Commercial Vehicle Brake Disc Recess Design for Heat Dissipation
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Solution Overview
Problem
Existing commercial vehicle brake discs face challenges in achieving high stability while maintaining excellent thermal behavior, as prior configurations often result in increased weight, pad wear, and inefficient heat dissipation.
Innovation Solution
A brake disc design featuring a friction disc with strategically positioned recesses and indentations that disrupt the contour, increasing the surface area for heat radiation and inducing turbulence for enhanced heat dissipation, while maintaining stability through precise positioning and depth control of these features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ventilation channels are provided in the brake disc, then heat dissipation is improved, but structural stability deteriorates
Solution Approach 1:
The brake disc incorporates a porous metal matrix composite structure with controlled porosity (5-30% volume fraction). The pores are distributed throughout the disc body, providing internal ventilation channels that facilitate heat dissipation while the surrounding metal matrix maintains structural integrity and stability during braking operations.
Solution Approach 2:
The brake disc is constructed as a composite material system combining a metal matrix (such as cast iron or aluminum alloy) with a porous structure. This composite design allows the material to simultaneously provide mechanical strength for stability and thermal conductivity for heat dissipation, resolving the contradiction between structural integrity and thermal management.
2Temperature
If the brake disc width is increased for better heat dissipation, then thermal behavior is improved, but weight increases
Solution Approach 1:
The porous structure reduces the density of the brake disc material while maintaining adequate mechanical properties. The void spaces within the porous matrix reduce overall mass, allowing for improved thermal behavior through enhanced heat dissipation surface area and internal convection channels without proportionally increasing weight.
Solution Approach 2:
The invention changes the physical parameters of the brake disc by introducing controlled porosity and modifying the density distribution. This allows optimization of the weight-to-heat-dissipation ratio, where the porous structure provides increased surface area for heat transfer while reducing material mass, thereby improving thermal behavior without linear weight increase.
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 design achieves a balance between stability and heat dissipation, reducing pad wear and improving thermal management by maximizing heat radiation and natural frequency control.
Implementation Method 1
increase the surface area for dissipating the heat to the air and generates an air flow due to the centrifugal force when the brake disc rotates
Implementation Method 2
generates an air flow due to the centrifugal force when the brake disc rotates
Data Source
Figure 1a~1b
Figure 2~3
Figure 4
AI summary
Brake disc, in particular for commercial vehicles, comprising at least one friction disc which has a friction surface, wherein the friction disc comprises at least one recess which forms a contour on the friction surface, and wherein the contour or the course of the contour is interrupted by at least one recess.