Brake Disc Core-and-Pad Assembly for Heat and Torque Transfer
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Solution Overview
Problem
Aircraft brake discs face challenges in balancing thermal stability, mechanical strength, and friction properties, as materials with high thermal stability often lack heat transfer efficiency and strength, while strong materials may not provide adequate friction or thermal dissipation.
Innovation Solution
The design incorporates a structural core with pockets and friction pads featuring raised bosses that engage with the core's pockets, allowing for efficient torque transfer and heat dissipation, with the structural core providing mechanical strength and the friction pads offering improved friction properties, and both being made from materials tailored for their respective properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If materials with high thermal stability are used for brake discs, then thermal stability is improved, but heat transfer efficiency and mechanical strength deteriorate
Solution Approach 1:
The brake disc is divided into two distinct components: a structural core made from high thermal stability material (such as ceramic composite) and friction pads made from different material. This segmentation allows each component to be optimized for its specific function - the core provides thermal stability while the friction pads provide the necessary mechanical strength and friction properties.
Solution Approach 2:
The invention uses composite material construction where the structural core is made from materials with high thermal stability (such as ceramic matrix composites) while friction pads use materials optimized for mechanical strength and friction. This composite approach resolves the contradiction by combining materials with complementary properties rather than relying on a single material to satisfy all requirements.
2Stability of the object's composition
If materials with high thermal stability are used for brake discs, then thermal stability is improved, but heat transfer efficiency deteriorates
Solution Approach 1:
By segmenting the brake disc into a thermal stability core and separate friction pads, the design allows the core to maintain thermal stability while the friction pads can be designed with materials and structures that optimize heat transfer. The friction pads act as intermediate elements that facilitate heat dissipation from the friction interface to the core.
Solution Approach 2:
Different regions of the brake disc assembly are given different material properties optimized for their local function. The structural core has high thermal stability for withstanding thermal loads, while the friction pads have material properties optimized for heat transfer and friction. This local differentiation resolves the contradiction between thermal stability and heat transfer efficiency.
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 enhances the brake disc's strength, friction performance, and heat dissipation capabilities, allowing for effective braking and reduced stress on components, leading to improved braking efficiency and extended service life.
Implementation Method 1
The first pad surface includes a first planar pad surface configured to contact the first core surface... The friction pads may be configured to provide a friction surface for the brake disc assembly, while the structural core may be configured to provide strength to the brake disc assembly and remove heat from the friction pads
Implementation Method 2
The first plurality of bosses are configured to engage with the plurality of pockets to position the first friction pad relative to the structural core... Each elongated fastener is configured to pass through the first bore of a corresponding one of the first plurality of bosses and the second bore of a corresponding one of the second plurality of bosses to fasten the first and second friction pads to the structural core
Implementation Method 3
The friction pads may be configured to provide a friction surface for the brake disc assembly... When a jet-powered aircraft lands, the aircraft braking system, various aerodynamic drag sources (e.g., flaps, spoilers, and the like) and aircraft thrust reversers may be used to slow the aircraft down
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
An article includes a structural core (102), one or more friction pads (104), and a plurality of elongated fasteners (108). The structural core includes two core surfaces (124) and a plurality of pockets (110) extending between the core surfaces. Each friction pad (104) includes a pad surface (115) and a friction surface (112) opposite the pad surface. Each pad surface (115) includes a planar pad surface (114A, 114B) configured to contact the core surface (124) and a plurality of bosses (116) extending from the first planar pad surface and including a bore (106). Each planar pad surface is at least about 50% of a surface area of the respective first and second pad surfaces. The plurality of bosses (116) engages with the plurality of pockets (110) to position the respective first and second friction pads (104) relative to the structural core (102). The plurality of elongated fasteners (108) passes through bores (106) of corresponding bosses of friction pads to fasten the friction pads to the structural core.