Vehicle Brake Cooling Duct with Phase-Change Actuator
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Solution Overview
Problem
Modern automotive vehicles face challenges in maintaining brake temperature within a preferred range while minimizing drag, as airflow redirection systems can impede cooling air flow to brake components, especially in designs optimized for low drag coefficients.
Innovation Solution
A closeable air flow duct system utilizing a thermally activated smart material actuator that senses brake temperature and controls airflow to maintain optimal temperature, incorporating a phase-changing material to open and close the duct inlet, ensuring supplementary cooling when needed without external power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If air flow is redirected to reduce vehicle drag, then vehicle aerodynamics are improved, but brake cooling is insufficient
Solution Approach 1:
The duct inlet is made dynamically controllable through an actuator that adjusts the inlet opening area based on brake temperature conditions. This allows the system to adapt between two states: closed or restricted position for reduced drag during normal operation, and open position for maximum cooling during high-temperature braking conditions.
Solution Approach 2:
The system changes the flow resistance parameter of the duct inlet based on operating conditions. By varying the inlet opening area from restricted to fully open, the system optimizes the balance between drag reduction and cooling efficiency according to actual brake temperature requirements.
2Temperature
If a closeable duct system is added to control airflow, then brake temperature control is improved, but device complexity increases
Solution Approach 1:
The system uses the brake assembly's own thermal energy to drive the cooling control mechanism. The temperature-sensitive actuator automatically opens or closes the duct inlet based on brake temperature without requiring external power sources, control systems, or additional sensors, thereby minimizing added complexity.
Solution Approach 2:
The patent replaces complex electronic control systems with a passive thermal-mechanical actuation mechanism. The actuator uses direct thermal expansion or phase change of a temperature-sensitive material to mechanically open or close the duct inlet, eliminating the need for motors, sensors, controllers, and power wiring.
3Temperature
If duct inlet area is increased for better cooling, then brake cooling efficiency is improved, but vehicle drag increases
Solution Approach 1:
The duct inlet area is made dynamically adjustable rather than fixed. The temperature-sensitive actuator enables the inlet to transition between a restricted area (for drag reduction) and a fully open area (for maximum cooling), allowing optimal area to be selected based on real-time thermal conditions.
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 system effectively directs cooling air to brake components when required, maintaining brake temperature within a preferred range while minimizing drag and eliminating the need for external power, thus enhancing brake performance and vehicle aerodynamics.
Implementation Method 1
incorporating a phase-changing material to open and close the duct inlet
Implementation Method 2
A closeable air flow duct system utilizing a thermally activated smart material actuator that senses brake temperature
Data Source
AI summary
An inlet, positioned to access the flow of air passing around and under a moving vehicle, draws in air which is conveyed through a duct and discharged to cool a brake on a vehicle. The inlet has a closure so that access of cooling air may be denied when the brake temperature is less than a predetermined temperature and opened only when the brake temperature exceeds that predetermined temperature. The closure is operated by a temperature-operated actuator. In embodiments the actuator may be suitably positioned to sense a temperature representative of the brake temperature and to incorporate a thermally activated phase change, active or smart material preselected to operate the inlet closure when the sensed brake temperature exceeds the predetermined temperature.