Brake Piston Assembly With Failsafe Pressure Path Under Heat

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Brake assembly components, particularly the piston assembly, fail due to excessive heat during hot brake rejected takeoff, leading to loss of structural integrity and brake failure.

Innovation Solution

A piston assembly with a secondary load path is introduced, comprising a spring guide, insulator, and insulator shield, which maintains brake pressure by transferring force to a heat sink even when the primary path fails under high temperatures, using high-temperature capable materials and thermal barriers to minimize heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the brake assembly uses a conventional single load path design, then the structure is simple and cost-effective, but the piston assembly fails under excessive heat during hot brake rejected takeoff

Engineering Contradiction:

Improvebrake assembly reliabilityVSAvoidpiston assembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The brake assembly load path is segmented into multiple independent pathways: a primary load path through the piston and insulator shield, and a secondary load path through the spring guide and component. This segmentation ensures that if one path fails due to heat, the other can maintain braking function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spring guide and component are positioned and configured beforehand to provide a secondary load path that activates when the primary path fails. This preparatory arrangement ensures immediate backup support without requiring real-time detection or activation mechanisms.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Strength

If the piston assembly uses high-temperature capable materials throughout, then structural integrity is maintained under heat, but the cost and weight increase

Engineering Contradiction:

Improvestructural integrityVSAvoidpiston assembly weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

High-temperature capable materials are applied selectively only to components exposed to extreme heat (insulator shield, spring guide, and component), while other piston components can use lighter, lower-cost materials. This localized application maintains structural integrity where needed without unnecessary weight increase.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The brake assembly employs a composite structure combining different materials with appropriate heat resistance properties in different zones, allowing the system to withstand high temperatures while minimizing overall weight by not over-engineering all components with high-temperature materials.

Inventive Principle:

Principle #40Composite materials

3Strength

If the piston assembly uses high-temperature capable materials throughout, then structural integrity is maintained under heat, but the manufacturing cost increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

4Reliability

If the component is positioned close to the insulator shield, then the secondary load path activates quickly, but heat transfer to the component increases

Engineering Contradiction:

Improvefailover response timeVSAvoidcomponent temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The spring guide acts as an intermediary element between the insulator shield and the component, providing a thermal barrier that reduces heat transfer to the component while still allowing mechanical force transmission. This intermediary structure enables the component to remain thermally protected while maintaining mechanical connectivity for rapid failover.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 secondary load path ensures consistent brake pressure during hot brake rejected takeoff, preventing failure and allowing the use of cheaper, lighter materials while maintaining structural integrity.

Implementation Method 1

an insulator having a first portion extending from the second end of the piston and a second portion disposed within the piston, an insulator shield disposed adjacent the first portion of the insulator

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS12416342B2Failsafe piston pressure path

Publication Date: 2025.09.16 GOODRICH CORP

AI summary

A piston assembly is disclosed herein. The piston assembly includes a piston having a first end, an opposing second end, and a sidewall extending from the first end to the second end, the piston further including a cavity at least partially defined by the sidewall, a spring guide having a first end and an opposing second end, the spring guide disposed within the cavity of the piston and adjacent the sidewall, an insulator having a first portion extending from the second end of the piston and a second portion disposed within the piston, an insulator shield disposed adjacent the first portion of the insulator, and a component coupled to the second end of the spring guide, the component being offset from the insulator shield by a distance.