Ventilated Disc Brake Band Fin Layout for Squeal and Crack Resistance
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Solution Overview
Problem
Existing ventilated disc brake systems face issues with heat dispersion and mechanical resistance in the middle annular zone, leading to temperature increases and potential cracking, while also experiencing vibrations that result in noise due to resonances, which prior solutions fail to adequately address by compromising structural integrity.
Innovation Solution
The braking band features enlarged, tapered fins with a greater outer radial width and short fins extending partially into the gap, enhancing air flow turbulence and mass distribution, reducing vibrations, and increasing mechanical resistance without occluding ventilation channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the number and size of ventilation channels are increased to improve heat disposal, then cooling efficiency is improved, but mechanical resistance and structural integrity deteriorate
Solution Approach 1:
The patent applies local quality by creating a non-uniform distribution of connecting elements: the first series of fins has a larger cross-sectional area and is positioned in the middle annular zone where heat generation is highest, while the second series of fins has a smaller cross-sectional area toward the outer diameter. This localized differentiation optimizes both heat disposal in critical zones and structural integrity in less critical zones, resolving the contradiction between ventilation efficiency and mechanical strength.
2Strength
If the middle annular zone is reinforced to increase mechanical resistance, then structural integrity is improved, but heat dispersion capability deteriorates
Solution Approach 1:
The patent applies parameter changes by varying the cross-sectional area of connecting elements based on their radial position. The first series of fins in the middle annular zone has a larger cross-sectional area (first parameter configuration) to provide mechanical reinforcement, while the second series of fins toward the outer diameter has a smaller cross-sectional area (second parameter configuration) to maintain heat dispersion capability. This parameter differentiation allows simultaneous optimization of both mechanical resistance and heat dispersion.
3Strength
If connecting elements are increased in size to improve structural strength, then mechanical resistance is improved, but ventilation channel occlusion increases
Solution Approach 1:
The patent applies local quality by positioning larger connecting elements (first series of fins) only in the middle annular zone where structural strength is most needed, while using smaller connecting elements (second series of fins) in the outer radial zones where structural demands are lower. This localized approach ensures structural strength is enhanced where required without unnecessarily reducing ventilation channel area in other zones, thus resolving the contradiction between structural strength and ventilation efficiency.
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 design achieves superior braking comfort by reducing vibrations and noise, maintaining high cooling efficiency, and increasing thermal resistance while preventing crack formation and imbalance, thus enhancing brake performance.
Implementation Method 1
enhancing air flow turbulence
Implementation Method 2
channels are crossed by airflows according to a centrifugal direction during the rotary motion of the disc itself
Implementation Method 3
the friction between the pads of the brake calipers and the braking surfaces of the braking band generates a high amount of heat
Data Source
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AI summary
A braking band (1) of a disc brake disc of a ventilated type unusually capable of avoiding vibrations which induce annoying squeals during the braking action, said braking band (1) extending between an inner diameter (D1), near a rotation axis (X-X) of the braking band (1), and an outer diameter (D2), far from said rotation axis (X-X); said braking band (1) comprising two plates (3, 4) facing each other; said plates comprising inner surfaces (5, 6) directly or indirectly facing each other and delimiting a gap (7); said plates being joined to each other by heat dissipating and connecting elements (16, 17, 19), said connecting elements project from a plate reaching the opposite plate, thereby forming bridges which connect the plates to each other; wherein a first series of fins (18) of said connecting elements is each a fin (19) which is in a single piece and extends from near said inner diameter to near said outer diameter; and wherein each of said fins (19) of said first series of fins (18) comprises a fin outer end portion (20) located near said outer diameter; the fin outer end portion (20) of said fin (19) comprises a predetermined extension along the outer circumferential direction; said fin (19) comprises a fin inner end portion (21) located near said inner diameter; said fin inner end portion (21) of said fin (19) comprises a predetermined extension along the inner circumferential direction; wherein considering a section taken along a section plane comprising a radial (R-R) and circumferential (C-C) direction, section made by passing through a mean air flowpoint which runs through said gap, said outer circumferential width is greater than said inner circumferential width; and wherein said fin outer end portion (20) of said each fin (19) of said first series of fins (18) faces only an adjacent fin (19) of said first series of fins (18) on both sides in circumferential direction (C-C).