Brake Pad Cooling via Conductive Sheet and Heat Sink
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Solution Overview
Problem
Existing disk brake systems face inefficiencies and potential failures due to excessive heat in brake pads, leading to brake fluid boiling, damaged caliper components, and brake pad vaporization, which are not effectively addressed by existing cooling solutions that require modification or replacement of expensive caliper components.
Innovation Solution
A brake pad cooling apparatus utilizing a thermally conductive sheet positioned between the brake pad and hydraulic piston, with a heat sink featuring cooling fin members to dissipate heat away from the pad, allowing for efficient heat transfer without modifying existing brake system components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat is removed from brake pads through contact with the rotor and brake fluid via hydraulic pistons, then the brake system operates with standard components, but brake pad temperatures can reach well over the melting point of aluminum causing brake fluid boiling, damaged caliper seals, warped pistons, and brake fade
Solution Approach 1:
The brake pad cooling system is segmented into distinct functional components: a heat receiving portion in thermal communication with the brake pad, a heat transfer medium (thermally conductive sheet), and a heat dissipating portion (heat sink with fins) positioned away from the brake pad. This segmentation allows heat to be extracted from the brake pad through a controlled thermal pathway without requiring modification of the rotor or caliper structure, thereby resolving the contradiction between maintaining standard brake components and preventing overheating-related failures
Solution Approach 2:
A thermally conductive sheet serves as an intermediary element between the brake pad and the heat sink. This intermediary transfers heat from the brake pad to the heat sink without requiring direct contact between the brake pad and the cooling mechanism, enabling effective heat removal while preserving the integrity of the brake pad and preventing brake fluid boiling and component damage
2Temperature
If specially manufactured custom calipers with ventilation channels are used to cool brake pads, then brake pad cooling is improved, but the cost increases significantly as calipers are the most expensive component of the brake system
Solution Approach 1:
The cooling function is extracted from the expensive caliper component and implemented as a separate, inexpensive attachment system. The heat sink and thermally conductive sheet can be installed independently of the caliper, allowing effective brake pad cooling without requiring costly custom-manufactured calipers with integrated ventilation channels
Solution Approach 2:
The cooling system uses inexpensive materials such as aluminum heat sinks with fins and simple thermally conductive sheets instead of expensive custom-caliper solutions. These components can be manufactured at low cost and replaced if necessary, providing an economically viable alternative to costly custom caliper manufacturing
3Temperature
If a duct is formed inside the caliper body to direct air to hydraulic pistons with radiator elements, then brake pad cooling is achieved, but the complexity of the caliper increases and manufacturing cost increases further due to specially constructed pistons
Solution Approach 1:
The cooling mechanism is extracted from the caliper body, eliminating the need for internal ducts and specially constructed pistons. The heat sink with fins is positioned externally or as a separate component that receives heat through a thermally conductive sheet, simplifying the caliper structure to its standard design while achieving effective brake pad cooling
Solution Approach 2:
Instead of directing air through the caliper to cool the pistons (as in prior art), this invention inverts the approach by placing the heat sink away from the brake pad and using a thermally conductive sheet to transfer heat to the sink. This inversion eliminates the need for complex internal caliper modifications while achieving the cooling objective
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 solution effectively reduces brake pad temperatures, preventing brake fluid boiling and pad vaporization, enhancing brake efficiency and safety while being economically viable by not requiring replacement of expensive caliper components.
Implementation Method 1
The conductive sheet includes a thermally conductive material for conducting heat away from the brake pad
Implementation Method 2
The heat sink includes at least two cooling fin members for dissipating heat into the surrounding air
Implementation Method 3
the kinetic energy of the rotor is converted into heat through the frictional contact between the pad and the rotor
Data Source
AI summary
An exemplary embodiment providing one or more improvements includes a brake cooling apparatus and method in which heat is conducted from a brake pad to a heat dissipating portion through a heat receiving portion and a heat dissipating portion dissipates the heat into a cooling medium.