels, and these ribs are precisely located on the transmission path of the principal stress, significantly improving the structural strength of the component while dissipating heat. Circular cross-sections are suitable for components with balanced stress in all directions. Rhomboid or triangular cross-sections are suitable for components where stress is dominant in one direction; the long axis of the rhombus is aligned with the principal stress direction, which can evenly distribute the stress to the reinforcing ribs on both sides of the channel. Trapezoidal or fan-shaped cross-sections are suitable for rotating components with large radial stress.

[0020] Furthermore, the cross-sectional shape of the channel is not limited to the types listed. Any closed channel cross-section that conforms to stress flow lines and gradually increases in diameter from the inside to the outside is within the scope of protection of this invention.

[0021] Step 5: Starting from the synergy of multiple physics fields of "thermal-mechanical-fluid" – the underlying design paradigm of this assembly After completing the above four-step deduction, the inventors further refined the underlying design paradigm of this assembly. The traditional design concept for heat dissipation structures is "design the structure first, then drill holes for heat dissipation"—the heat dissipation holes are an addition outside the structure. The design concept of this assembly is "shape determined by heat, solidified by force, and optimized by flow"—the shape, arrangement direction, and cross-sectional variation law of the heat dissipation channels are jointly determined by the laws of heat diffusion, stress distribution, and flow field guidance requirements.

[0022] Specifically: the gradient direction of heat diffusion from the high-temperature region to the low-temperature region determines the basic shape of the channel, which gradually expands in diameter from the inside to the outside. The transmission path of the principal stress determines the arrangement direction and cross-sectional shape of the channel. The airflow direction of the external flow field determines the distribution density of the channel on the surface of the part and the orientation of its opening.

[0023] Under the combined effect of these three physical laws, the channel shape serves multiple functions: a heat dissipation channel—guiding heat outwards in a directional manner; a reinforcing rib—strengthening the structure by conforming to the principal stress path; and a dust barrier—externally sealing off to prevent the intrusion of foreign objects. These three functions are not "superimposed" on the same structure, but rather three properties naturally exhibited by the same structure under three different physical fields. This is precisely what distinguishes this assembly from all traditional heat dissipation designs. This design paradigm based on the synergy of multiple physical fields—heat, force, and flow—is applicable to any mechanical structure with triple requirements for heat dissipation, strength, and protection.

[0024] Step 6: Starting from different application scenarios – Why is a universal assembly needed? The inventors designed this gradually expanding diameter heat dissipation structure as a universal assembly, maintaining the same core principle while adjusting the cross-sectional shape, arrangement, and number of stages of the channels according to specific application scenarios. Rotating machinery such as brake discs and wheel hubs utilize radially expanding diameter channels, radiating outwards from the center to dissipate heat in accordance with centrifugal force. Shell-type machinery such as engine housings employ axial or oblique gradually expanding diameter channels, arranged in accordance with the principal stress direction of the housing. Heavy-duty equipment such as large brake drums utilize large-section trapezoidal or fan-shaped gradually expanding channels, significantly improving structural strength while ensuring heat dissipation, adapting to heavy-duty continuous braking conditions.

[0025] 3.3 Core Structure This assembly features a gradually expanding channel with a smaller inner diameter and a larger outer diameter inside the main body. The inner end of the channel has a smaller diameter, while the outer end has a larger diameter, creating a gradient flow structure that expands from the inside out. The outer side of the channel is sealed, forming a closed heat dissipation cavity inside. Heat is directed and evenly dissipated along the channel from the inside out, achieving balanced heat dissipation throughout the entire area and preventing localized overheating and thermal deformation.

[0026] The channels are arranged along the principal stress direction and along the generatrix on curved parts to reduce fluid resistance. In high-temperature areas, they are densely arranged to match the heat source intensity, forming a synergistic layout logic of "stress-flow field-heat source". The cross-sectional shape of the channels can be flexibly designed according to the stress state of the equipment, and can be at least one of the following: circular, rhomboid, triangular, trapezoidal, fan-shaped, or irregular. Any closed channel cross-section that can conform to the stress flow lines and gradually expand from the inside to the outside is within the protection scope of this invention. A reinforcing structure is formed between the channels to improve overall strength and resistance to deformation. The channels are externally enclosed, without openings or perforations, and are waterproof, dustproof, and prevent the entry of mud and sand.

[0027] The gradient diameter expansion channels can be arranged radially, axially, or obliquely in one or more combinations. The entire assembly can be integrally cast, or manufactured using various processes such as additive manufacturing, powder metallurgy, diffusion welding, or welding after separate machining.

[0028] 3.4 Working Principle The heat generated during equipment operation enters the internal gradually expanding channels through heat conduction. Within the sealed heat dissipation cavity, heat diffuses directionally from the inside out along the expanding channels, which are narrower at the inside and wider at the outside, following the natural diffusion trend of heat. The external enclosed structure prevents water, sediment, and dust from entering while ensuring a continuous and uniform heat dissipation surface on the outer surface. The channels are arranged along the principal stress lines, and the reinforcing ribs between the channels enhance the structural strength of the components while dissipating heat. Under the synergistic effect of the "thermal-mechanical-fluid" fields, the channel shape simultaneously achieves the triple functions of heat dissipation and airflow guidance, structural reinforcement, and dust protection, ensuring long-term operation without warping, cracking, or localized failure.

