Brake Disc Connecting Members with Overhangs for Cooling and Strength
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Solution Overview
Problem
Ventilated brake discs face issues with connecting members bending or loosening under high braking torques, leading to potential corrosion and reduced cooling efficiency due to differences in material electrolytic potentials and structural thickness changes.
Innovation Solution
The use of three different materials (cast iron for the friction ring, stainless steel for connecting links, and aluminum or light metal for the disc chamber) with formed overhangs and a high-temperature-resistant lubricant in small gaps to prevent corrosion and enhance cooling, while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the number of pins is increased to achieve greater strength in the connection between the support part and the friction ring, then the connection strength is improved, but the entry of cooling air onto the friction ring is reduced, negatively affecting the cooling
Solution Approach 1:
The patent changes the geometric parameters of the connecting members by providing extensions on the friction ring that protrude into the disc chamber. This extension design increases the effective connection length and surface area without requiring additional pins, thereby strengthening the connection while preserving cooling air flow paths.
2Strength
If three different materials (cast iron for friction ring, stainless steel for connecting link, aluminum for disc chamber) are used, then the cooling efficiency is improved and structural integrity is enhanced, but corrosion problems occur due to different electrolytic potentials
Solution Approach 1:
The patent introduces a galvanic isolation measure by providing a galvanic isolation layer on at least one of the different materials. This isolation layer acts as an intermediary that prevents direct galvanic contact between dissimilar materials, eliminating corrosion risks while preserving the benefits of using three different materials for structural integrity and cooling efficiency.
3Reliability
If extensions are formed on the friction ring to prevent connecting members from loosening, then the connection reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the extension formation process with the existing friction ring manufacturing process. The extensions are formed as integral parts of the friction ring during its production, utilizing the existing manufacturing capabilities and tooling. This integration approach increases connection reliability while minimizing additional manufacturing complexity.
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 configuration minimizes gap lengths, prevents corrosion, and increases the cooling area between friction ring halves, thereby extending the service life and ensuring effective heat dissipation without compromising the brake disc's overall construction.
Implementation Method 1
With the help of a rust-protecting medium, in particular a high-temperature-resistant lubricant in the gap, the corrosion resistance can be improved
Implementation Method 2
The extensions are formed in particular in the radial direction of the friction ring, viewed from the center of rotation outwards, and open towards the outside of the brake disc in order to increase the cooling effect
Data Source
Figure 1
Figure 2~3
AI summary
A brake disc (10) is provided with a friction ring (12) and a disk chamber (11) connected to the friction ring (12) via connecting members (16). Extensions (20) are provided at the circumference of the friction ring (12), the connecting members (16) extending said extensions.