Bicycle Brake Disc Structure for Adaptive Heat Dissipation
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Solution Overview
Problem
Existing bicycle brake discs for hydraulic disc brakes are expensive and have a cooling capacity that is independent of the brake band's temperature, limiting their efficiency in heat dissipation.
Innovation Solution
A bicycle brake disc design featuring a brake tape with high heat resistance and an inner part with higher thermal conductivity, incorporating recesses and extensions for enhanced contact and heat transfer, allowing effective heat dissipation through a simple structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a brake disc with three-layer brake band and cooling fins is used, then cooling capacity is improved, but manufacturing cost and structural complexity increase
Solution Approach 1:
The brake band is segmented into multiple layers with different material properties: outer layers made of heat-resistant material and an intermediate layer made of thermally conductive material. This segmentation allows each layer to perform its specific function optimally while maintaining overall cooling efficiency.
Solution Approach 2:
Different regions of the brake disc are assigned different material properties and structural features. The intermediate layer has higher thermal conductivity specifically in regions where heat transfer is most needed, while the outer layers maintain heat resistance. Cooling fins are strategically positioned to maximize heat dissipation from critical areas.
2Temperature
If a complex multi-layer brake band structure is used, then cooling capacity is improved, but manufacturing cost increases
Solution Approach 1:
The brake band layers are merged into a single integrated component through casting or extrusion processes, eliminating the need for separate assembly steps. The cooling fins and brake band form a unified structure, reducing manufacturing complexity and cost while maintaining effective cooling performance.
Solution Approach 2:
The intermediate layer serves multiple functions simultaneously: it provides thermal conduction pathways, structural support, and heat distribution across the brake band. This multi-functionality reduces the need for additional separate components, simplifying manufacturing and reducing costs.
3Adaptability or versatility
If fixed cooling capacity design is used, then structural simplicity is maintained, but adaptability to varying temperatures is reduced
Solution Approach 1:
The brake disc design incorporates dynamic thermal management through the intermediate layer's thermal conductivity, which enables adaptive heat transfer. As temperature increases, the thermal conduction pathways become more effective, automatically adjusting heat dissipation rates to match thermal loads without requiring active control mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design improves heat dissipation by ensuring good contact between the brake tape and inner part, effectively transmitting torque and heat, while being more cost-effective and adaptable to varying temperatures.
Implementation Method 1
an inner part of a second material having a higher thermal conductivity than the first material
Implementation Method 2
a brake tape of a first material having a high heat resistance
Data Source
Figure 1~2
Figure 3
Figure 4~6
AI summary
A brake disc (1) for a hydraulic disc brake with a brake band (100) made of a first material having high heat resistance and an inner part (200) made of a second material having a lower density than the first material, wherein the brake band (100) has several recesses (110) into which extensions (210) of the inner part (200) engage.