Diamond Composite Brake Disc Heat Dissipation
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Solution Overview
Problem
Current brake systems face issues with heat dissipation, mechanical resistance, weight, and environmental impact due to material limitations, leading to increased wear, frequent maintenance, and high particulate matter emissions.
Innovation Solution
A brake system utilizing a composite material comprising diamond particles and a binder, which enhances thermal conductivity, mechanical resistance, and reduces weight, allowing for efficient heat dissipation and extended lifespan while minimizing particulate matter production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cast iron or steel discs are used, then manufacturing cost is reduced, but wear increases and lifespan decreases
Solution Approach 1:
The patent applies composite materials by combining a metal matrix (aluminum, copper, or iron) with diamond particles to create a brake disc that exhibits wear resistance comparable to ceramic discs while maintaining lower manufacturing costs. The diamond particles embedded in the metal matrix provide exceptional hardness and wear resistance, resolving the contradiction between cost-effective manufacturing and durability.
2Temperature
If ventilated disc structure is used, then heat dissipation capacity is improved, but device complexity and weight increase
Solution Approach 1:
The patent changes the thermal parameters of the brake disc material by incorporating diamond particles, which have extremely high thermal conductivity. This material parameter change enables effective heat dissipation without requiring complex ventilated structures, thus resolving the contradiction between heat dissipation capacity and construction simplicity.
3Reliability
If disc size is increased to ensure sufficient thickness, then wear resistance is improved, but weight increases and energy efficiency decreases
Solution Approach 1:
The patent uses composite materials with diamond particles in a metal matrix to achieve high wear resistance in a thinner disc configuration. The exceptional hardness and wear resistance of diamond allow the disc to maintain sufficient thickness for durability while being lighter than traditional cast iron or steel discs, resolving the contradiction between wear resistance and weight.
4Weight of moving object
If Al/SiC composite material is used, then weight is reduced, but heat resistance decreases due to low melting temperature
Solution Approach 1:
The patent improves upon Al/SiC composites by replacing SiC particles with diamond particles in the aluminum matrix. Diamond has significantly higher heat resistance and melting temperature than SiC, while maintaining the lightweight advantage. This composite material substitution resolves the contradiction between weight reduction and heat 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 diamond-based composite material improves brake system performance by reducing weight, extending lifespan, and lowering environmental impact through enhanced heat dissipation and reduced wear, achieving efficient braking with lower emissions.
Implementation Method 1
the composite material comprising diamond particles and a binder, which enhances thermal conductivity, mechanical resistance, and reduces weight, allowing for efficient heat dissipation
Implementation Method 2
the braking member frictionally operates in conjunction with another component of the brake system to produce a braking action due to the friction force developed between the braking member and the other component
Data Source
Figure 1~3
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Figure 6~7
AI summary
This disclosure relates to a braking member (1, 2) for a brake system (9) and a method for making it. The braking member (1, 2) comprises at least one friction portion (13, 23) intended to be put into contact with a component (2, 1) of the brake system (9) to produce a braking action due to a friction force. The surface (15, 25) and/or the friction portion (13, 23) is made of a composite material comprising diamond particles (41) and a binder (43).