Ventilated Disc Brake Band Projections for Cooling and Noise Reduction
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Solution Overview
Problem
Existing ventilated disc brake systems face challenges in efficiently dissipating heat generated during braking, leading to deformation, material deterioration, and increased noise due to vibrations, while current solutions fail to balance cooling efficiency with mechanical resistance and vibration reduction without causing structural stresses.
Innovation Solution
A braking band with a specific design featuring projections that extend circumferentially between connecting elements, creating a non-uniform distribution to enhance airflow turbulence and reduce vibrations, thereby improving cooling efficiency and minimizing noise and stress concentrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional ventilated disc designs with uniform connecting elements are used, then structural simplicity is maintained, but heat dissipation efficiency is insufficient and vibration noise increases
Solution Approach 1:
The braking band is segmented into multiple zones with different connecting element configurations. The first zone has connecting elements with larger cross-sectional area for enhanced heat dissipation, while the second zone has connecting elements with smaller cross-sectional area, creating a non-uniform distribution that optimizes both cooling efficiency and structural complexity
Solution Approach 2:
Different regions of the braking band are assigned different local properties. The connecting elements in the first zone (closer to the friction surface) have different characteristics than those in the second zone, allowing each region to be optimized for its specific functional requirements regarding heat dissipation and structural integrity
2Temperature
If connecting elements with larger cross-sectional area are used throughout, then heat dissipation improves, but mechanical stress concentrations increase
Solution Approach 1:
The solution applies local quality by varying the cross-sectional area of connecting elements based on their radial position. Elements closer to the friction surface (first zone) have larger cross-sectional area for better heat dissipation, while elements farther away (second zone) have smaller cross-sectional area to reduce mechanical stress concentrations in less critical regions
3Object-affected harmful factors
If uniform connecting elements are used, then manufacturing simplicity is maintained, but vibration reduction and noise control are insufficient
Solution Approach 1:
The braking band is divided into radial zones with different connecting element configurations. This segmentation creates a non-uniform structure that disrupts vibration patterns and reduces noise, while still using standard manufacturing techniques for each zone, balancing performance improvement with manufacturing feasibility
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 solution achieves enhanced braking comfort by reducing vibrations and noise, maintaining high cooling efficiency, and increasing mechanical resistance, thus addressing the limitations of prior art.
Implementation Method 1
creating a non-uniform distribution to enhance airflow turbulence and reduce vibrations, thereby improving cooling efficiency
Implementation Method 2
the inner surfaces, together with the pillars or fins, delimit ventilation channels for cooling the disc, which channels the air flows through according to a centrifugal direction during the rotary motion of the disc itself
Implementation Method 3
the friction between the brake caliper pads and the braking surfaces of the braking band generates an increased quantity of heat which requires being disposed of
Data Source
AI summary
A braking band extends between an inner diameter and an outer diameter. The braking band has two plates having inner surfaces delimiting a gap, outer surfaces having opposite flat circumferential portions and a plate body having an extension in axial direction. The plates are joined by connecting elements. At least one plate has at least one projection projecting into the gap without reaching the opposite plate, forming a localized narrowing of the gap and a thickening of the plate body, creating a localized increase of the thickness of plate. The projection extends from a first connecting element to an adjacent connecting element, connecting them, and along the circumferential direction, connecting at least two adjacent connecting elements. A group of projections extends circumferentially along a discontinuous annular path, avoiding a uniform distribution in circumferential direction.