Brake Disc Material Layout to Reduce Thermal Coning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Disc brakes in vehicles experience significant thermal expansion during braking, leading to deformation and reduced braking performance due to shielding or coning, which existing designs struggle to effectively mitigate.
Innovation Solution
A brake disc design featuring a piston-side friction disc with a lower coefficient of thermal expansion than the pot-side friction disc, combined with efficient heat dissipation through materials like aluminum and optimized thermal conductivity, minimizes thermal expansion and deformation by counteracting the usual shielding or coning direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the friction disc is made of material with high thermal expansion coefficient, then the braking power is maintained under normal conditions, but thermal expansion causes deformation and shielding during braking
Solution Approach 1:
The friction disc is divided into two separate friction discs (pot-side and piston-side) that can expand independently, allowing each to be optimized for different functions while reducing overall deformation
Solution Approach 2:
Different materials with different thermal expansion coefficients are used for the pot-side friction disc and piston-side friction disc, allowing local optimization where the piston-side disc uses low expansion material to counteract shielding while the pot-side disc maintains normal braking characteristics
2Shape
If the friction disc is designed to allow axial movement during thermal expansion, then shielding is reduced, but braking precision and stability deteriorate
Solution Approach 1:
The two friction discs are designed asymmetrically with different material properties and expansion characteristics, where the piston-side disc's constrained expansion creates a counteracting force that maintains braking precision while reducing shielding
Solution Approach 2:
The invention utilizes differential thermal expansion between two friction discs made of different materials, where the piston-side disc's lower expansion coefficient creates a counteracting force against shielding deformation
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 significantly reduces thermal expansion of the piston-side friction disc, leading to reduced deformation and enhanced braking performance by efficiently dissipating heat and counteracting the deformation of the brake disc pot, thereby minimizing shielding or coning.
Implementation Method 1
thermal expansion can cause the friction disc and the whole brake disc to assume the shape of a section of a cone, because thermal expansion of the friction disc and its attachment to a brake disc pot can cause deformation of the pot
Implementation Method 2
efficient heat dissipation through materials like aluminum and optimized thermal conductivity
Data Source
AI summary
The task of reducing the shielding or coning of a brake disc as a result of a temperature rise is solved by selecting a suitable material for the friction discs. The invention relates to a brake disc for a disc brake of a vehicle with a brake disc pot which has a pot base, a pot wall and an axis and with a friction disc unit, which is firmly connected to the wall and has two friction discs arranged parallel to one another in the form of a pot-side friction disc and a piston-side friction disc with friction surfaces which are arranged perpendicular to the axis (3), with the pot-side friction disc being closer to the bottom or base of the pot than the piston-side friction disc. In such a brake disc, it is provided that the piston-side friction disc consists at least partially of a material whose specific thermal expansion coefficient is lower than the thermal expansion coefficient of the pot-side friction disc.