Brake Disc Structure With Segmented Ventilation Holes

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Solution Overview

Problem

Existing brake disc structures face issues with weight, wear resistance, and heat dissipation, particularly due to the deformation of exposed aluminum rotor portions when used in conjunction with stainless steel components, leading to reduced durability.

Innovation Solution

A brake disc structure comprising a central metal or metal alloy disc with ferrous metal first and second discs, connected through a metallurgical reaction, featuring through orifices and varying hole diameters for enhanced heat dissipation and structural reinforcement, ensuring light weight and wear resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If aluminum alloy is used for the rotor portion to reduce weight, then weight is reduced, but the exposed aluminum portion deforms easily after prolonged use

Engineering Contradiction:

ImproveweightVSAvoiddurability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The brake disc is divided into three distinct segments: a first rotor portion (aluminum alloy), a central disc, and second/third rotor portions (stainless steel). This segmentation allows each material to perform its optimal function while preventing the deformation issues of exposed aluminum by structurally integrating it with supported steel components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining aluminum alloy (first rotor portion) with stainless steel (second and third rotor portions) and a central disc. This composite approach leverages the light weight of aluminum while using steel for structural support and wear resistance, preventing the deformation problems of pure aluminum designs.

Inventive Principle:

Principle #40Composite materials

2Strength

If stainless steel is used for rotor portions to improve wear resistance, then wear resistance is improved, but weight increases

Engineering Contradiction:

Improvewear resistanceVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

Different regions of the brake disc have different material properties: the first rotor portion uses aluminum alloy where weight reduction is prioritized, while the second and third rotor portions use stainless steel where wear resistance is critical. This local differentiation optimizes overall performance without unnecessary weight increase throughout the entire disc.

Inventive Principle:

Principle #3Local quality

3Temperature

If ventilation holes are added to improve heat dissipation, then heat dissipation is improved, but structural strength decreases

Engineering Contradiction:

Improveheat dissipationVSAvoidstructural strength

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The ventilation system is segmented into multiple hole patterns: the first rotor portion has first ventilation holes, the central disc has second ventilation holes, and the second/third rotor portions have third ventilation holes. This segmentation distributes the structural load around each hole group, maintaining strength while achieving effective heat dissipation throughout the disc.

Inventive Principle:

Principle #1Segmentation

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 structure achieves improved heat dissipation, reduced weight, and enhanced durability by utilizing ferrous metal materials and metallurgical connections, preventing deformation and maintaining stability during use.

Implementation Method 1

a central disc (30) made of metal material or metal alloy material... Multiple heat dissipation portions of the central disc are defined by the plural third holes of the central disc and the plural first holes of the first disc or are defined by the plural third holes of the central disc and the plural second holes of the second disc

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a first disc (10) and a second disc (20) which are made of ferrous metal materials, and a through orifice passing through central positions of the first disc, the central disc, and the second disc... the first disc is connected with a first surface of the central disc, and the second disc is coupled with a second surface of the central disc

Methodology Applied

Scientific EffectMetallurgical reaction: Welding

Data Source

PatentUS10030726B1Brake disc structure

Publication Date: 2018.07.24 HUANG CHIEH METAL COMPOSITE MATERIAL TECH CO LTD

AI summary

A brake disc structure contains: a central disc made of metal material or metal alloy material, a first disc and a second disc which are made of ferrous metal materials, and a through orifice passing through central positions of the first disc, the central disc, and the second disc. The first disc includes a first brake face and plural first holes, the second disc includes a second brake and plural second holes, and the central disc includes plural third holes, wherein each of the plural first and second holes has a first diameter and a second diameter less than the first diameter, and diameters of any two adjacent first and second holes are different. Furthermore, multiple heat dissipation portions of the central disc are defined by the plural third holes and the plural first holes or are defined by the plural third holes and the plural second holes.