Brake Pad Thermoelectric Module Integration via Backplate Extraction
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Solution Overview
Problem
Existing thermoelectric energy harvesting systems for brake pads face challenges in maximizing thermal gradient, reliability, and manufacturability, with potential disruptions to Noise, Vibration, and Harshness (NVH) behavior and friction material detachment due to integration issues and pressure sensitivity.
Innovation Solution
A braking pad design with integrated thermoelectric modules within spigot holes in the backplate, utilizing high thermal conductivity materials for heat exchangers and a structured integration that minimizes mechanical modifications, ensuring efficient thermal gradient and enhanced reliability under pressure loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thermoelectric modules are integrated on the backplate surface on the friction material side, then energy recovery efficiency is improved, but NVH behavior and friction material detachment are disrupted
Solution Approach 1:
The invention extracts the thermoelectric modules from the friction material side and relocates them to the opposite side of the backplate, away from the friction material. This extraction eliminates the interference with friction material detachment and NVH behavior while preserving the thermal energy recovery function through alternative thermal coupling mechanisms.
Solution Approach 2:
The invention transitions the thermoelectric module placement from a two-dimensional surface integration on the friction material side to a three-dimensional configuration on the opposite side of the backplate, utilizing the depth dimension of the backplate structure. This dimensional change allows thermal coupling without direct contact interference with the friction material.
2Loss of energy
If thermoelectric modules are integrated into the backplate structure, then energy recovery efficiency is improved, but manufacturing complexity and structural modifications increase
Solution Approach 1:
The invention makes the backplate structure multi-functional by integrating it with the thermoelectric energy harvesting system. The backplate serves both its original structural support function and as a thermal coupling medium for the thermoelectric modules, eliminating the need for separate integration structures and reducing overall device complexity.
Solution Approach 2:
The invention merges the thermoelectric module assembly with the backplate structure by positioning the modules on the opposite side of the backplate and coupling them thermally through the backplate material. This merging eliminates the need for separate mounting structures and simplifies the overall brake pad design.
3Reliability
If thermoelectric modules are placed on the opposite side of the friction material, then NVH behavior and friction material detachment are maintained, but thermal gradient efficiency is reduced
Solution Approach 1:
The invention introduces the backplate as a thermal intermediary medium between the friction material and the thermoelectric modules. The backplate conducts thermal energy from the friction material to the thermoelectric modules on its opposite side, enabling thermal coupling without direct physical contact between the modules and friction material, thus maintaining both reliability and thermal efficiency.
Solution Approach 2:
The invention replaces direct mechanical contact for thermal coupling with thermal conduction through the backplate material. Instead of placing modules in direct contact with the friction material (mechanical system), the solution uses the backplate as a thermal conduction path, substituting mechanical coupling with thermal field coupling.
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 maximizes energy recovery by optimizing thermal gradient and maintaining brake pad performance and reliability, with improved NVH behavior and resistance to shear forces, demonstrating enhanced efficiency and durability in thermoelectric energy harvesting.
Implementation Method 1
The thermoelectric effect is the direct conversion of temperature difference between two sides of the thermoelectric material into electric voltage and vice versa it can create a temperature difference by applying an electric voltage to it.
Implementation Method 2
utilizing high thermal conductivity materials for heat exchangers
Data Source
Figure 1~3b
Figure 4a~5
Figure 6~8
AI summary
A braking pad (1) comprising a back plate (2), a pad of friction material (4), and at least a thermoelectric module (6), the back plate (2) being provided with at least a through hole (3) wherein at least the N and P doped semiconductor elements of the thermoelectric module (6) are integrated.