Multi-Layer Brake Piston Insulator for Lower Brake Fluid Heat
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Solution Overview
Problem
Aircraft braking systems face challenges in effectively managing heat transfer from friction disks to brake fluid, leading to elevated brake fluid temperatures and potential system inefficiencies.
Innovation Solution
A multi-layer insulator is introduced for piston assemblies, comprising insulator layers and a cover plate with axially extending surface features, which reduces thermal conductance by minimizing contact areas and increasing thermal resistance between the friction disks and brake fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a single-layer insulator is used in the piston assembly, then the structure is simple, but the thermal resistance is insufficient and brake fluid temperature is elevated
Solution Approach 1:
The insulator is divided into multiple layers (first insulator layer, second insulator layer, third insulator layer) with different materials and thermal conductivity values. Each layer provides a specific thermal resistance contribution, and the combined multi-layer structure achieves superior overall thermal resistance compared to a single-layer design, directly reducing brake fluid temperature while managing structural complexity through modular construction
Solution Approach 2:
The patent employs composite material construction with at least two different insulator materials having different thermal conductivity values. The first insulator layer uses a material with lower thermal conductivity for higher thermal resistance, while subsequent layers use materials with progressively higher thermal conductivity to manage heat distribution. This composite approach optimizes thermal resistance while controlling the temperature gradient across the piston assembly
2Temperature
If insulator layers are placed in contact over large areas, then the structural integrity is improved, but the thermal conductance increases and thermal resistance decreases
Solution Approach 1:
The patent implements partial contact between insulator layers through annular contact surfaces that extend only radially outward from the central axis to a predetermined radius less than the outer radius of the piston. This partial contact provides sufficient structural support and alignment while maintaining large portions of the insulator surfaces in non-contact, thereby preserving thermal resistance. The contact area is optimized to be just enough for structural integrity without compromising thermal performance
Solution Approach 2:
The patent introduces a adhesive layer or interference fit mechanism as an intermediary between insulator layers to provide structural bonding without requiring large contact areas. This intermediary allows the insulator layers to be structurally integrated while maintaining thermal isolation, as the adhesive or interference fit provides sufficient mechanical strength without creating extensive thermal conduction paths
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 multi-layer insulator effectively reduces thermal energy transfer from friction disks to brake fluid, lowering brake fluid temperatures and enhancing the overall efficiency of the braking system.
Implementation Method 1
A multi-layer insulator is introduced for piston assemblies, comprising insulator layers and a cover plate with axially extending surface features, which reduces thermal conductance by minimizing contact areas and increasing thermal resistance between the friction disks and brake fluid
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A piston assembly for a multi-disk system may comprise an adjustor sleeve (102) and a piston (100) configured to telescope relative to the adjustor sleeve. A puck (116) may be located at an end of the piston. The piston assembly may include a multi-layer insulator (120). The multi-layer insulator may comprise a first insulator layer (122) contacting the puck or the piston, and a second insulator layer contacting the first insulator layer. The first and second insulator layers may each comprise a solid disk.