Brake Rotor Coning Control via Segmented Air Channels
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Solution Overview
Problem
Existing brake rotor designs fail to effectively manage coning due to uneven heat distribution, leading to braking roughness and disc thickness variation, as they either cone towards the inboard or outboard direction due to inadequate heat management and structural support.
Innovation Solution
A one-piece brake rotor with alternating sets of mounting members and air directing structures that connect the inboard and outboard friction sections, allowing for adjustable structural rigidity to control coning direction and amount by varying the number, spacing, design, and volume of mounting members, creating a substantially continuous channel for air flow and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a heat sink structure is provided to offset tilting of the inboard friction section, then the inboard friction section tilting is reduced, but the outboard friction section outer diameter increases at a greater rate causing the rotor to cone toward the inboard direction
Solution Approach 1:
The patent applies local quality by providing different structural configurations for the inboard and outboard friction sections. The inboard section has a heat sink structure while the outboard section has a different thermal management approach, allowing each section to have optimized local properties for its specific thermal and structural requirements
Solution Approach 2:
The patent changes physical parameters by modifying the thermal conductivity, mass distribution, and structural rigidity parameters of different rotor sections. The heat sink structure changes the thermal parameter to reduce temperature-induced tilting, while the overall design balances the dimensional parameters to control coning
2Ease of operation
If the inboard and outboard friction surfaces are connected to the hub with individual solid portions, then air inlet ports can be provided for both surfaces, but the connecting portions may be too weak to adequately support the rotor
Solution Approach 1:
The patent segments the connection structure by providing multiple discrete mounting members (typically 3 or more) that connect the friction sections to the hub, rather than using a single solid portion. This segmentation distributes the structural load across multiple points while maintaining air flow channels between the segments
Solution Approach 2:
The mounting members serve multiple functions simultaneously: they provide structural support to hold the friction sections, define air inlet ports for cooling, and maintain the proper spacing and alignment of the rotor components. This multi-functionality resolves the contradiction by making the structural portions sufficient for both support and cooling purposes
3Strength
If mounting members are provided to connect friction sections to the hub, then structural support is improved, but the number and arrangement affect the air flow channels and heat dissipation
Solution Approach 1:
The patent employs asymmetric arrangement of mounting members around the rotor hub, typically positioned at specific angular intervals (e.g., 120 degrees apart for three members). This asymmetric placement optimizes both the structural triangulation for support and the air flow patterns for heat dissipation, as the members are positioned to create effective air channels while maintaining structural integrity
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
Enables neutral coning or predictable coning in either direction, improving braking performance by managing heat-induced distortions and structural support, thus reducing braking roughness and disc thickness variation.
Implementation Method 1
A plurality of air directing structures connect the inboard friction section and the outboard friction section... creating a substantially continuous channel for air flow
Implementation Method 2
One or more brake pads of the caliper assembly frictionally interface with the rotation of the rotor to slow its movement. Through the frictional interfacing of the brake pads with the rotor, the kinetic energy of the moving vehicle is converted to heat.
Implementation Method 3
The heat within the rotor leads to an unequal distribution of thermal stresses which distort the brake rotor. This process is known as coning.
Data Source
AI summary
An apparatus for controlling the coning in a brake rotor in which the brake rotor comprises a central rotor portion, a first set of mounting members connected to the central rotor portion and an inboard friction section and a second set of mounting members connected to the central rotor portion and an outboard friction section where the inboard and outboard friction sections are connected by a plurality of air directing structures. A channel comprising the first set of mounting members, the second set of mounting member and the plurality of air directing structures is provided.