Brake Disc Concave Profile Heat Dissipation
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Solution Overview
Problem
Current disc brake systems face challenges in managing heat generated during braking, leading to thermal stress, reduced lifespan, and increased risk of cracks and noise due to uneven temperature distribution across the braking surfaces.
Innovation Solution
A brake disc with a concave surface profile in the central portion, where the protrusion distance increases with radial distance from the minimum position, enhancing heat dissipation and reducing thermal stress by increasing the contact area and heat dissipating surface, while the brake pads have a structured coating matching the disc's surface profile for optimal fit and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the braking surface is made flat with uniform protrusion distance, then the manufacturing is simpler and the structure is easier, but the heat distribution becomes uneven leading to thermal stress and reduced lifespan
Solution Approach 1:
The braking surface is designed with non-uniform protrusion distance that varies in the radial direction, creating different surface characteristics in different regions. The central portion has a different profile than the outer regions, allowing localized optimization of heat distribution and stress patterns to prevent thermal cracking while maintaining effective braking across the entire surface.
Solution Approach 2:
The braking surface incorporates a curved profile rather than a flat surface. The protrusion distance varies continuously in the radial direction, creating a concave or curved geometry that promotes more uniform heat distribution across the braking surface, reduces thermal stress concentration, and extends component lifespan.
2Temperature
If the protrusion distance varies significantly in the central portion, then heat dissipation is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The protrusion distance parameter is varied systematically in the radial direction of the central portion to optimize heat dissipation. By controlling how this parameter changes across the radius, the design achieves improved thermal management while maintaining manufacturability through defined geometric progressions or continuous variations that can be produced with standard precision machining.
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
This design significantly extends the lifespan of the brake disc by 25% compared to standard designs, reduces thermal stress, and minimizes the risk of cracks and noise, ensuring improved braking performance and vehicle utilization.
Implementation Method 1
pressing first and second brake pads against the brake disc resulting in frictional interaction between first and second brake pad surfaces and corresponding first and second annular braking surfaces
Implementation Method 2
improved distribution of the heat generated during braking, as well as more efficient heat dissipation from the brake disc between braking events
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
A brake disc (10) for arrangement in a vehicle to rotate around a rotational axis (11). First and second annular braking surfaces (15a-b) extend radially between an inner braking surface radius (Ri) and an outer braking surface radius (Ro). Each of the first and second braking surfaces has an annular proximal portion (17), an annular distal portion (18), and an annular central portion (19). At least one of the first and second braking surfaces is structured to protrude from a base plane (16a, 16b) perpendicular to the rotational axis (11) to exhibit a surface profile cross-section (14a, 14b) with a plane including the rotational axis (11). A protrusion distance (ha(r), hb(r)) from the base plane (16a, 16b) to the surface profile cross-section (14a, 14b) as a function of radial distance (r) from the rotational axis (11) exhibits a minimum protrusion distance (ha,min, hb,min) at a minimum protrusion radial position (Rmin) in the central portion (19), and the protrusion distance (ha(r), hb(r)) increases with increasing radial distance from the minimum protrusion radial position (Rmin) everywhere in the central portion (19).