Brake Rotor Insignia Etching Through Wear-Resistant Coatings
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Solution Overview
Problem
Brake disks experience uneven wear and corrosion, leading to warpage and brake fade, and existing insignia applications on brake rotors are prone to rapid wear, affecting both the performance and aesthetics of braking systems.
Innovation Solution
The development of brake disks with raised island formations and air flow channels for improved cooling, combined with a wear and corrosion-resistant coating, and an etching method for applying insignia that penetrates through the coating layers to ensure durability and visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If traditional insignia application methods are used on brake rotors, then the insignia can be applied to the surface, but the insignia wears off rapidly due to friction and heat
Solution Approach 1:
The patent applies preliminary action by etching the insignia into the brake rotor substrate before applying the coating layer. This ensures the insignia is established in advance and will not wear off with the coating, maintaining durability and retention under friction and heat conditions.
Solution Approach 2:
The patent transitions from surface-level insignia application to multi-dimensional embedding by etching the insignia into the substrate and covering it with a coating layer. This dimensional change from 2D surface application to 3D embedded structure ensures the insignia persists through coating wear.
2Shape
If the brake disk surface is made smooth for aesthetics, then the appearance is improved, but heat dissipation and wear resistance are reduced
Solution Approach 1:
The patent applies local quality by creating raised island formations with specific surface characteristics in certain areas while maintaining different surface properties in other areas. The air flow channels between islands provide localized heat dissipation zones, while the raised islands maintain structural integrity and aesthetic appearance.
3Reliability
If the brake disk material is made harder to resist wear, then wear resistance is improved, but the disk becomes more prone to warpage under heat stress
Solution Approach 1:
The patent employs composite materials by combining the brake rotor substrate with a coating layer having different physical properties. The substrate provides wear resistance while the coating layer with raised island formations and air flow channels manages heat distribution, preventing thermal warpage while maintaining wear resistance.
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 extends the service life of brake disks, reduces maintenance costs, enhances safety by preventing brake fade, and maintains the appearance of the insignia over time, while providing a visually appealing and efficient braking system.
Implementation Method 1
applying a first material to an area comprising at least the portion of the parallel surfaces through vapor deposition, wherein the first material is deposited onto the area by energizing a first material source to cause charged particles of the first material source to be dissociated from the first material source and deposited on the area
Implementation Method 2
applying a second compound to the area through vapor deposition, the applying comprising energizing a second material source to cause charged particles of the second material source to be dissociated from the second material source, and reacting a reactive gas with the charged particles of the second material to form the second compound applied to the area
Data Source
AI summary
An etched logo is provided at a location within the layers. This etched section is viewable to the user on the working surface as a form of insignia (logo, trademark, letters, words, serial numbers, designs, patters, artwork, and the like) and does not wear off in normal use because of the coating layers and. Alternatively, the etching (or other slight indentation) may penetrate the 26 while still being viewable in the finished product to display the insignia. Even further, the etching may extend through the coating layers and the substrate. In this particular embodiment, the substrate includes a surface texture (also a form of insignia) viewable to a person in the finished product.