Composite Brake Disc Assembly for Strength and Heat Dissipation
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Solution Overview
Problem
Aircraft brake disc systems face challenges in balancing mechanical strength, corrosion resistance, and thermal properties, as materials with high thermal stability often lack efficient heat transfer and strength, while strong materials may not provide adequate friction or thermal dissipation.
Innovation Solution
The design incorporates a structural core with pockets and friction pads featuring raised bosses that interface with the core, allowing for efficient torque transfer and heat dissipation, with the structural core providing mechanical strength and the friction pads offering high friction properties, and materials tailored for specific properties to address these challenges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If materials with high thermal stability are used for the brake disc, then thermal stability is improved, but heat transfer efficiency and mechanical strength deteriorate
Solution Approach 1:
The brake disc assembly uses a composite structure combining a structural core made from materials optimized for mechanical strength and thermal conductivity (such as metal or carbon-composite materials) with friction pads made from materials optimized for friction properties and thermal stability. This composite approach allows each component to contribute its superior properties to the overall system, resolving the contradiction between thermal stability and mechanical strength.
2Strength
If strong materials are used for the brake disc, then mechanical strength is improved, but friction properties and thermal dissipation deteriorate
Solution Approach 1:
The brake disc is segmented into distinct functional components: a structural core responsible for mechanical strength and thermal dissipation, and separate friction pads responsible for friction properties and heat generation. The structural core is designed with thermal conductivity optimization and heat dissipation features (such as ventilation channels or heat sinks), while the friction pads are optimized for friction characteristics. This segmentation allows each component to excel at its specific function without compromising the others.
3Device complexity
If a single material is used for the brake disc, then device complexity is reduced, but the ability to simultaneously provide strength, friction, and thermal management deteriorates
Solution Approach 1:
The structural core is designed to perform multiple functions simultaneously: providing mechanical strength to support braking loads, facilitating thermal dissipation through its material properties and geometric features (such as ventilation channels or heat sinks), and serving as a mounting structure for the friction pads. This multi-functional design of the structural core, combined with the specialized friction pads, achieves comprehensive performance without excessive complexity.
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
This configuration enhances the strength and thermal management of brake discs, enabling effective heat dissipation and reduced stress on friction pads, improving braking performance and longevity.
Implementation Method 1
the structural core may be configured to provide strength to the brake disc assembly and remove heat from the friction pads
Data Source
AI summary
An article includes a structural core, one or more friction pads, and a plurality of elongated fasteners. The structural core includes two core surfaces and a plurality of pockets extending between the core surfaces. Each friction pad includes a pad surface and a friction surface opposite the pad surface. Each pad surface includes a planar pad surface configured to contact the core surface and a plurality of bosses extending from the first planar pad surface and including a bore. Each planar pad surface is at least about 50% of a surface area of the respective first and second pad surfaces. The plurality of bosses engages with the plurality of pockets to position the respective first and second friction pads relative to the structural core. The plurality of elongated fasteners passes through bores of corresponding bosses of friction pads to fasten the friction pads to the structural core.