Brake Disc Recesses and Porous Ceramic Coating for Heat Dissipation
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Solution Overview
Problem
Existing brake discs for commercial vehicles face challenges in combining high stability with excellent thermal behavior and reduced pad wear, as conventional ventilation methods increase weight and pad wear, and previous designs have not effectively balanced stability and heat dissipation.
Innovation Solution
A brake disc design featuring a friction disc with recesses and indentations that prevent contact with the brake pad, allowing for increased heat radiation and stability, where the recesses are positioned within the contour of the depression, and the friction disc is designed as a friction ring with elongated holes or grooves that promote air flow and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If internal ventilation is incorporated to improve heat dissipation, then thermal behavior is improved, but weight and width increase
Solution Approach 1:
The brake disc incorporates a porous ceramic coating material on its friction surfaces, creating a porous structure that enables internal ventilation and heat dissipation without requiring additional heavy ventilation channels or structures. The porous material itself provides the ventilation function while maintaining lightweight construction.
Solution Approach 2:
The brake disc uses a composite structure combining a metallic base material with a ceramic coating layer. This composite material approach allows the disc to achieve excellent thermal behavior and heat dissipation properties through the ceramic layer's porous structure, while the metallic base maintains structural integrity without requiring excessive weight.
2Temperature
If perforations are incorporated to control heat transfer, then thermal behavior is improved, but pad wear increases
Solution Approach 1:
Instead of using perforations that expose sharp edges capable of cutting the brake pad, the invention employs a porous ceramic coating that provides heat transfer control through its porous structure. The porous material gradually wears down the brake pad through abrasion rather than cutting, significantly reducing pad wear while maintaining effective heat transfer control.
3Temperature
If maximum heat dissipation is achieved through increased surface area, then thermal behavior is improved, but stability decreases
Solution Approach 1:
The ceramic coating is applied locally on the friction surfaces of the brake disc where heat generation and dissipation are most critical. This localized application provides enhanced heat dissipation capability exactly where needed, while the rest of the disc maintains its original stable structure and composition, preserving overall stability.
Solution Approach 2:
The composite structure of metallic base with ceramic coating provides both enhanced heat dissipation through the ceramic layer's high thermal radiation properties and maintained stability through the metallic base's structural integrity. The combination allows maximum heat dissipation surface area without compromising the disc's structural stability.
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 effectively reduces pad wear, enhances heat dissipation, and maintains stability by positioning recesses within the contour of the depression, allowing for efficient heat radiation and improved braking performance.
Implementation Method 1
allowing for increased heat radiation and stability
Implementation Method 2
the centrifugal force generated by the rotating brake disc creates an airflow
Implementation Method 3
the vehicle's kinetic energy is completely converted into heat during braking
Data Source
Figure 1
Figure 2
AI summary
Brake disc, in particular for commercial vehicles, comprising at least one friction disc (10) which has a friction surface (12), wherein the friction disc comprises at least one recess (20) which forms a contour (22) on the friction surface, and wherein at least one recess (40) is provided within the contour.