Ceramic Insulation Body for Disk Brake Piston Thermal Management
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Solution Overview
Problem
Existing brake systems for partially lined disk brakes face challenges in preventing thermal loading and damage to components due to heat generation during braking, which can impair braking performance and lead to unfavorable vibrations.
Innovation Solution
A ceramic insulation body, preferably made of zirconium oxide, is used to enclose or embed a metallic brake lining with convexly rounded side faces, effectively preventing heat transfer to the piston and pressure medium by creating a thermal barrier, thereby reducing component loading and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal insulation material is used to prevent heat transfer to the piston, then thermal loading of the actuating apparatus is reduced, but the structural complexity increases
Solution Approach 1:
The insulation body is integrated into the piston structure with the brake lining embedded within it, creating a nested configuration where the brake lining is received in an enclosing manner in the annular insulation body, which is inserted into the piston. This nesting approach combines multiple functions (insulation, structural support, brake lining mounting) into a single integrated component, reducing overall structural complexity while maintaining effective thermal insulation.
Solution Approach 2:
The solution employs composite construction by combining ceramic insulation material with metallic brake lining in a single integrated component. The insulation body made from ceramic material provides thermal insulation while the embedded metallic brake lining provides structural strength and braking function, creating a composite structure that achieves both thermal protection and mechanical performance without requiring separate components.
2Temperature
If ceramic insulation body is used to prevent heat transfer, then thermal insulation effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The brake assembly is segmented into distinct functional zones: the ceramic insulation body for thermal protection, the metallic brake lining for structural and braking functions, and the piston for actuation. This segmentation allows each component to be manufactured separately using optimal processes for that material and function, then assembled together, simplifying the overall manufacturing process compared to creating a monolithic complex component.
Solution Approach 2:
The brake lining is embedded into the ceramic insulation body in a nested configuration, where the metallic lining is received within the annular insulation structure. This nesting approach simplifies assembly by allowing components to be pressed or fitted together in sequence, reducing the need for complex fastening mechanisms or multi-step assembly procedures.
3Temperature
If brake lining is embedded in insulation body, then thermal transfer to piston is avoided, but device complexity increases
Solution Approach 1:
The brake lining and insulation body are merged into a single integrated component where the metallic brake lining is embedded within the ceramic insulation body. This merging combines the thermal insulation function with the braking and structural functions in one unified component, eliminating the need for separate insulation and brake lining assemblies, thereby reducing device complexity while maintaining effective thermal isolation.
Solution Approach 2:
The integrated component uses composite materials combining ceramic insulation with metallic brake lining, where each material contributes its superior properties (thermal insulation from ceramic, structural strength and friction properties from metal) to create a single component that performs multiple functions without requiring complex multi-component assemblies.
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 provides effective thermal insulation, maintaining high loading capacity while minimizing heat transfer and component damage, thus ensuring consistent braking performance.
Implementation Method 1
a ceramic insulation body, preferably made of zirconium oxide, is used to enclose or embed a metallic brake lining with convexly rounded side faces, effectively preventing heat transfer to the piston and pressure medium by creating a thermal barrier
Data Source
AI summary
An apparatus for thermal insulation on an actuating apparatus, which can be loaded with a pressure medium, of a disk brake having a piston which slides in a cylinder for the axial displacement of the brake linings against a brake disk, in particular a partially lined disk brake having an insulation body made from non-thermally conducting/poorly thermally conducting material for the insulation of the components of the actuating apparatus with respect to a brake lining. It is possible for a substantially circularly annular, metallic brake lining to be inserted into an insulation body which is made from ceramic material and separates the piston from the brake lining in a thermally insulating manner. The insulation body is configured with side faces which adjoin the circularly annular brake contact face so as to run toward the annular circumferential face in a convexly rounded manner in the direction of the piston.