Brake Disk Radial Expansion and Cooling via Projection Channels
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Solution Overview
Problem
Existing brake discs face challenges in efficiently dissipating heat generated during braking, leading to high thermal stresses and potential cracks, while also being costly to produce due to complex manufacturing processes.
Innovation Solution
A brake disc design featuring projections with through-channels on the friction ring and ventilation channels that allow for continuous airflow, ensuring effective heat dissipation and minimizing thermal stresses, with a cast aluminum supporting part that can be produced at lower temperatures, and bushings for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the friction ring is connected to the carrier part in a rotationally fixed manner via radially aligned projections, then the friction ring can expand in the radial direction when heated, but the heat dissipation is insufficient leading to high thermal stresses and potential cracks
Solution Approach 1:
The brake disc is divided into two separate connection partners: a friction ring and a carrier part, connected via projections that allow independent thermal expansion. This segmentation enables the friction ring to expand radially without constraining the carrier part, reducing thermal stresses while maintaining structural integrity.
Solution Approach 2:
The connection geometry is designed to accommodate parameter changes during operation. The projections with through-channels allow the friction ring to change its radial dimension due to thermal expansion while maintaining rotational fixation, adapting to temperature variations without generating excessive stress.
2Temperature
If ventilation channels are formed in the friction ring to improve heat dissipation, then thermal stresses are reduced, but the manufacturing complexity and production costs increase
Solution Approach 1:
The ventilation channels in the friction ring are merged with the through-channels in the projections. This integration creates a unified cooling pathway system that improves heat dissipation without requiring separate, complex manufacturing processes for each feature, thereby reducing overall manufacturing complexity.
Solution Approach 2:
The projections serve multiple functions: they provide rotational fixation between the friction ring and carrier part, allow radial thermal expansion, and form ventilation channels for heat dissipation. This multi-functionality reduces the number of separate components and features needed, simplifying manufacturing while achieving multiple technical goals.
3Stability of the object's composition
If a form-fitting connection is used between the friction ring and carrier part, then rotational fixation is achieved, but the production effort and costs are considerable
Solution Approach 1:
The projections with through-channels are designed to be self-aligning and self-fixing during the casting process. The form-fitting connection between the projections and corresponding recesses automatically ensures rotational fixation without requiring additional alignment operations or complex assembly procedures, reducing production effort while maintaining 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 achieves efficient heat dissipation, reduces the risk of thermal cracks, and simplifies production, resulting in a lightweight, reliable brake disc with improved cooling and reduced production costs.
Implementation Method 1
ventilation channels are formed in the friction ring, via which, in practical operation, ambient air is conducted out of or into the passage channels of the projections
Implementation Method 2
A brake disc design featuring projections with through-channels on the friction ring and ventilation channels that allow for continuous airflow, ensuring effective heat dissipation
Implementation Method 3
The essentially purely form-fitting connection between the support part and the friction ring provided in the brake discs described in the last three documents via the 'projection/recess' connecting elements allows the friction ring to expand when it heats up
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The present invention relates to a brake disk for a disk brake, which is intended particularly for use in motor vehicles, comprising a friction ring (2) as the first connecting part and a carrier part (3) as the second connecting part, wherein the connecting parts (2, 3) are rotatably fixed to each other by radially oriented projections (10), which are integrally formed as one piece on one of the connecting parts (2, 3) and positively engage in correspondingly shaped recesses (19) of the other connecting part (2, 3). The brake disk (1) according to the invention can be produced cost-effectively, guarantees high operating reliability, and at the same time exhibits optimized behavior under the influence of the heat that inevitably develops during a braking operation. This is achieved in that at least one of the projections has a through-channel (12) and that in the friction ring (2) at least one ventilation channel (7) for removing ambient air from, or for feeding ambient air to, the through-channel (12) of the respective projection (10).