[0029] 3.5 Beneficial Effects First, it ensures uniform heat dissipation across the entire area, preventing localized overheating, thermal deformation, and thermal cracking at the source. The gradually expanding channel with a smaller inner diameter and a larger outer diameter follows the natural heat diffusion trend, allowing heat to diffuse directionally and evenly from high-temperature areas to low-temperature areas, eliminating localized hot spots.

[0030] Secondly, the internal gradient airflow is small while the external gradient airflow is large, resulting in a unified heat dissipation direction, no backflow, and high efficiency. The inner end of the channel is densely distributed near the heat source to quickly absorb heat, while the outer end gradually expands to guide the heat to diffuse evenly, forming a unidirectional and orderly heat dissipation airflow organization.

[0031] Third, the exterior is sealed and not open, providing waterproofing, dustproofing, and protection against mud and sand. The outer surface remains intact and continuous, forming a uniform heat dissipation surface, ensuring stability under all operating conditions. This prevents heat dissipation failure caused by blocked openings.

[0032] Fourth, the channels are arranged along the principal stress and have their own reinforcing structure, making them stronger than traditional solid and perforated parts. The reinforcing ribs between the channels are precisely on the principal stress transmission path, completing structural reinforcement while dissipating heat, thus resolving the contradiction that "heat dissipation inevitably reduces strength" in traditional perforated parts.

[0033] Fifth, the channel cross-section can be designed as circular, rhomboid, triangular, trapezoidal, fan-shaped, or irregular in shape to flexibly adapt to components with different stress directions. Any closed channel cross-section that can conform to the stress flow line and gradually expand from the inside to the outside is within the protection scope of this invention.

[0034] Sixth, it has a simple structure, can be manufactured using multiple processes, and has low mass production costs. It can be integrally cast or manufactured using various processes such as additive manufacturing, powder metallurgy, diffusion welding, or welding after separate processing. No post-processing drilling is required, making it highly adaptable to different processes.

[0035] Seventh, it is extremely versatile and applicable to all kinds of rotating, reciprocating, and stationary heat-generating mechanical equipment. A single core design paradigm can be adapted to all scenarios, including brake discs, brake drums, wheel hubs, flywheels, rotors, impellers, engine housings, compressor housings, motor housings, reducer housings, engineering machinery components, and marine equipment components, by adjusting the cross-sectional shape, arrangement direction, and number of stages.

[0036] Eighth, the synergistic advantage of the "thermal-mechanical-fluid" multi-physics field. This assembly is not simply a splicing of heat dissipation and reinforcing ribs, but rather a naturally evolved optimal topological structure that synergizes the "thermal-mechanical-fluid" three fields under the combined effect of three physical laws: heat diffusion, stress distribution, and flow field guidance requirements. The channel shape simultaneously achieves three functions: heat dissipation and flow guidance, structural reinforcement, and dust protection. These three functions are not "superimposed" on the same structure, but rather are three properties naturally exhibited by the same structure in the three physical fields.

[0037] Ninth, it significantly improves equipment lifespan, operational stability, and safety. It fundamentally alleviates thermal degradation problems, reduces the risk of failures and accidents, and extends the entire lifespan of the equipment. Attached Figure Description

[0038] Figure 1 Cross-sectional view of the heat dissipation structure of the circular assembly Figure 2 External General Schematic Diagram Figure 3 Cross-sectional view of the heat dissipation structure of the square assembly Figure 4 Axial section view of circular gradient channel Figure 5 Axial section view of a circular gradient channel Figure 6 Axial section view of a square, outwardly expanding, gradually changing channel Figure 7 Axial section view of a square center-gradient channel Figure 8 Rotary equipment application diagram Figure 9 Application diagram of housing equipment Attached diagram labels: 1-Gradual heat dissipation expansion channel with central shaft; 2-Gradual heat dissipation expansion channel without central shaft; 3-Square outward-expanding gradual heat dissipation expansion channel; 4-Square centrally located gradual heat dissipation expansion channel; 5-Hollow buffer heat dissipation cavity in the inner layer of the wheel hub; 6-Gradual heat dissipation channel of the brake drum; 7-Outer edge closed ring; 8-Gradual heat dissipation channel of a large compressor; 9-Gradual heat dissipation channel of a large generator. Detailed Implementation

[0039] Example 1: Brake Disc Application The brake disc employs radially tapering channels with a rhomboid cross-section. The major axis of the rhombus is aligned with the tangent to the brake disc's circumference, conforming to the direction of the principal shear stress during braking. The inner ends of the channels are densely distributed in the central friction area of ​​the brake disc, with smaller inner diameters to quickly absorb heat generated by braking friction. The channels gradually expand radially outwards, utilizing the centrifugal force generated by the brake disc's rotation to dissipate heat in a directional manner. The external channels are sealed to prevent the intrusion of brake dust, mud, and moisture. Reinforcing ribs between the channels form a mesh-like support structure along the radial and circumferential directions, significantly improving the brake disc's resistance to thermal deformation and fatigue life.

