Ventilated Brake Disc Radial Blade Segmentation

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Solution Overview

Problem

Conventional ventilated brake discs are complex and expensive to manufacture due to the need for a casting mould with multiple shells and cores to create inner ventilation cavities.

Innovation Solution

A brake disc design featuring a solid outer wall with radially interposed intermediate blades that act as a ventilation rotor, allowing air flow through openings between the blades, eliminating the need for a complex mould structure and enabling a simpler, cost-effective casting process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional ventilated brake discs are manufactured using a casting mould with multiple shells and cores to create inner ventilation cavities, then ventilation efficiency is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveventilation efficiencyVSAvoidmould structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The brake disc is segmented into an outer circumferential portion (solid wall) and an intermediate circumferential portion (ventilated wall with blades), allowing different structural characteristics in different zones to optimize both braking performance and ventilation while simplifying manufacturing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of creating ventilation cavities by removing material through complex cores, the invention inverts the approach by creating ventilation through radial blades that extend from the hub, with air passage holes formed between adjacent blades, eliminating the need for complex internal cavity structures

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If conventional ventilated brake discs are manufactured using a casting mould with multiple shells and cores, then ventilation efficiency is improved, but manufacturing cost increases

Engineering Contradiction:

Improveventilation efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The ventilation structure is created by replicating the blade pattern around the hub, where multiple identical radial blades are cast in sequence, simplifying the mould design and reducing manufacturing complexity compared to creating unique internal cavities

Inventive Principle:

Principle #26Copying

3Ease of manufacture

If the outer circumferential portion is made as a solid wall, then manufacturing simplicity is improved, but ventilation efficiency may be reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidventilation efficiency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Different zones of the brake disc wall are given different structural qualities: the outer circumferential portion has a solid wall structure for manufacturing simplicity and structural integrity, while the intermediate circumferential portion has a ventilated structure with radial blades for heat dissipation, optimizing both regions for their specific functions

Inventive Principle:

Principle #3Local quality

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 simplifies and reduces the manufacturing cost of ventilated brake discs while maintaining high ventilation efficiency, allowing for a larger diameter disc that meets current vehicle trends.

Implementation Method 1

during rotation of the disc, fulfil the function of a disc ventilating rotor

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Data Source

PatentEP3495684B1Brake disk for a disk brake device of a motor-vehicle

Publication Date: 2020.03.25 FCA ITALY SPA

Figure 1~2
Figure 3~4
Figure 5~6

AI summary

A brake disc for a disc brake device has a disc body (2) comprising a central hub (3) and a wall surrounding the central hub (3), and having an outer circumferential portion with two opposite faces that define two annular crown surfaces (5) constituting the braking surfaces of the disc. The wall surrounding the hub (3) has an intermediate circumferential portion (6), which is radially interposed between the hub (3) and the outer circumferential portion (4) defining the two braking surfaces (5). In the intermediate circumferential portion (6), a plurality of disc ventilating radial blades (7) are formed in one piece with the disc, alternated with through-openings (8) formed through the wall of the disc.