Multi-Layer Brake Disc Cooling With Sodium-Filled Chambers
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Solution Overview
Problem
Existing brake discs for vehicles, such as bicycles, motorcycles, and cars, face damage due to heat generated from friction during braking, which affects their functionality.
Innovation Solution
A brake disc design featuring a first and second outer disc with an inner disc, forming chambers for coolant placement, where sodium is used as a heat exchanger, effectively dissipating heat through gravity-driven redistribution within the disc.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional solid brake disc is used, then the structure is simple and easy to manufacture, but the brake disc overheats and gets damaged during braking
Solution Approach 1:
The brake disc is segmented into multiple chambers (6-12 chambers preferred) formed by recesses in the inner disc, allowing coolant to be distributed throughout the disc structure. This segmentation enables efficient heat dissipation while maintaining the overall disc integrity and braking performance.
Solution Approach 2:
A coolant (preferably sodium) is introduced as an intermediary substance within the chambers to facilitate heat transfer from the brake disc to the surrounding environment. The coolant absorbs heat generated during braking and redistributes it through gravity-driven movement, preventing overheating and damage to the brake disc.
2Temperature
If chambers are added to the brake disc for coolant placement, then cooling efficiency is improved, but the manufacturing complexity increases
Solution Approach 1:
The brake disc is segmented into multiple chambers (6-12 chambers preferred) formed by recesses in the inner disc, allowing coolant to be distributed throughout the disc structure. This segmentation enables efficient heat dissipation while maintaining the overall disc integrity and braking performance.
Solution Approach 2:
The inner disc serves multiple functions: it provides structural support, forms the chambers through its recesses, and contributes to the overall heat dissipation system. This multi-functionality reduces the need for additional separate components, thereby managing complexity while achieving effective cooling.
3Reliability
If openings are made to pass through all disc layers, then aquaplaning is prevented, but the structural integrity is reduced
Solution Approach 1:
The brake disc is segmented into multiple chambers (6-12 chambers preferred) formed by recesses in the inner disc, allowing coolant to be distributed throughout the disc structure. This segmentation enables efficient heat dissipation while maintaining the overall disc integrity and braking performance.
Solution Approach 2:
The openings are strategically positioned and sized to provide just enough venting to prevent aquaplaning while minimizing impact on structural strength. The local modifications are concentrated in specific areas where they are most effective, preserving the overall structural integrity of the brake disc.
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 provides enhanced cooling and prevents aquaplaning, ensuring effective heat management and prolonged brake disc functionality, particularly suitable for lighter vehicles like bicycles and electric bicycles.
Implementation Method 1
a coolant, in particular sodium, is arranged in the chambers, which changes its state of aggregation at about 97° C. and is therefore suitable as a good heat exchanger
Implementation Method 2
when the brake disc rotates, the coolant can move in the chamber due to gravity if it is only partially filled... the coolant is redistributed, can absorb heat in the radially outer area, in which the brake elements usually act and which therefore has a higher temperature
Implementation Method 3
the brake disc has a plurality of openings which pass through the two outer disks and the inner disk... prevent aquaplaning between the outer disc and a brake element
Data Source
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AI summary
Brake disc (10) for a disc brake, preferably of bicycles, wherein the brake disc (10) has a first and a second outer disc (22) and an inner disc (24) which is arranged between the two outer discs (22), wherein the brake disc (10) has a plurality of chambers (30) which are formed by way of recesses (26) which are arranged in the inner disc (24), and wherein the brake disc (10) has a plurality of apertures (36) which penetrate the two outer discs (22) and the inner disc (24), wherein the chambers (30) are arranged in a manner which is separated spatially from the apertures (36).