[0040] Example 2: Application of Brake Drum The brake drum employs axially tapered expansion channels with trapezoidal or fan-shaped cross-sections, evenly distributed circumferentially along the cylindrical surface of the brake drum. The inner end of the channel is close to the friction surface of the brake drum's inner wall, rapidly absorbing braking heat. The channel gradually expands radially outward, allowing heat to diffuse evenly to the outer surface of the brake drum. The externally enclosed structure creates a complete, continuous heat dissipation surface on the outer surface of the brake drum. The trapezoidal cross-section channels, while ensuring sufficient heat dissipation area, significantly enhance the radial expansion resistance and structural rigidity of the brake drum, making it suitable for heavy-load continuous braking conditions.

[0041] Example 3: Application of heavy-duty truck wheel hubs The heavy-duty truck wheel hub adopts a radially expanding channel with a fan-shaped cross-section, evenly distributed along the circumference of the hub. The inner end of the channel is close to the hub bearing area, and the channel gradually expands radially outward. The external enclosed structure prevents the intrusion of mud, sand, and moisture from the field. The reinforcing ribs between the channels significantly improve the radial load-bearing capacity and fatigue life of the wheel hub, making it suitable for heavy-duty, long-distance, and bumpy operating conditions.

[0042] Example 4: Engine Housing Application The engine housing employs axially or obliquely tapered expansion channels with circular or rhomboid cross-sections, arranged along the principal stress direction and generatrix direction. The inner end of the channel is close to the high-temperature region of the cylinder block, and the channel gradually expands outward along the housing wall thickness. An external sealing structure ensures the housing's airtightness. Reinforcing ribs between the channels enhance the overall rigidity of the housing.

[0043] Example 5: Application of Field Engineering Machinery Components The components of the field engineering machinery feature a fully enclosed outer contour and an internally tapered, expanded-diameter airflow guide. The channel cross-section is flexibly designed according to the stress state of the components, with denser arrangement in high-temperature zones to match the heat source intensity. The external enclosed structure provides dustproof, mudproof, and anti-clogging protection, making it suitable for harsh working conditions such as mining areas and construction sites.

[0044] Example 6: Additive Manufacturing Integrated Molding Application For parts with complex shapes that are difficult to machine using traditional casting, additive manufacturing is used for integrated molding. The gradually expanding diameter channels and reinforcing rib structures are generated simultaneously during the printing process, eliminating the need for post-processing drilling, resulting in high material utilization and a high degree of design freedom.

Claims

1. A universal assembly for uniform heat dissipation with a gradient expansion diameter (smaller inner diameter and larger outer diameter), characterized in that: The device body has an internally designed channel with a gradually expanding diameter, smaller at the inner end and larger at the outer end, forming a gradient flow guiding structure that expands from the inside out. The outer side of the channel is closed and not open, forming a sealed heat dissipation cavity inside. Heat is directed and uniformly discharged from the inside out along the channel, achieving balanced heat dissipation across the entire area and preventing local overheating and thermal deformation. The channel is arranged along the principal stress direction and along the generatrix on curved parts to reduce fluid resistance. In high-temperature areas, the channel is densely arranged to match the heat source intensity, forming a three-way synergistic layout logic of "stress-flow field-heat source". The cross-sectional shape of the channel is designed according to the stress state of the device. Any closed channel cross-section that can conform to the stress flow line and gradually expand from the inside out is within the protection scope of this invention. A reinforcing structure is formed between the channels to improve the overall strength and resistance to deformation.

2. The assembly according to claim 1, characterized in that, The arrangement direction of the gradually expanding channels is one or more combinations of radial, axial, or oblique arrangement.

3. The assembly according to claim 1, characterized in that, The cross-sectional shape of the channel is at least one of the following: circular, rhomboid, triangular, trapezoidal, fan-shaped, or irregular, to accommodate the principal stress distribution in different directions.

4. The assembly according to claim 1, characterized in that, The channel is externally enclosed, without any openings or perforations, making it waterproof, dustproof, and preventing the entry of mud and sand. The outer surface forms a continuous and uniform heat dissipation surface.

5. The assembly according to claim 1, characterized in that, The equipment body is at least one of rotating machinery, reciprocating machinery, or stationary machinery, including braking components, hubs, flywheels, rotors, impellers, engine housings, compressor housings, motor housings, reducer housings, engineering machinery components, or marine equipment components.

6. The assembly according to claim 1, characterized in that, It can be cast as a single piece, or it can be manufactured through various processes such as additive manufacturing, powder metallurgy, diffusion welding, or welding after separate processing.

7. The assembly according to claim 1, characterized in that, Under the synergistic effect of the "thermal-mechanical-fluid" three fields, the channel shape simultaneously achieves three functions: heat dissipation and airflow guidance, structural reinforcement, and dust protection. These three functions are three attributes that the same structure naturally exhibits in three physical fields.

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