Disc Brake Rotor Pillar Layout for Faster Heat Dissipation
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Solution Overview
Problem
Disc brake rotors experience excessive heat buildup during prolonged or hard braking, leading to reduced braking efficiency and potential failure, despite the use of ventilated designs that allow air flow between inboard and outboard discs.
Innovation Solution
A disc brake rotor design featuring an array of individually shaped pillars arranged in repeating families within 22.5-degree sectors, with specific geometric configurations to maximize air flow and heat transfer, including larger and smaller diamond-shaped pillars with inclined axes and strategically placed gaps to optimize cooling air flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ventilated brake disc rotors are used to allow air flow between inboard and outboard discs, then heat dissipation is improved, but excessive heat build-up still occurs during hard or prolonged braking
Solution Approach 1:
The patent applies local quality by varying the pillar shapes within different radial zones of the rotor. Inner pillars have different geometries compared to outer pillars, with each zone optimized for its specific thermal and structural requirements. This localized optimization allows better heat dissipation in high-heat areas while maintaining structural integrity where needed.
Solution Approach 2:
The patent employs asymmetry by using non-uniform pillar shapes and arrangements. The pillars are not identical but rather have varying cross-sectional areas, lengths, and orientations positioned at specific angular locations. This asymmetric design creates optimized airflow patterns that enhance cooling efficiency during hard and prolonged braking operations.
2Ease of manufacture
If pillars are arranged in uniform patterns to simplify manufacturing, then ease of manufacture is improved, but heat dissipation efficiency deteriorates
Solution Approach 1:
The patent implements local quality by specifying different pillar configurations for different radial positions. Inner pillars and outer pillars have distinct geometric characteristics optimized for their respective locations, allowing enhanced heat dissipation while maintaining manufacturability through standardized families of pillar shapes that can be replicated using modern casting or additive manufacturing techniques.
Solution Approach 2:
The patent applies parameter changes by varying pillar geometric parameters (cross-sectional area, length, orientation angles) based on radial position. These controlled parameter variations optimize thermal performance without requiring completely different manufacturing processes, as the variations can be incorporated into standard design and manufacturing workflows.
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 design enhances heat dissipation rates from the rotor surfaces, maintaining braking efficiency and prolonging rotor life by streamlining air flow and minimizing flow deflection, thus addressing the issue of excessive heat buildup.
Implementation Method 1
air drawn into the spaces between the inner and outer discs flows between spacing pillars from an inner periphery towards and out of the rotor's periphery
Implementation Method 2
the rotor must be able to dissipated heat as fast as possible, both to maintain braking efficiency and to prolong the life of the rotor
Data Source
AI summary
Disclosed is a disc brake rotor; the rotor including a central hub coaxial with and supporting annular rings which form an inboard brake band and an outboard brake band for engagement with brake pads of a disc brake; the inboard brake band and the outboard brake band maintained in a parallel spaced apart configuration by an array of pillars; the array of pillars arranged in repeating families of individually shaped pillars. Also disclosed is a method of optimising shape of pillars in groups of pillars of a disc brake rotor; the disc brake rotor comprising inner and outer annular brake bands maintained in spaced apart parallel configuration by the groups of pillars; the method including the steps of:—arranging the pillars into repeating families of pillars; each family lying in a 22.5 degree sector of the rotor;—further arranging each family into two groups of pillars; an outer group of pillars and an inner group of pillars;—forming each outer group of pillars and inner group of pillars to comprise of two larger pillars and two smaller pillars, and wherein each larger pillar and each smaller pillar in a family of pillars has a distinctive shape.