Composite Wheel Heat Shield Structure for Brake Heat Protection
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Solution Overview
Problem
Carbon fiber reinforced plastic wheels are prone to thermal damage due to high thermal conductivity and limited heat resistance, which can lead to damage from brake system heat transfer, especially when active cooling is absent after high-speed braking.
Innovation Solution
A heat shield structure integrated into the wheel, comprising a heat reflecting layer, a low thermal conductive layer, and a high thermal conductive layer, which reduces thermal energy flux and distributes heat to prevent hot spots, without requiring additional space between the wheel and brake system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber reinforced plastics are used for wheels to reduce mass and moment of inertia, then weight is reduced, but thermal resistance deteriorates due to high thermal conductivity and limited heat resistance
Solution Approach 1:
The wheel is constructed as a composite structure combining fiber reinforced plastic (for low weight) with an integrated heat shield structure made of thermally insulating material (for thermal protection). This composite approach allows the wheel to maintain lightweight properties while gaining thermal resistance through the insulating layer that prevents heat transfer from the brake system to the wheel rim.
2Reliability
If a heat shield structure is added to protect the wheel from thermal damage, then thermal resistance is improved, but device complexity increases
Solution Approach 1:
The heat shield structure is merged with the wheel rim structure, forming an integrated composite component rather than a separate attachment. The insulating material is applied directly to the inner surface of the wheel rim, creating a unified structure that provides both structural support and thermal protection, thereby reducing overall device complexity.
Solution Approach 2:
The heat shield structure serves multiple functions: it provides thermal insulation to protect the wheel rim from brake heat, acts as a thermal barrier to prevent heat transfer to the brake system, and maintains the structural integrity of the wheel. This multi-functionality reduces the need for additional separate components.
3Weight of moving object
If the wheel rim is made from fiber reinforced plastic to reduce weight, then weight is reduced, but susceptibility to thermal damage increases due to high thermal conductivity
Solution Approach 1:
A thermally insulating material is introduced as an intermediary layer between the brake system and the fiber reinforced plastic wheel rim. This intermediate heat shield blocks the thermal energy transfer path, preventing the high thermal conductivity of the fiber reinforced plastic from causing thermal damage to the wheel structure.
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 heat shield structure effectively controls and dissipates thermal energy, preventing thermal damage to the wheel by reducing heat transfer and dispersing energy over a larger area, making it suitable for a wide range of vehicles without modifying suspensions or brake systems.
Implementation Method 1
comprising a heat reflecting layer (9)
Implementation Method 2
a low thermal conductive layer (10)
Implementation Method 3
a high thermal conductive layer (12) which reduces thermal energy flux and distributes heat
Data Source
Figure 1~3
Figure 4~5
Figure 6~10
AI summary
The invention is directed to a heat shield structure (8) for a wheel (1) which comprises a base structure (11) that is at least partially made from a composite material. The heat shield structure (8) is arranged on the base structure (11) and is at least partially covering the base structure (11).