Brake Disk Air Routing Between Friction Ring Halves
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Solution Overview
Problem
Existing brake disks face challenges in achieving efficient heat dissipation while maintaining a compact size and reducing weight, as they often have a large design volume and high weight due to the integration of air routing elements with friction rings.
Innovation Solution
The air routing elements are strategically placed between the planes of friction ring halves and situated in an annular receiving region between the brake cup and friction ring, allowing for selective air flow into and out of cooling channels without transverse losses, and can be designed as separate components or integrated during casting to reduce weight and enhance cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air routing elements are placed on the side of friction rings in a plane outside the two friction rings, then cooling capacity is improved, but brake disk thickness increases
Solution Approach 1:
The air routing elements are repositioned from a radial arrangement (outside the friction rings) to an axial arrangement (between the friction ring planes). This dimensional shift allows the cooling function to be achieved within the existing thickness envelope, eliminating the need to increase brake disk thickness while maintaining effective cooling capacity.
Solution Approach 2:
The air routing elements are nested within the space between the two friction ring halves, utilizing the existing internal volume of the brake disk. This nesting approach allows the cooling system to be embedded within the brake disk structure rather than adding to its external dimensions.
2Ease of manufacture
If support section and friction ring are designed as one piece from casting material, then manufacturing is simplified, but brake disk weight increases
Solution Approach 1:
The brake disk is divided into separate components: the support section (brake cup) and the friction ring assembly. This segmentation allows each component to be optimized independently - the support section can be made from lighter materials or with optimized wall thicknesses, while the friction ring can be made from denser, more wear-resistant materials, thereby reducing overall weight without compromising manufacturing feasibility.
3Ease of manufacture
If air routing elements are placed in an open region, then manufacturing is easier, but cooling air loses efficiency due to transverse flow losses
Solution Approach 1:
The potentially harmful transverse flow losses are converted into beneficial directed flow by strategically positioning the air routing elements and designing their geometry to channel air flows. The routing elements act as guides that transform random or loss-prone air movement into efficient, targeted cooling flows that reach the friction rings effectively.
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 configuration results in improved cooling characteristics, reduced thickness, and lower weight, enabling a compact and efficient brake disk design with adaptable cooling capacity through adjustable air routing elements.
Implementation Method 1
the air routing elements convey the cooling air into the cooling channels or evacuate it therefrom in a selective manner
Implementation Method 2
cooling channels disposed between two friction rings... to improve the heat dissipation
Data Source
AI summary
A brake disk is made up essentially of a brake cup and a friction ring. The friction ring includes two friction ring halves, between which cooling channels are situated. Additional air routing elements are situated at the level between the friction ring halves. The brake disk has especially satisfactory cooling characteristics.