Brake Disk Double Cooling Structure Thermal Deformation
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Solution Overview
Problem
Conventional brake disks experience thermal deformation and increased cost and weight due to excessive frictional heat during braking, leading to reduced NVH performance and handling issues, as larger disks are required to manage heat but result in increased unsprung mass and costs.
Innovation Solution
A brake disk with a double cooling structure featuring integrally formed vanes and cooling channels between disk plates, with air passages that allow fluid communication, reducing the need for external cooling ducts and enabling effective self-cooling without increasing the disk size, while allowing for prime number vane configurations to minimize resonance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the size of the brake disk is increased to obtain suitable heat capacity, then thermal deformation is reduced, but cost and weight of the vehicle increase
Solution Approach 1:
The brake disk is segmented into multiple functional zones including cooling channels formed between vanes and an air passage formed between disk plates. This segmentation allows different regions to perform specific cooling functions, enabling effective heat dissipation without increasing overall disk size, thereby resolving the contradiction between thermal deformation control and weight reduction.
Solution Approach 2:
The invention introduces a dual-dimensional cooling approach: cooling channels extending in the radial direction between vanes, and an air passage extending in the circumferential direction between disk plates. This two-dimensional cooling network enhances heat dissipation efficiency without increasing the disk's radial or axial dimensions, thus controlling weight while managing thermal deformation.
2Temperature
If the size of the brake disk is increased to obtain suitable heat capacity, then thermal deformation is reduced, but cost of the vehicle increases
Solution Approach 1:
The cooling channels and air passage are merged into a unified cooling system where both structures work together to dissipate heat. The cooling channels formed between vanes connect with the air passage between disk plates, creating an integrated cooling network that achieves effective thermal management without requiring a larger disk, thereby controlling manufacturing cost.
Solution Approach 2:
The brake disk structure itself provides cooling functionality through integrally formed vanes with cooling channels and an air passage between disk plates. This self-cooling design eliminates the need for separate external cooling systems or larger disk sizes, achieving cost-effective thermal management through the disk's own structural features.
3Temperature
If cooling ducts are introduced to reduce thermal deformation, then cooling performance is improved, but cost and weight of the vehicle increase
Solution Approach 1:
The invention extracts the cooling function from separate external cooling ducts and integrates it directly into the brake disk structure itself. By forming cooling channels between vanes and an air passage between disk plates as integral features of the disk, the design eliminates the need for additional external cooling components, thereby reducing device complexity, cost, and weight while maintaining effective cooling performance.
Solution Approach 2:
The brake disk structure serves multiple functions: it provides braking surface area, structural support, and integrated cooling through its vanes and air passage. This multi-functionality allows the disk to perform cooling duties without requiring separate dedicated cooling components, reducing overall system complexity and cost while achieving effective thermal management.
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 double cooling structure effectively suppresses thermal deformation, enhances cooling performance, reduces vehicle weight and cost, and improves NVH by allowing air to flow efficiently through the disk, thereby maintaining performance without increasing the disk size or adding cooling ducts.
Implementation Method 1
cooling channels and the air passage formed between the disk plates to allow air to flow therethrough
Implementation Method 2
a brake disk having a double self-cooling structure to inhibit thermal deformation
Data Source
AI summary
A disk brake having a double self-cooling structure to suppress thermal deformation may include a brake disk having a double cooling structure, which is capable of securing cooling performance of the disk while reducing cost and weight of a vehicle compared with the prior art by configuring a self-cooling structure of the disk that can suppress thermal deformation due to excessive frictional heat during braking a vehicle.